Grizzly Drill G1005Z User Manual

MODEL G1005Z

MILL/DRILL

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.

#JK8304 PRINTED IN TAIWAN

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Table of Contents

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

Foreword .................................................................................................................................... 2

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

Machine Data Sheet................................................................................................................... 3

Identification ............................................................................................................................... 5

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

Additional Safety for Mill/Drills.................................................................................................... 8

SECTION 2: CIRCUIT REQUIREMENTS ........................................................................................ 9

110/220V Operation................................................................................................................... 9

Grounding................................................................................................................................. 10

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

SECTION 3: SET UP...................................................................................................................... 11

Set Up Safety........................................................................................................................... 11

Items Needed for Set Up ......................................................................................................... 11

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

Inventory................................................................................................................................... 12

Clean Up .................................................................................................................................. 13

Site Considerations.................................................................................................................. 13

Mounting................................................................................................................................... 14

Assembly.................................................................................................................................. 14

Test Run................................................................................................................................... 15

SECTION 4: OPERATIONS ........................................................................................................... 16

Operation Safety ...................................................................................................................... 16

Installing/Removing Tooling..................................................................................................... 16

Table ........................................................................................................................................ 18

Graduated Dials ....................................................................................................................... 19

Backlash................................................................................................................................... 19

Micro-Downfeed Handwheel.................................................................................................... 19

Quill Lock ................................................................................................................................. 20

Depth Stop ............................................................................................................................... 20

Choosing Milling Speeds.......................................................................................................... 21

Choosing Drilling Speeds......................................................................................................... 21

Changing Speeds..................................................................................................................... 23

Drilling Guidelines .................................................................................................................... 24

SECTION 5: ACCESSORIES......................................................................................................... 25

SECTION 6: MAINTENANCE ........................................................................................................ 26

Schedule .................................................................................................................................. 26

Cleaning ................................................................................................................................... 26

Unpainted Cast Iron ................................................................................................................. 26

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

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

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

Depth Stop Calibration............................................................................................................. 30

Feed Shaft Spring Tension ...................................................................................................... 30

Electrical Components ............................................................................................................. 32

Wiring Diagram ........................................................................................................................ 33

G1005Z Main Assembly Breakdown........................................................................................ 34

G1005Z Main Assembly Parts List........................................................................................... 35

G1005Z Table Breakdown ....................................................................................................... 36

G1005Z Table and Labels Parts List ....................................................................................... 37

WARRANTY AND RETURNS........................................................................................................ 38

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INTRODUCTION

Foreword

Contact Info

We are proud to offer the Model G1005Z Mill/Drill.

This machine is part of a growing Grizzly family of

fine woodworking and 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.

If you have any comments regarding this manual,

please write to us at the address below:

Grizzly Industrial, Inc.

Technical Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

We are pleased to provide this manual with

the Model G1005Z. It was written to guide you

through assembly, review safety considerations,

and cover general operating procedures. It repre-

sents our effort to produce the best documenta-

tion possible.

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

The specifications, drawings, and photographs

illustrated in this manual represent the Model

G1005Z as supplied when the manual was pre-

pared. However, owing to Grizzly’s policy of con-

tinuous improvement, 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!

E-Mail: [email protected]

Web Site: http://www.grizzly.com

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Machine Data Sheet

MACHINE DATA

SHEET

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

MODEL G1005Z MILL/DRILL MILLING MACHINE #25

Product Dimensions:

Weight.............................................................................................................................................................. 374 lbs.

374

Length/Width/Height.................................................................................................................36-1/2 x 34-1/2 x 40 in.

Foot Print (Length/Width)....................................................................................................................... 20-1/2 x 13 in.

Shipping Dimensions:

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

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

Weight.............................................................................................................................................................. 444305 lbs.

28" x 29" x 42"

Length/Width/Height............................................................................................................................. 28 x 29 x 41 in.

Electrical:

Switch........................................................................................................................................................ Push Button

Switch Voltage...................................................................................................................................................... 110V

Cord Length............................................................................................................................................................ 6 ft.

Cord Gauge....................................................................................................................................................14 gauge

Recommended Breaker Size............................................................................................................................ 20 amp

Plug.........................................................................................................................................................................Yes

Motors:

Main

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

Horsepower.................................................................................................................................................1 HP

Voltage.................................................................................................................................................110/220V

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

Phase........................................................................................................................................................Single

Amps..........................................................................................................................................................12/6A

Speed.................................................................................................................................................1725 RPM

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

Number Of Speeds........................................................................................................................................... 1

Power Transfer ...................................................................................................................................Belt Drive

Bearings........................................................................................................Shielded, Permanently Lubricated

Main Specifications:

Operation Info

Spindle Travel........................................................................................................................................ 3-5/8 in.

Swing..........................................................................................................................................................16 in.

15"

Longitudinal Table Travel...........................................................................................................................15 in.

5-1/2"

Cross Table Travel.................................................................................................................................5-1/2 in.

Head Swivel.......................................................................................................................................... 360 deg.

Max. Dist Spindle To Column.......................................................................................................................8 in.

Max. Dist Spindle To Table..................................................................................................................14-3/8 in.

14-3/8"

Drilling Cap For Cast Iron.............................................................................................................................1 in.

Drilling Cap For Steel................................................................................................................................... 1 in.

No. Of Vert. Spindle Speeds...........................................................................................................................12

Range Of Vert. Spindle Speeds................................................................................................110 - 2580 RPM

Quill Dia.................................................................................................................................................2.440 in.

The information contained herein is deemed accurate as of 3/18/2007 and represents our most recent product specifications.

Model G1005Z

PAGE 1 OF 3

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

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Table Info

Table Length.............................................................................................................................................. 23 in.

Table Width............................................................................................................................................7-1/2 in.

Table Thickness.....................................................................................................................................1-3/4 in.

No. Of T Slots....................................................................................................................................................4

T Slots Width.............................................................................................................................................1/2 in.

T Slots Height............................................................................................................................................7/8 in.

T Slots Centers...................................................................................................................................... 1-1/2 in.

1-1/2"

Stud Size...................................................................................................................................................3/8 in.

Lead Screw Info

Lead Screw Diameter............................................................................................................................0.935 in.

Lead Screw TPI...............................................................................................................................................10

Lead Screw Length.................................................................................................................X-30, Y-15-3/4 in.

X-Axis 30"; Y-Axis 15-3/4"

Construction

Spindle Housing Const.........................................................................................................................Cast Iron

Table Const............................................................................................................................. Ground Cast Iron

Head Const...........................................................................................................................................Cast Iron

Column Const..........................................................................................................................Ground Cast Iron

Base Const...........................................................................................................................................Cast Iron

Paint........................................................................................................................................................Enamel

Other

Collars Calibrated..................................................................................................................................0.001 in.

Column Dia............................................................................................................................................ 3-5/8 in.

3-5/8"

Optional Stand..........................................................................................................................................G5943

Mobile Base..............................................................................................................................................G7314

Spindle Info

Spindle Taper................................................................................................................................................R-8

Spindle Sleeve Diameter.........................................................................................................................2.424.4i4n".

End Milling Cap......................................................................................................................................... 1/2 in.

Face Milling Cap...........................................................................................................................................3 in.

Draw Bar Diameter..................................................................................................................................7/16 in.

Draw Bar TPI........................................................................................................................................ 7/16 - 20

Draw Bar Length.................................................................................................................................. 13-1/2 in.

Spindle Bearings......................................................................................................................... Tapered Roller

Other Specifications:

ISO Factory ...................................................................................................................................................ISO 9001

Country Of Origin ..............................................................................................................................................Taiwan

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

Serial Number Location ............................................................................................ Machine Label on Head Casting

Assembly Time ........................................................................................................................................... 30 minutes

Sound Rating ...................................................................................................................................................... 80 dB

Features:

Head Swivels 360 deg.

Front Mounted On/Off Switch with Thermal Overload Protection

Excellent Speed Range

Extremely Quiet Machine

Easy Clutch-Type Mechanism for Engaging Fine Down-Feed

Positive Quill Lock

Adjustable Gibs on Table and Saddle

& Saddle

Adjustable Stops on Table

Spindle Supported by Heavy Duty, Tapered Roller Bearings

Graduations in Inches

The information contained herein is deemed accurate as of 3/18/2007 and represents our most recent product specifications.

Model G1005Z

PAGE 2 OF 3

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

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Identification

Figure 1. G1005Z Identification.

A. Junction Box

B. Headstock Height Crank

C. Return Spring Assembly

D. Quill Lock

E. Depth Stop

F. ON/OFF Swtich

G. Micro-Downfeed Handwheel

H. Motor Pivot Lock

I. Downfeed Handles

J. Pinion Hub Lock Knob

K. Table Handwheels

L. Longitudinal Stops

M. Gib Screws

N. Longitudinal Locks

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SECTION 1: SAFETY

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Additional Safety for Mill/Drills

1. UNDERSTANDING CONTROLS. Make sure

9. POWER DISRUPTION. In the event of a

local power outage during use of the mill,

turn OFF all switches to avoid possible sud-

den start up once power is restored.

you understand the use and operation of all

controls.

2. SAFETY ACCESSORIES. Always use a

chip guard in addition to your safety glasses

when milling to prevent bodily injury.

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.

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.

11. DISCONNECT POWER. Make sure the

mill/drill is turned OFF, disconnected from

its power source and all moving parts have

come to a complete stop before starting any

inspection, adjustment, or maintenance pro-

cedure.

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.

12. CLEAN-UP. DO NOT clear chips by hand.

Use a brush, and never clear chips while the

mill/drill is turning.

6. STOPPING SPINDLE. DO NOT stop the

spindle by hand. Allow it to come to a stop by

itself.

13. CUTTING TOOL INSPECTION. Inspect drills

and end mills for sharpness, chips, or cracks

before each use. Replace dull, chipped, or

cracked cutting tools immediately. Handle

new cutting tools with care. Leading edges

are very sharp and can cause lacerations.

7. AVOIDING ENTANGLEMENT. Keep loose

clothing articles such as sleeves, belts or

jewelry items away from the mill/drill spindle.

Never wear gloves when operating the mill/

drill.

14. EXPERIENCING DIFFICULTIES. If at any

time you are experiencing difficulties per-

forming the intended operation, stop using

the machine! Contact our Technical Support

at (570) 546-9663.

8. BE ATTENTIVE. DO NOT leave mill/drill run-

ning unattended for any reason.

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 lessen the pos-

sibility of operator injury. If normal safety

precautions are overlooked or ignored, seri-

ous personal injury may occur.

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SECTION 2: CIRCUIT REQUIREMENTS

Plug Type

110/220V Operation

The Model G1005Z comes prewired with a NEMA

5-15 plug. If you wish to rewire the motor to 220V

we recommend using the following plug (see

Figure 2 for an example):

Serious personal injury could occur if you

220V Plug & Receptacle ...................NEMA 6-15

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 G1005Z features a 110/220V motor

that is prewired for 110V and draws the following

amps under maximum load:

Motor Draw at 110V............................... 12 Amps

Motor Draw at 220V ................................6 Amps

Circuit Requirements

Figure 2. NEMA 6-15 plug and outlet.

We recommend using a dedicated circuit for this

machine. You MUST connect your machine to a

grounded circuit that is rated for the amperage

given below. Never replace a circuit breaker on

an existing circuit with one of higher amper-

age without consulting a qualiﬁed electrician 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.

110V Circuit...........................................15 Amps

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

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Grounding

Extension Cords

In the event of an electrical short, grounding

reduces the risk of electric shock. The grounding

wire in the power cord must be properly connect-

ed to the grounding prong on the plug; likewise,

the outlet must be properly installed and ground-

ed. All electrical connections must be made in

accordance with local codes and ordinances.

110V Operation

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

extension cord at 110V with your machine:

•

Use at least a 14 gauge cord that does not

exceed 50 feet in length!

Electrocution or fire could

result if this machine is

not grounded correctly or

if your electrical configu-

ration does not comply

with local and state codes.

Ensure compliance by

checking with a qualified

electrician!

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.

220V Operation

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

extension cord at 220V with your machine:

•

Use at least a 16 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.

This machine must have a ground prong in

the plug to help ensure that it is grounded.

DO NOT remove ground prong from plug

to fit into a two-pronged outlet! If the plug

will not fit the outlet, have the proper outlet

installed by a qualified electrician.

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SECTION 3: SET UP

Items Needed for Set

Set Up Safety

The following items are needed to complete the

set up process, but are not included with your

machine:

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!

Description

Qty

•

Safety Glasses (for each person) .............. 1

Rubber Mallet............................................. 1

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

Wrench 17mm............................................ 1

Solvent Cleaner...........................As needed

Rags for cleaning ........................As needed

Wear safety glasses dur-

ing the entire set up pro-

cess!

Unpacking

The Model G1005Z 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.

The Model G1005Z is an

extremelyheavymachine

(400 lbs). Serious per-

sonal injury may occur

if safe moving methods

are not followed. To be

safe, you will need power

equipment when mov-

ing the shipping crate,

and a number of assis-

tants when moving the

machine onto a stand or

workbench.

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, you should inventory the

contents.

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Inventory

After all the parts have been removed from the

shipping crate, you should have the following

items:

Main Components: (Figure 3)

Qty

A. Mill/Drill (not shown)................................... 1

B. Downfeed Handle Knobs ¹⁄2"-12................. 3

C. Downfeed Handles ¹⁄2"-12........................... 3

D. Face Mill Arbor R8 ..................................... 1

E. Chuck Key.................................................. 1

F. Handwheels................................................ 3

G. Face Mill 2¹⁄2" ............................................. 1

H. Arbor R⁸⁄JT6 (installed, not shown)............ 1

I. Handwheel Handles ³⁄8-16 x ⁷⁄8................... 4

J. Vise 3¹⁄2"..................................................... 1

K. Drill Chuck JT6 ¹⁄2" ..................................... 1

Figure 3. G1005Z Inventory.

In the event that any nonproprietary parts are

missing (e.g. a nut or a washer), we would be

glad to replace them, or for the sake of expedi-

ency, replacements can be obtained at your local

hardware store.

Other Components and Hardware:

•

Cap Screw ³⁄8-16 x 1 (mill arbor) ................ 1

Flat Washer ³⁄8" (mill arbor) ........................ 1

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

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

NOTICE

Some hardware/fasteners on the inventory

list may arrive pre-installed on the machine.

Check these locations before assuming that

any items from the inventory list are miss-

ing.

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Clean Up

Site Considerations

The unpainted surfaces are coated with a waxy

oil to protect them from corrosion during ship-

ment. Remove this protective coating with a sol-

vent cleaner or citrus-based degreaser such as

Grizzly’s G7895 Degreaser. To clean thoroughly,

some parts may need to be removed. For opti-

mum performance from your machine, make

sure you clean all moving parts or sliding

contact surfaces that are coated. Avoid chlo-

rine-based solvents, such as acetone or brake

parts cleaner, as they may damage painted sur-

faces should they come in contact. Always follow

the manufacturer’s instructions when using any

type of cleaning product.

Workbench Load

Refer to the Machine Data Sheet for the weight

and footprint specifications of your machine.

Some workbenches may require additional rein-

forcement to support both the machine and

workpiece.

Operational Clearances

Consider existing and anticipated needs, size of

material to be processed through each machine,

and space for auxiliary stands, work tables or

other machinery when establishing a location for

your new machine. See Figure 4 for the minimum

operational clearances.

48³⁄4

Gasoline and petroleum

products have low flash

points and could cause

an explosion or fire if

used to clean machinery.

DO NOT use gasoline or

petroleum products to

clean the machinery.

34¹⁄2

Many of the solvents

commonly used to clean

machinery can be toxic

when inhaled or ingest-

ed. Lack of ventilation

while using these sol-

vents could cause seri-

ous personal health risks

or fire. Take precautions

from this hazard by only

using cleaning solvents

in a well ventilated area.

Figure 4. Minimum working clearances.

Unsupervised children and

visitors inside your shop

could cause serious per-

sonal injury to themselves.

Lock all entrances to the

shop when you are away and

DO NOT allow unsupervised

children or visitors in your

shop at any time!

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Mounting

Assembly

The Model G1005Z must be mounted to a

workbench or stand before it can be safely used.

TheModelG1005Zmustbecompletelyassembled

before it can be safely used.

If mounting to a stand, follow the mounting

instructions included with the stand. We

recommend using the Grizzly Model G5943

stand, which can be found in SECTION 5:

ACCESSORIES on Page 25.

To assemble the Model G1005Z:

1. Thread the downfeed handle knobs onto the

downfeed handles.

2. Thread the downfeed handles into the pinion

hub, as shown in Figure 7.

For workbenches, the strongest mounting option

is a "through mount" where holes are drilled all

the way through the workbench, and hex bolts,

washers, and hex nuts are used to secure the

mill/drill to the workbench.

��

Figure 7. Downfeed handles installed.

3. Remove the caps from the handwheel hubs.

Figure 5. Example of a through mount setup.

4. Slide the handwheels onto the handwheel

shafts as shown in Figure 8, and tighten the

handwheel setscrews.

Another option for mounting is a "direct mount"

where the machine is simply secured to the work-

bench with a lag screw.

��

Figure 8. Table handwheels installed.

Figure 6. Example of a direct mount setup.

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To test run the machine:

5. Thread the handwheel handles into the

handwheels and tighten using a 5mm hex

wrench.

1. Make sure you have read the safety instruc-

tions at the beginning of the manual and that

the machine is setup properly.

6. Thread the remaining handwheel handle into

the headstock adjustment handle.

2. Make sure all tools and objects used during

set up are cleared away from the machine.

Test Run

3. Ensure the machine is switched OFF.

4. Connect the machine to the power source.

5. Turn the machine ON.

Once the assembly is complete, test run your

machine to make sure it runs properly.

If, during the test run, you cannot easily locate

the source of an unusual noise or vibration, stop

using the machine immediately, then review the

Troubleshooting on Page 27.

6. Listen to and watch for abnormal noises or

actions. The machine should run smoothly

with little or no vibration or rubbing noises.

—Strange or unusual noises should be inves-

tigated and corrected before operating the

machine further. Always disconnect the

machine from power when investigating or

correcting potential problems.

If you still cannot remedy a problem, contact our

Tech Support at (570) 546-9663 for assistance.

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SECTION 4: OPERATIONS

Installing/Removing

Operation Safety

Tooling

The Model G1005Z is supplied with both an R8

face mill arbor, for use with the included 2¹⁄2" face

mill, and a JT6 drill chuck.

Damage to your eyes, lungs, and ears could

result from using this machine without

proper protective gear. Always wear safety

glasses, a respirator, and hearing protection

when operating this machine.

Using Clean Tapers

When installing any tapered tooling, always ensure

that both tapers (the tooling and the spindle) are

clean and free of grit, oil, dust, and other debris

that could prevent a good fit. Dirty tapers can lead

to poor seating, causing loose (and potentially

dangerous) tooling, or can cause jammed tapers,

making them near impossible to separate.

To install tooling on included mill arbor:

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.

1. UNPLUG THE MILL/DRILL!

2. Seat the tooling on the mill arbor as shown in

Figure 9.

Cap Screw

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.

Mill Arbor

Face Mill

Flat Washer

Figure 9. Attaching a face mill to the mill arbor.

3. Secure the tooling in place with the included

cap screw and flat washer.

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To install an arbor:

To install end mill tooling:

1. UNPLUG THE MILL/DRILL!

2. Slide the arbor into the spindle, ensuring that

the arbor keyway aligns with the pin inside

the spindle.

2. Insert the appropriate-sized R8 collet into

the spindle, ensuring that the collet keyway

aligns with the pin inside the spindle.

3. While holding the arbor in place, turn the

drawbar clockwise until the drawbar engages

with the arbor.

3. Using a heavy rag or gloves to protect your

hands, insert the end mill tooling into the

collet.

4. Continue turning the drawbar until the arbor

4. While holding the collet in place, turn the

drawbar hex nut clockwise until the drawbar

engages with the collet.

is firmly secured in place.

To remove an arbor:

5. Turn the drawbar nut clockwise until the tool-

1. UNPLUG THE MILL/DRILL!

ing is completely secured in the collet.

2. Using a 17mm wrench, turn the drawbar hex

nut counterclockwise two turns, as shown in

Figure 10.

To install the drill chuck:

1. UNPLUG THE MILL/DRILL!

2. Ensure that both the arbor and chuck are

clean, dry and free of dirt, debris or grit.

3. Slide the chuck onto the arbor.

4. Securely seat the chuck in place by giving

it a single hard tap with a rubber mallet, as

shown in Figure 11.

Note: Once the chuck is seated on the arbor, it is

a semi-permanent connection. If you wish to use

a different chuck, we recommend obtaining a new

arbor for that chuck.

Figure 10. Turning the drawbar nut.

3. Strike the end of the drawbar with a dead

blow mallet to unseat the arbor from the

spindle.

4. While holding the arbor, unscrew the drawbar

until the arbor comes free.

Figure 11. Seating the JT6 drill chuck.

-17-

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To install a drill bit:

Table

1. UNPLUG THE MILL/DRILL!

The mill/drill table can be moved in the X-axis

(side-to-side) and Y-axis (forward/backward). The

various features are called out in Figure 12 and

are described below.

2. Open the drill chuck wide enough to accept

the shank of the drill bit.

3. Insert the drill bit as far as possible into the

chuck WITHOUT allowing the chuck jaws to

touch the fluted portion of the bit, and tighten

the chuck using the chuck key.

Longitudinal

Stops

Note: Make sure the bit is not trapped between

the edges of two jaws, as it will not be secure

enough to use for drilling.

4. Once you are sure the bit is installed cor-

rectly, tighten the chuck as tight as possible.

To remove a drill bit:

Longitudinal

Gib Screws

Locks

1. UNPLUG THE MILL/DRILL!

Figure 12. G1005Z table components.

2. Open the drill chuck using the chuck key,

and catch the drill bit with a rag to protect

your hands.

Longitudinal Feed:

The longitudinal feed, or X-axis, is moved by

handwheels at either end of the table. These

handwheels will move the table in both direc-

tions side to side. One complete revolution of the

handwheel moves the longitudinal feed 0.100".

Larger bits turning at slower speeds tend

to grab the workpiece aggressively. This

can result in the operator's hand being

pulled into the bit or the workpiece being

thrown with great force. Always clamp the

workpiece to the table to prevent injuries.

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".

Longitudinal Locks:

The longitudinal feed can be temporarily locked in

position using one or both lock handles located on

the front of the table.

Longitudinal Stops:

The two sliding longitudinal stops are used to limit

the X-axis travel distance. These can be loosened

and locked in place using a 5mm hex wrench.

Gib Screws:

Both the longitudinal and cross slides can each

be locked via a gib screw, located respectively on

the right side of the cross slide underneath the

table, and on the front right of the cross slide.

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Graduated Dials

Micro-Downfeed

Handwheel

The handwheels and the micro-downfeed adjust-

ment knob have graduated dials. Each mark

represents 0.001" of movement and one full revo-

lution of the micro-downfeed knob equals 0.100".

The graduated dials float and can be indexed or

"zeroed" using the knurled knob on the dial. One

full revolution of the handwheel equals 0.100".

The micro-downfeed handwheel (Figure 13) is

used when vertical milling accuracy is required.

Eachfullrotationofthemicro-downfeedhandwheel

is equal to 0.100".

Backlash

Backlash and graduated dials are somewhat

interconnected. When you change direction of the

table in either axis, you must correct the gradu-

ated dial for backlash. Normal recommended

backlash is less than 0.010".

Note: It is up to you to determine an acceptable

amount of backlash for your system. The frictional

wear on your lead screw increases as backlash

is reduced. Attempting to completely eliminate

backlash can place excessive wear on your lead

screw and decrease its operational capability.

Figure 13. Pinion hub lock knob.

To engage the micro-downfeed handwheel, tight-

en the pinion hub lock knob clockwise against the

pinion hub.

To correct for backlash:

1. Turn the handwheel and move the table the

opposite direction of your next operation.

To disengage the micro-downfeed handwheel,

hold the downfeed handles and loosen the pinion

hub lock knob counterclockwise.

2. Turn the handwheel to move the table in the

intended direction.

3. The exact moment the lead screw catches

and the table begins to move, backlash has

been eliminated and the graduated dial can

be "zeroed."

Note: You will not need to adjust for back-

lash as long as the table keeps moving in the

same direction.

-19-

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The depth stop also features a return height

nut that is used to set the minimum spindle

return distance. Figure 15 shows the various

components of the depth stop.

Quill Lock

The spindle can be locked in place to provide tool

stability when milling.

Depth Nut

To lock the quill in place:

Jam Nut

1. Lower the quill to the desired height.

2. Tighten the quill lock handle clockwise to lock

the quill in place, as shown in Figure 14.

Depth Stop

Bracket

Return

Height Nut

Calibration

Nut

Figure 15. Depth stop components.

To set the depth stop:

1. Lower the tooling/bit to the required height.

2. Thread the depth nut down against the stop

bracket.

3. Lower the jam nut against the depth nut.

Figure 14. Quill lock handle.

4. Hold the depth nut in place and tighten the

To unlock the quill:

jam nut against the depth nut.

1. While holding the downfeed handles, turn the

quill lock handle counterclockwise until the

quill is free to move.

To set the spindle return distance:

1. Lower the tooling/bit.

2. Thread the return height nut up the stud to

Depth Stop

the desired height.

Note: The scale on the depth stop can be recali-

brated if it gets moved or has changed since the

factory setting. Refer to Depth Stop Calibration

on Page 30 for instructions on how this is done.

The Model G1005Z has a depth stop that allows

you to lower the drill bit or milling tool to the same

point every time.

The depth stop consists of a stud attached to the

quill with two hex nuts that can be lowered or

raised on the stud, so the lower nut (depth nut) hits

a stop bracket when the drill bit is lowered. The

upper nut (jam nut) is then used to tighten against

the depth nut to secure it in place, so the depth

nut doesn't move with repeated operations.

-20-

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Choosing Milling

Speeds

Failure to follow RPM and Feed Rate

Guidelines may result in ejected parts or

broken tools. Parts ejected at high speeds

can cause serious injury!

It is essential to closely follow the proper cutting

speed and proper feed to reduce undue strain on

all moving parts and for operator safety.

Choosing Drilling

Speeds

Prior to machining, you need to determine the

RPM needed to cut your workpiece, and then set

the speed on the machine.

To determine the needed RPM:

Using the Drill Bit Speed Chart

1. Use the table in Figure 16 to determine the

cutting speed required for the material of your

workpiece.

The chart shown on Page 22 is intended as a

guide only. Always follow manufacturer's speed

recommendations if provided with your drill bits,

cutters, or hole saws. Exceeding the recommend-

ed speeds may be dangerous to the operator.

2. Measure the diameter of your cutting tool in

inches.

The speeds shown here are intended to get you

started. The optimum speed will always depend

on various factors, including tool diameter, drilling

pressure, material hardness, material quality, and

desired finish.

3. Use the following formula to determine the

needed RPM for your operation:

(Cutting Speed x 4) / Tool Diameter =

RPM

Often, when drilling materials other than wood,

some type of lubrication is necessary.

Note: For carbide cutting tools, double the cut-

ting speed. These values are a guideline only.

Refer to the MACHINERY'S HANDBOOK for

more detailed information.

Lubrication Suggestions

Wood/Cast Iron ...........................................None

Plastics ........................................... Soapy Water

Brass .............................. Water-Based Lubricant

Aluminum......................Paraffin-Based Lubricant

Mild Steel..............................Oil-Based Lubricant

Cutting Speeds for High Speed Steel (HSS)

Milling Tools

Workpiece Material

Aluminum & alloys

Brass & Bronze

Copper

Cutting Speed (sfm)

300

150

100

Cast Iron, soft

Cast Iron, hard

Mild Steel

Cast Steel

Alloy Steel, hard

Tool Steel

Stainless Steel

Titanium

Plastics

300-800

300-500

Wood

Figure 16. Cutting speeds for HSS cutting tools.

-21-

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Steel

1/16" – 3/16"

13/64" – 3/8"

25/64" – 5/8"

11/16" – 1"

3000

2000

1500

750

2500

1500

750

2500

2000

1500

1000

2500

1250

750

3000

2500

1500

1000

2500

1250

600

500

400

350

Steel

1/4" – 1/2"

9/16" – 1"

2000

1500

1000

500

1500

1250

750

1-1/8" – 1-7/8"

2–3"

350

Steel

1/2" – 7/8"

1" – 1-7/8"

2" – 2-7/8"

3" – 3-7/8"

4" – 5"

500

400

300

200

100

500

400

300

200

100

600

500

400

300

200

600

500

400

300

200

600

500

400

300

200

500

400

300

200

100

250

500

teel

Carbide Insert Type

One-Piece Type

350

1800

teel

3/8" – 1/2"

5/8" – 1"

1200

800

1000

600

Figure 17. Drill bit speed chart.

�

��

� ��

Figure 18. Belt configuration and speed settings.

-22-

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5. Locate the desired speed on the belt cover

speed chart or on Page 22 and move the V-

belts to the desired V-grooves on the motor,

idler, and spindle pulleys.

Changing Speeds

The belts in the head of the mill/drill must be

rearranged to change speeds. A chart on the belt

cover shows the belt positions needed to make

the mill/drill run at the desired speed.

For Example: As indicated in the speed

chart (Figure 21), a belt combination of A-2

creates 730 RPM.

Note: Both belts may have to be removed

before certain speed changes can be made.

It is normal for the idler bracket to move in

response to a belt change.

To change speeds:

1. UNPLUG THE MILL/DRILL!

2. Loosen the motor lock screw (shown in

Figure 19), so the motor is free to pivot.

�

� �

�

� ��

�

��

A-2

Figure 19. Motor lock screw.

3. Pivot the motor to loosen the belt tension.

4. Loosen, but do not remove, the two idler

bracket hex bolts shown in Figure 20.

Spindle

Pulley

Idler

Pulley

Motor

Pulley

Figure 21. A-2 pulley combination for 730 RPM.

6. Tighten both idler bracket hex bolts.

7. Remove any slack in the motor pulley belt by

shifting the motor back into position.

8. Tighten the motor lock screw.

9. Close the cover before plugging in the

machine.

Figure 20. Idler bracket hex bolts.

-23-

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SOFT MATERIAL: The softer the material, the

faster the spindle may turn. (Plastics can melt at

too high of a spindle speed!)

Drilling Guidelines

The Model G1005Z is designed for drilling holes in

wood, plastics or metal. Basic operation consists

of lining up your drill bit with the intended hole

location, turning the mill/drill ON, and using the

downfeed handles to move the spinning drill bit

into the workpiece.

LUBRICANT: Use some form of lubricant on

all materials except wood. Refer to Lubrication

Suggestions on Page 21 to find the correct lubri-

cation for your application.

DRILLING ACCURACY: To prevent drill bit wan-

dering and ensure accurate placement of holes,

mark the hole location with a center punch before

drilling. Also consider using a center-point drill to

start the hole.

For safe operation and optimum results, it

is very important to follow these guidelines

when drilling:

SECURING WORKPIECE TO TABLE: Secure

the workpiece to the table or in a vise that is

secured to the table before drilling.

PLUG/ROSETTE CUTTERS: Plug cutters and

rosette cutters are for wood only. However, car-

bide-tipped bits and cutters cut at a higher speed

and can cut materials other than wood, depending

on the cutter type.

CLEARING CHIPS: Raise the drill bit often to

clear chips and cool the drill bit. This will ease

the work of the mill/drill motor and extend the life

of your drill bits.

5-FLUTE/2-FLUTE CUTTERS: Use a 5-flute cut-

ter when cutting into plastics, brass, aluminum,

and mild steel. A 2-flute cutter can aggressively

grab the workpiece and damage the tool if used

with materials other than wood.

PROTECTING TABLE: Protect the table by plac-

ing the workpiece on scrap wood. Also, use the

depth stop so that the drill bit goes no deeper

than necessary.

SPADE BITS AND PLASTIC: When drilling plas-

tic with a spade bit, use a spade bit with spurs.

USING CORRECT SPEEDS: Use the correct

speed for the diameter of the drill bit being used

and the type of material being drilled. Refer to the

Drill Bit Speed Chart on Page 22 to help you

choose the correct speed for your application.

HOLE SAWS: When using hole saws, apply firm

and even pressure, so the saw teeth contact the

surface all at the same time—not at an angle. You

can also flip the workpiece and finish cutting from

the other side.

LARGE DIAMETER BITS: Large diameter drill

bits require slower spindle speeds.

SMALL DIAMETER BITS: Smaller diameter drill

bits require faster spindle speeds.

Larger bits turning at slower speeds tend

to grab the workpiece aggressively. This

can result in the operator's hand being

pulled into the bit or the workpiece being

thrown with great force. Always clamp the

workpiece to the table to prevent injuries.

HARD MATERIAL: The harder the material,

(steel vs. wood) the slower the spindle speed.

-24-

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SECTION 5: ACCESSORIES

H2689—R8 Quick Change Collet Set

G7984—Face Shield

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 inlcudes an R8

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.

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!

H1300

H1298

G7984

H0736

H2347

Figure 24. H2689 R8 Quick Change Collet Set.

Figure 22. Our most popular safety glasses.

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

Includes these sizes and styles in two and four

G5943—Stand for Model G1005Z Mill/Drill

This companion stand for the Model G1005Z Mill/

Drill features a snap-style door handle and raised

lip to guard against coolant splashes.

flute styles: /16", /4", /16", /8", /16", /2", /16", /8",

8", ¹¹/16", and ³/4".

Figure 25. G9760 20-PC End Mill Set.

Figure 23. G5943 Stand for G1005Z.

-25-

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SECTION 6: MAINTENANCE

Unpainted Cast Iron

Always disconnect power

to the machine before

performing maintenance.

Failure to do this may

result in serious person-

Protect the unpainted cast iron surfaces on the

table by wiping the table clean after every use—

this ensures moisture does not remain on bare

metal surfaces.

al injury.

Keep tables rust-free with regular applications of

products like G96^®Gun Treatment, SLIPIT^®, or

Schedule

Boeshield^®T-9.

For optimum performance from your machine,

follow this maintenance schedule and refer to any

specific instructions given in this section.

Lubrication

Daily Check:

•

Loose mounting bolts.

Worn or damaged wires.

Since all bearings are shielded and permanently

lubricated, simply leave them alone until they

need to be replaced. DO NOT lubricate them.

Any other unsafe condition.

Mill/drill is completely powered down at the

end of use.

Excess cutting fluids and chips have been

removed and unpainted surfaces are dry and

protected.

Keep quill, spindle, column, and table top well

lubricated to prevent rust.

•

Each table handwheel must be oiled periodically

to prevent binding. For each handwheel, use an

ISO VG 68 or SAE-20 oil in the location shown in

Figure 26.

Weekly Maintenance:

•

Clean/grease all dovetail ways.

Mill/drill is clean and lubricated.

Cleaning

Cleaning the Model G1005Z is relatively easy.

Remove excess cutting fluid and chips, and wipe

off the remaining moisture with a dry cloth. Treat

all unpainted cast iron and steel with a non-stain-

ing lubricant after cleaning.

Figure 26. Handwheel oiling location.

-26-

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SECTION 7: SERVICE

Review the troubleshooting and procedures in this section to fix your machine if a problem develops. 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

Symptom

Possible Cause

Possible Solution

Machine does not 1. Plug or receptacle is at fault or wired incor- 1. Test power plug and receptacle for good contact and

start or a breaker

trips.

rectly.

correct wiring.

2. Start capacitor is faulty.

2. Replace capacitor.

3. Motor connection is wired incorrectly.

4. Power supply is faulty, or is switched OFF.

3. Correct motor wiring (see Page 33).

4. Make sure all hot lines and grounds are operational

and have correct voltage on all legs.

5. Replace faulty switch.

5. ON/OFF switch is faulty.

6. Cable or wiring is open or has high resis- 6. Troubleshoot wires for internal or external breaks,

tance.

check for disconnected or corroded connections and

repair or replace wiring.

7. Motor is at fault.

7. Test, repair or replace motor.

Machine stalls or 1. Incorrect spindle speed for task.

1. Decrease spindle speed.

is underpowered.

2. Machine is undersized for the task.

2. Use smaller drill bits/cutters and reduce feed rate

and spindle speed.

3. Belt(s) is slipping.

3. Replace bad belts, align pulleys, and re-tension.

4. Test power plug and receptacle for good contact and

correct wiring.

4. Plug or receptacle is at fault.

5. Motor connection is wired incorrectly.

6. Pulley is slipping on shaft.

5. Correct motor wiring (see Page 33).

6. Replace loose pulley and shaft.

7. Rotate motor shaft for noisy or burnt bearings,

repair/replace as required.

7. Motor bearings are at fault.

8. Motor has overheated.

8. Let cool, clean linside/outside of motor, and reduce

workload on machine.

9. Motor is at fault.

9. Test, repair or replace motor.

10. Feed rate is too high.

10. Reduce feed rate.

-27-

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Symptom

Possible Cause

Possible Solution

Machine has

vibration or noisy

operation.

1. Motor or component is loose.

1. Inspect, replace for damaged bolts/nuts and retight-

en with thread locking fluid.

2. Belts are slapping belt cover.

2. Replace/realign belts with a new matched set, and

retension belts (refer to Page 23).

3. V-belt(s) is worn or is loose.

3. Replace belts.

4. Motor fan is rubbing on fan cover.

4. Replace/repair dented fan cover, and replace loose

or damaged fan.

5. Pulley is loose.

5. Remove pulley, replace with key as required, and

re-install securely.

6. Machine is incorrectly mounted to the bench, 6. Make sure bench mounting hardware is tight; place

or the bench is uneven.

shims under machine.

7. Chuck or cutter is at fault.

7. Replace out-of-round chuck, replace or resharpen

cutter, use appropriate feed rate and cutting RPM.

8. Check bearings, replace motor or bearings as

required.

8. Motor bearings are at fault.

9. Spindle bearings at fault.

9. Replace bearing.

Operation

Symptom

Possible Cause

Possible Solution

Milling/drilling 1. The belt is loose or worn.

1. Replace and/or adjust the belt.

stops, but the

motor still oper-

ates.

2. The pulley for the spindle shaft or the motor is 2. To resecure the pulley:

slipping on the shaft.

a. UNPLUG THE MILL/DRILL!

b. Remove nut and slipping pulley.

c. Clean all dust, grit and debris from the pulley

arbor.

d. Warm the pulley and nut so that they slide back

onto the pulley arbor.

e. Tighten the nut.

3. Drill bit slips in chuck.

3. Tighten bit; inspect bit for burrs or other obstructions

that might interfere with clamping surface.

Chuck, arbor or 1. Foreign material is stuck between the arbor-to- 1. Remove the chuck and clean and de-burr the

tooling wobbles

or is loose on the

spindle shaft.

spindle mating surface.

tapered chuck and spindle mating surfaces, then

reassemble.

2. Damaged tooling or chuck.

2. Replace.

The spindle does 1. The quill shaft is gummy with sawdust and oil. 1. Clean the gummy substance with penetrating oil and

not retract com-

pletely in the

uppermost posi-

tion or it binds.

lubricate with a light coat of oil.

2. The feed shaft return spring is weak.

2. Increase the feed shaft return spring tension as

described on Page 30.

3. The quill deflection screw is binding the quill.

3. Loosen jam nut, and slightly turn out screw where

the quill binds. Retighten jam nut and recheck for

binding and looseness at all spindle locations.

The quill has 1. The quill shaft is at fault.

1. Adjust the quill screw.

excessive deflec-

tion.

2. The quill and/or bearings are worn.

2. Replace the quill and/or bearings.

-28-

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Symptom

Possible Cause

Possible Solution

Drill bit wobbles, 1. Drill bit installed incorrectly.

1. Remove drill bit and reinstall.

2. Replace drill bit.

holes are over-

sized.

2. Drill bit is bent.

Tool slips in

collet.

1. Collet is not fully drawn up into spindle taper. 1. Snug up draw bar.

2. Wrong size collet.

2. Measure tool shank diameter and match with

appropriate diameter collet.

3. Debris in collet or in spindle taper.

4. Taking too big of a cut.

3. Remove all oil and debris from collet and spindle

taper.

4. Lessen depth of cut and allow chips to clear.

Breaking tools or 1. RPM and or feed rate is too fast.

1. Use tables to set correct RPM and feed rates.

2. Use cutting fluid or oil for appropriate application.

3. Lessen depth of cut and allow chips to clear.

cutters.

2. Cutting tool getting too hot.

3. Taking too big of a cut.

Machine is loud

when cutting,

overheats or

bogs down in the

cut.

1. Excessive depth of cut.

2. Dull cutting tools.

3. RPM and feed rate too high.

1. Decrease depth of cut.

2. Use sharp cutting tools.

3. Use appropriate RPM and feed for the job.

Workpiece

vibrates or

chatters during

operation.

1. Table locks not tight.

2. Spindle lock not tight.

3. Workpiece not securely clamped to table or

into mill/drill vice.

4. RPM and feed rate too high.

1. Tighten down table locks.

2. Tighten spindle lock.

3. Check that clamping is tight and sufficient for the

job. Make sure mill/drill vice is tight to the table.

4. Use appropriate RPM and feed for the job.

Table hard to

move.

1. Table locks are tightened down.

2. Chips have loaded up on bedways.

1. Make sure table locks are fully released.

2. Frequently clean away chips that load up during

milling operations.

3. Bedways are dry and in need of lubrication.

4. Longitudinal stops are interfering.

3. Lubricate bedways and handles.

4. Check to make sure that stops are loose and not

hitting the center stop.

5. Gibs are too tight.

5. Loosen gib screw(s).

Bad surface fin-

ish.

1. Wrong RPM or feed rate.

2. Dull cutting tool or poor cutting tool selection. 2. Sharpen cutting tool or select a better cutting tool

for the intended operation.

1. Adjust for appropriate RPM and feed rate.

3. Wrong rotation of cutting tool.

4. Workpiece not securely clamped.

3. Check for proper cutting rotation for cutting tool.

4. Secure properly.

-29-

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Depth Stop

Calibration

Feed Shaft Spring

Tension

The Model G1005Z comes fitted with a depth

stop to use when drilling multiple holes at the

same depth. The scale on this depth stop can be

calibrated if it ever becomes incorrect.

The feed shaft return spring is adjusted at the

factory; however, during the life of the mill/drill

you may want to adjust the feed shaft return

spring so the return pressure suits your operating

needs.

To calibrate the depth stop:

1. Loosen the calibration nut shown in Figure

27.

Wear safety glasses when

adjusting springs. Serious

injury may occur if this

warning is ignored!

Depth Nut

Jam Nut

To adjust the feed shaft spring tension:

1. UNPLUG THE MILL/DRILL!

Depth Stop

Bracket

2. Wipe off any oil on the spring lock cover so

it does not slip in your fingers when you hold

the cover from spinning (see Figure 28 for

spring lock cover identification).

Return

Height Nut

Calibration

Nut

Spring Cover

Lock Slot

Figure 27. Depth stop assembly.

Cap Screw

2. Set the depth nut to zero, and secure it with

the jam nut.

3. Tighten the calibration nut to hold the depth

stop in position.

4. Move the depth nut and jam nut to a non-zero

measurement to allow the spindle to move.

Spring Lock

Cover

5. Test the depth stop by measuring how far the

spindle actually moves from where you set

the depth stop.

Figure 28. Return spring assembly.

-30-

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5. Pull the cover outward just enough to

disengage the spring-cover lock slot from the

locking lug.

A high tension coiled spring is underneath

the cover. Put on heavy leather gloves to

protect yours hands from possible injury

when removing the cover.

Note: It is important to keep a good grip

during this step. Letting go of the cover will

cause the spring to rapidly uncoil, which

could cause serious injury!

6. Rotate the cover counterclockwise to increase

spring tension, or let the cover slowly unwind

in the clockwise direction to reduce spring

tension.

7. Engage the next available spring-cover lock

slot with the locking lug and hold the spring

cover tightly against the side of the head

stock.

8. Tighten the lock nut against the spring cover

just until the cap screw stops, and then back

off the cap screw approximately ⁄3 turn, or

just enough so there is no binding at complete

spindle travel.

Figure 29. Loosening cover and cap screw.

3. Put on heavy leather gloves to protect your

hands from possible injury if the spring

uncoils during the next step.

4. While holding the spring lock cover against

the side of the head stock so the cover stays

splined with the locking lug; loosen the cap

screw approximately ¹⁄4" (see Figure 29).

-31-

G1005Z Mill/Drill

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Electrical Components

Figure 30. G1005Z Junction Box.

-32-

G1005Z Mill/Drill

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Wiring Diagram

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-33-

G1005Z Mill/Drill

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G1005Z Main Assembly Breakdown

-34-

G1005Z Mill/Drill

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G1005Z Main Assembly Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

P1005001

P1005002

P1005003

P1005004

P1005005

PS04

HEAD BODY

PSB01

CAP SCREW 1/4-20 X 5/8

WORM SHAFT

CHUCK ARBOR BOLT 7/16-20

SPINDLE LOCKNUT 34 X 16

SPINDLE PULLEY

P1005044

P1005045

P1005Z046

P1005Z048

P1005049

P1005Z050

P1005Z051

P1005Z052

PW01

BUSHING

CRANK ARM

OUTER BEARING PLATE

PHLP HD SCR 1/4-20 X 1/2

SPINDLE TAPER SLEEVE SET

SPINDLE TAPER SLEEVE

BALL BEARING 6007ZZ

WASHER 60 X 55 X 16

EXT RETAINING RING 35MM

EXT RETAINING RING 61MM

RUBBER SEAL

CRANK HANDLE

WORM GEAR

P1005007

P1005007-1

P6007

WORM GEAR SHAFT

GIB

7-1

7-2

7-3

7-4

GIB

P1005007-3

PR12M

FLAT WASHER 1/2

LOCK HANDLE

P1005Z054

P1005Z055

PN08

P1005Z008

P1005Z009

P1005010

SPECIAL SET SCREW 3/8-16 X 32

HEX NUT 3/8-16

RACK SLEEVE SET

P1005Z057

P1005058

P1005Z059

P1005Z060

PW01

COMPRESSION SPRING 1/2 X 3-1/16

10-1 P1005010-1

SPANNER NUT 24.5-20

10-2 P1005Z010-2 EXT TOOTH WASHER 25

RUBBER BUSHING

HEX BOLT 1/2-12 X 6-3/4

FLAT WASHER 1/2

HEX NUT 1/2-12

10-3 P30205

TAPERED ROLLER BEARING 30205

10-4 P1005Z010-4 RACK SLEEVE

10-5 P30206

TAPERED ROLLER BEARING 30206

PN41

10-6 P1005010-6

10-7 P1005010-7

SPINDLE SHAFT

P1005063

PS09

THUMB SCREW 3/8-16 X 17

PHLP HD SCR 1/4-20 X 1/4

BELT COVER

BEARING CAP

P1005011

PB10

FEED BASE

P1005066

P1005Z067

P1005068

P1005Z069

PW06

HEX BOLT 1/4-20 X 2

HEX NUT 1/4-20

SLIDING COVER

PN05

SPINDLE COVER

FLAT HD SCR M3-0.5 X 15

FLAT WASHER 1/4

PHLP HD SCR 1/4-20 X 1/2

IDLER PULLEY BASE

HEX NUT 5/8-11

P1005015

P1005016

PN08

CHUCK ARBOR R8 W7/16-20

CUTTER ARBOR R8 W7/16-20

HEX NUT 3/8-16

PS04

P1005018

PN01

GRADUATED ROD SET

HEX NUT 1/2-20

P1005Z074

PN04

P1005020

PFH08

PINION SHAFT

P1005Z076

P1005077

P1005078

PVA30

IDLER PULLEY SET

MOTOR PULLEY SET

OILER 1/4

FLAT HD SCR 10-24 X 1/2

KEY 7 X 7 X 20

PK25M

P1005023

FEED COVER SET

FEED COVER

V-BELT A-30 4L300

V-BELT A-38 4L380

FLAT WASHER 5/16

HEX BOLT 5/16-18 X 1-1/2

MOTOR 1HP 110V/220V 60HZ 1PH

23-1 P1005023-1

23-2 P1005023-2

23-3 P6202

PVA38

WORM SHAFT

PW07

BALL BEARING 6202ZZ

EXT RETAINING RING 15MM

PB11

23-4 PR05M

P1005083

23-5 P1005Z023-5 SPACER 34 X 28

83-1 P1005Z083-1 MOTOR FAN

P1005024

PS06

WORM COVER

83-2 P1005Z083-2 MOTOR FAN COVER

83-3 P1005Z083-3 START CAPACITOR 150 MFD 250VAC

83-4 P1005Z083-4 MOTOR JUNCTION BOX

PHLP HD SCR 10-24 X 3/8

MICRO ADJUSTING INDICATOR

HANDWHEEL ASSEMBLY

CAP SCREW 5/16-18 X 3/4

WORM GEAR

P1005Z026

P1005Z028

PSB07

P1005084

P1005085

PB03

KEY 7 X 7 X 38

MOTOR MOUNT PLATE

HEX BOLT 5/16-18 X 1

FLAT WASHER 5/16

HEX NUT 5/16-18

HEX BOLT 3/8-16 X 1/2

WIRE RELIEF RETAINER

PHLP HD SCR 1/4-20 X 1/2

MILLING CUTTER

CHUCK 1/2-JT6

P1005031

P1005Z032

P1005Z033

P1005Z034

P1005Z035

P1005Z036

P1005Z037

PS08

COMPRESSION SPRING 11/16 X 1

PINION HUB

PW07

PN02

PINION HUB CAP

PB34

DOWNFEED HANDLE 1/2-12

DOWNFEED HANDLE KNOB 1/2-12

COIL SPRING BASE

P1005090

PS04

P1005092

P1005093

PHLP HD SCR 10-24 X 3/4

COIL SPRING & SPRING COVER

LOCK WASHER 1/4

P1005Z040

PLW02

93-1 P1005093-1

109 P1005109

CHUCK KEY

SWITCH

PW06

FLAT WASHER 1/4

-35-

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G1005Z Table Breakdown

-36-

G1005Z Mill/Drill

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G1005Z Table and Labels Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

601

602

603

604

605

606

607

609

610

611

612

613

616

617

618

619

620

621

622

623

624

625

626

627

628

P1005601

P1005602

P1005603

PSB04

TABLE

629

630

631

632

633

634

635

636

637

638

640

641

642

643

644

645

646

647

648

649

650

651

652

653

P1005Z629

P1005630

PSB03

LOCK HANDLE 5/16-18 X 1-3/8

T SCREW 5/16-18 X 42

CAP SCREW 5/16-18 X 1

CAP SCREW 5/16-18 X 1/4

ACME NUT 23.5 X 10

SWIVEL BASE

FIXED BLOCK

MOVABLE FIXED RING

CAP SCREW 1/4-20 X 1/2

OILER 1/4

PSB69

P1005605

P1005606

P1005Z607

P1005609

PRP82M

P1005Z633

P1005634

P1005Z635

P1005636

P1005637

P1005638

P1005640

PSB20

HAND WHEEL

HANDWHEEL HANDLE

TABLE CLUTCH

ACME SCREW 23.5 X 10 X 390

COLUMN BASE

ROLL PIN 5 X 38

LEFT FLANGE

RACK

P1005611

PSB07

COLUMN HEAD SET

COLUMN FLANGE RING

CAP SCREW 7/16-14 X 2

LOCK WASHER 7/16

CAP SCREW 5/16-18 X 3/4

LOCK WASHER 5/16

PLUG

CAP SCREW 5/16-18 X 3/4

TABLE NUT 23.5-10

ACME SCREW 1/4-20 X 762

KNURLED THUMB SCREW M6-1 x 10

LIMIT PLATE

P1005Z613

P1005Z616

P1005Z617

P1005618

P1005619

P1005Z620

P1005621

P1005622

P1005623

P1005624

P1005625

PB09

PLW05

PSB07

PLW01

RIVET 2

P1005645

P1005646

P1005Z647

P1005Z648

P1005Z649

P1005Z650

P1005Z651

P1005Z652

TABLE BASE

VISE

ANTIDUST PLATE

GIB STRIP

MACHINE NAME PLATE

MACHINE SPEED CHART

READ MANUAL HORIZ SMALL

SAFETY GLASSES HORIZ SMALL

HAND MILL WARNING SMALL

MACHINE WARNING LABEL

GIB STRIP

MOVABLE FIXED BLOCK

HEX BOLT 5/16-18 X 1/2

GIB STRIP BOLT 5/16-18 X 42

BUSHING

P1005627

P1005628

XLABEL04S ELECTRICITY

648

651

649

652

650

653

647

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.

-37-

G1005Z Mill/Drill

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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.

-38-

G1005Z Mill/Drill

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