Grizzly G1778 Welder User Manual
Contents
1. uot POWER FEEDER MODEL G1778 INSTRUCTIONAL MANUAL B GRIZZLY IMPORTS INC COPYRIGHT 1993 BY GRIZZLY IMPORTS INC TX3 601207 93 WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN CONSENT OF GRIZZLY IMPORTS INC REVISED OCTOBER 1994 DISCONTINUED MACHINE MANUAL DISCLAIMER THE INFORMATION IN THIS MANUAL REPRESENTS THE LAST CONFIGURATION OF THE MACHINE BEFORE IT WAS DISCONTINUED MACHINE CONFIGURATIONS MAY HAVE CHANGED AS PRODUCT IMPROVEMENTS WERE INCORPORATED IF YOU OWN AN EARLIER VER SION OF THE MACHINE THIS MANUAL MAY NOT EXACTLY DEPICT YOUR MACHINE CONTACT CUSTOMER SERVICE IF YOU HAVE ANY QUESTIONS ABOUT DIFFERENCES PREVIOUS VERSIONS ARE NOT AVAILABLE ONLINE WARNING some dust created by power sanding sawing grind ing 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 e 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 equipment such as those dust masks that are specially designed to fil ter out microscopic particles T2. DIRECTION OF FEED Always feed your work against the direction of the sanding spindle Workpieces fed in the same direction as the spindle travel could be forced out of your control NEVER LEAVE THE TOOL RUNNING UNATTENDED TURN POWER OFF Do not leave the tool until it comes to a full stop DRUGS ALCOHOL MEDICATION Do not operate the tool under the influence of drugs alco hol or any medication Never operate machinery when overly fatigued sTo IV UNPACKING The Model G1778 Power Feeder is shipped from the factory in two heavy duty cardboard packages Find a clear work area to open the packages and inventory their contents Use particular care when unpacking the boxes to inspect all of the parts for damage incurred during shipping If you find the machine is damaged after you ve signed for delivery and the truck and driver are already gone you will need to file a freight claim with the carrier Save the containers and all pack ing materials for inspection by the carrier or their agent Without the packing materials filing a freight claim can be difficult If you need advice regarding this situation please call us CAUTION The shipping weight of the Model G1778 Power Feeder is a hefty 86 pounds DO NOT over exert yourself while unpacking or moving the shipping boxes V PARTS INVENTORY Once the Model G1778 components are unpacked from their containers take a moment to verify that all the necessary parts have been include
3. on the column bracket If you find that you are still having trouble inserting the horizontal column into the bracket you may need to loosen the guide bolt After the horizontal column is attached to the vertical column attach the horizontal leadscrew See Figure 3 The leadscrew is attached to the column bracket by screwing it into the threaded opening just below the horizontal column After the leadscrew has been threaded through the bracket attach the column cap to the end of the horizontal column 6 Three setscrews hold the column cap to the horizontal column You will need to loosen those setscrews to properly seat the column cap on the column Two of the setscrews are seen in Figure 3 At this point attach the handles to the handwheels with a 12mm open end wrench 3 8 Through Bolt F Bit Tapped Figure 3 Figure 4 Once the first three components are attached snug up the guide bolt on the column bracket The bolt should be tight enough to keep the horizontal column from twisting in the bracket yet loose enough to allow for smooth column movement Tighten the bolt in small increments and turn the horizontal handwheel to test movement Once you ve found proper adjustment you can tighten the clamping lever Now that the columns are properly attached let s turn our attention to the power feeder s base Depending on what machine you intend to install the Model G1778 on locate the point on your machine s table wher
4. 0 438 5901 E Mail techsupport grizzly com Web Site http www grizzly com COMMENTARY To operate this or any power tool safely and efficiently it is essential to become as familiar with its characteristics as possible Take as much time as necessary to become acquainted with the Model G1778 Power Feeder The time you invest before you begin to use this machine will be time well spent If you do not understand something do not operate this machine The specifications drawings and photographs illustrated in this manual represent the Model G1778 as supplied when the manual was prepared However owing to Grizzly s policy of continuous improvement changes to the Model G1778 may be made at any time with no obligation on the part of Grizzly The information in this manual has been obtained from sources believed to be reliable and as up to date as possible We have focused primarily on the proper assembly and adjustment of your power feeder as well as some basic information on using the power feeder on specific machines We have also included some important safety measures which we believe to be essential to this machine s operation While most safety measures are generally universal Grizzly cautions that each workshop is different and safety rules should be considered as they apply to your individual situa tion The primary function of the Model G1778 is to provide automated material handling capabilities for your shaper or tab
5. ABLE OF CONTENTS PAGE INTRODUCTION 1 Il COMMENTARY nt Me Ml stat eee dates 1 lil SAFETY RULES FOR ALL TOOLS ageet ENER 2 IV UNPACKING aimons nine 4 V PIECE INVENTORY 4 Vi CLEAN UP BEFORE ASSEMBLY 5 Vil ELECTRICAL SERVICE REQUIREMENTS AAA 5 ASSEMBLY r a er hace 6 IX ADJUSTMENTS entiere Motte ne 8 ROLLER PLACEMENT ann means 8 FEED RATES nc 10 X GEARING EE 10 xI MAINTENANCE icira e a a E E 11 GEARBOX nn rates E E E S 11 e el E 11 AND GEARS asie 11 CLOSURE A dt tou 11 MACHINE DATA DEE 12 XIV WARRANTY AND 6 2 4 22 13 XV PARTS LISTS AND DIAGRAMS 14 AY GEARBOX DIAGRAM EE 14 PARTS LIST GEARBOX DIAGRAM ire 15 COLUMN Ree EE 16 D PARTS LIST COLUMN DIAGRAM 16 MOTOR DIAGRAM oor E A Eaei 17 PARTS LIST MOTOR DIAGRAM iii 17 COPYRIGHT 1993 BY GRIZZLY IMPORTS INC TX3 601207 93 WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM
6. EL Do not wear loose clothing gloves neckties or jewelry that might get caught in moving parts Non slip footwear is also recommended Wear a hat or other pro tective head wear if your hair is long USE SAFETY GLASSES AND EAR PROTECTION Also use a dust mask whenever operating the power feeder SECURE YOUR WORK Use clamps or a fixture to hold your work It is safer than using your hands and frees up both hands for operating the tool DO NOT OVERREACH Keep proper footing and balance at all times MAINTAIN TOOLS IN TOP CONDITION Keep tools sharp and clean for best and safest per formance Follow instructions for lubricating and changing accessories DISCONNECT TOOLS FROM POWER before servicing and when changing accessories such as spindles and inserts USE RECOMMENDED ACCESSORIES Consult the current catalog for recommended acces sories The use of improper accessories may be hazardous AVOID ACCIDENTAL STARTING Make sure the switch is in the OFF position before plug ging in the cord NEVER STAND OR LEAN ON TOOL Serious injury could occur if the tool is tipped or if the abrasive surfaces are accidentally contacted CHECK DAMAGED PARTS Before further use of the tool any part or guard that is damaged should be promptly repaired or replaced Do not operate the machine until you are certain it is in perfect running condition Failure to follow this precaution could result in further mechanical damage and operator injury
7. R ARRANGEMENT Figure 11 11 MACHINE DATA GRIZZLY MODEL G1778 POWER FEEDER Overall Dimensions ues DR t s 24 VS De LU E 30 Overall eee idee ieee 14 Shippin Weight EE 85 Ibs 80 16 Construction Steel SEENEN Ee Cast HOUSING Cast Aluminum Wheels 3 NEE Synthetic Rubber Motor Type see eee ee aia Neate TEFC Capacitor Start Induction E Ren 14 Phase Type Voltage Single Phase 110V 60 Hertz 1720 RPM igen Forward Reverse dense a nan tae Shielded and Lubricated For Life Features Spring Tension Rollers Heavy Duty Gear Reduction Universal Positioning with Locking Handles Six Feed Speeds Specifications while deemed accurate are subject to change without notice 12 XIV WARRANTY AND RETURNS LIMITED WARRANTY Grizzly Imports Inc warrants every product it sells for a period of one year on all parts and one year on all electric motors to the original purchaser from the date of purchase
8. RBOX DIAGRAM Ref Part 001 PSB15M 02 PLWO1M 03 P1778003 04 P1778004 05 1778005 1778006 1778007 1778008 1778009 1778010 1778011 PLWO4M 1778014 1778015 1778016 1778017 PKO6M P1778019 P1778020 P1778021 PSB33M P1778023 P1778024 P1778024A Description 3 4 5 Nut M8 1 25mm Oil Plug s 18 Cap Screw M5 0 8x12 Gear 26T Gear 18T 0 0 7 008 1 1 1 0 1 014 015 016 017 wech 019 020 021 022 023 024 024 15 Ref Part Description 024 1778024 Gear 20 0 P1778029 P1778030 PR17M Retaining Ring 32 33 34 35 36 37 38 43 Setscrew M6 1 0x12mm 44 Nut M10 1 5mm 45 Washer 7 4 PB10M Screw M6 1 0x25mm C COLUMN D D s 9 lt gt K lt i 5 28 CH E j H 2 2 Ea VA 5 44474446006 DIAGRAM D PARTS LIST COLUMN DIAGRAM Ref Part Description S S S e 16 a a a ech Ref Part 116 Pwor 119 21778119 Li Description Handle Setscrew M6 1 0x12mm Setscrew M8 1 25x12mm Bolt M12 1 75x45mm Flat Washer 1 2 Nut M16 1 5mm Lock Handle Angular Joint Angular Joint Flat Washer 8mm E MOTOR DIAGRAM PARTS LIST MOTOR DIAGRAM Ref Part De
9. This warranty does not apply to defects due directly or indirectly to misuse abuse negligence accidents repairs or alter ations or lack of maintenance This is Grizzly s sole written warranty for any and all warranties that may be implied by law including any merchantability or fitness for any particular purpose are here by limited to the duration of this written warranty We do not warrant or represent that the merchan dise 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 the product or part must be returned to either our Bellingham or Williamsport warehouse freight pre paid Proof of purchase must accompany the merchandise The manufacturers reserve the right to change specifications at any time as they continually 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 13 XV PARTS LISTS AND DIAGRAMS A GEARBOX DIAGRAM PARTS LIST GEA
10. WITHOUT THE WRITTEN CONSENT OF GRIZZLY IMPORTS INC REVISED OCTOBER 1994 INTRODUCTION We are proud to offer the Model G1778 Power Feeder The Model G1778 is part of a growing Grizzly family of fine woodworking machinery When used according to the guidelines set forth in this man ual you can expect years of trouble free enjoyable operation and proof of Grizzly s commitment to customer satisfaction The Model G1778 is intended for use in a home workshop or small professional shop Its heavy duty 1 4 motor combined with versatile reduction gearing and spring activated rollers provide plenty of power and traction even on large workpieces We are also pleased to provide this instructional manual with the Model G1778 Power Feeder This manual was written to guide you through assembly review safety considerations and cover general operating procedures If you have any constructive criticisms or comments you feel we should include in our next printing please write us at the address below Manager Technical Documentation Grizzly Industrial Inc P O Box 2069 Bellingham WA 98227 Finally we stand behind our machines We have two excellent regional service departments at your disposal should the need arise If you have any service questions or parts requests please call or write us at the appropriate location listed below Grizzly Industrial Inc 1203 Lycoming Mall Circle Muncy PA 17756 Phone 570 546 9663 Fax 80
11. ate the desired feed rate on the chart shown in Figure 11 Remove the hex nuts which hold the drive gears in place See Figure 10 Remove the existing gears and replace with the new gears Replace the hex nuts and attach the drive gear cover Figure 10 10 XI MAINTENANCE A GEARBOX The internal gearbox holds 65cc of SAE 30W gear oil The oil should be drained and replaced after every 500 hours of operation A drain plug at the bottom of the gearbox provides access for removal of old oil Re fill to within 2 4 of the filler plug B ROLLERS Each of the three roller wheels is fitted with a grease fitting Lubricate after every 200 hours of use C CHAINS AND GEARS Lubricate drive gears and chains with grease after every 200 hours of operation Clean and lubri cate all the machined surfaces with light machine oil CLOSURE The following pages contain machine specifications parts lists parts diagrams and warranty and return information for your Model G1778 Power Feeder Feel free to write or call us if you have questions Our service staff will be glad to help you if you need parts or service assistance If you have questions or comments about this manual please write to our Bellingham Washington location Thank you for your purchase We sincerely appreciate your business and look forward to serving you again FEED RATE FEET MIN 30 43 52 De sch sch d B a GEA
12. cessarily comprehensive Be sure your electrical configuration complies with local and state codes If you have questions about your specific situation feel free to call our service tech nicians ASSEMBLY Most of the power feeder has been assembled at the factory The remaining assembly requirements should not take a large amount of time Take a moment to examine the parts diagrams at the back of this manual to familiarize yourself with the various parts Horizontal Vertical Vertical Column Se Column Handwheels Horizontal Vertical Leadscrews Assembly Figure 2 While the Model G1778 Power Feeder looks somewhat complicated at first the assembly process is really quite simple Start the assembly process by attaching the horizontal column the vertical column and the hori zontal leadscrew Begin by removing the base from the vertical column assembly The base can be removed by loosening the clamping lever attached to the side of the base The next several steps of the procedure are probably most easily accomplished by laying all of the parts out on a table or workbench The first step of assembly requires attaching the horizontal column to the vertical column Begin by loosening the clamping lever on the column bracket The horizontal column should slip easily through the column bracket The column must be inserted so the guide notch goes through the bracket Keep in mind that the notch must line up with the guide bolt
13. d You should have Power Feed Unit 2 Angular Joints Vertical Column Assembly Horizontal Column Leadscrew Assembly Parts Bag VERTICAL LEAD COLUMN ASSEMBLY HORIZONTAL COLUMN ANGULAR POWER JOINTS FEEDER UNIT __ TOOLS PARTS BAG d GEARS PARTS BAG Figure 1 VI CLEAN UP All of the unpainted surfaces on this machine and a few of the painted ones are coated with a rust preventative oil The coating can be removed with paint thinner mineral spirits and a good sup ply of paper towels DO NOT use gasoline lacquer thinner acetone or other highly flammable solvents to remove the coating The possibility of flash fire or explosion is far greater and they don t work much better than mineral sprits anyway Don t use chlorinated solvents such as perchloroethelene they will lift the paint and ruin the Power Feeder s finish While you are cleaning the Power Feeder please pay attention to the following rules 1 Work only in a well ventilated area 2 Make sure there are no sources of open flame in your work area such as pilot lights or wood stoves 3 DO NOT smoke while you re working 4 Dispose of soiled towels in a proper manner to avoid fire and environmental damage Vil ELECTRICAL SERVICE REQUIREMENTS The Model G1778 is wired for 110 120V single phase operation it cannot be operated on 220 240V The 1 4 H P 1720 R P M motor draws 3 8 amps This is not a large load Ho
14. e installation will not affect movement of fences or other moving parts The base should be mounted as close to the actual work area as possible without interfering with machine operation The shorter the amount of distance between the base and the rollers the less likely the power feeder will torque out of its desired position You might consider mounting the base on a stable piece of hardwood with the mounting bolts countersunk in the bottom of the wood You can temporarily mount the power feeder on your table with clamps to find the base location that best suits your needs Using the base as your template locate the best mounting point Mark the outside perimeter of the base and the locations of the four bolt holes on your table Measure the distances of the four mount ing holes from the edges of the table with a tape measure or yardstick and compare those mea surements with the bottom of the table Make sure the mounting holes will not align with cast braces on the underside of the table The proper drilling pattern as shown in Figure 4 features 4 holes at 23 4 distance The holes should be drilled at s if you intend to attach the base to the table with through bolts If you intend to drill and tap holes for your mounting bolts use an F drill bit in con junction with a 5 16 18 tap When you are satisfied you have properly located the base drill through your table and attach the base with the fasteners you have chosen for your applicat
15. e resolved any questions you might have The following are important safety rules for all tools 1 KNOW YOUR POWER TOOL Read the owner s manual carefully Learn the tool s applications and limitations as well as its particular hazards 2 KEEP GUARDS AND INSERTS IN PLACE and in working order 3 GROUND ALL TOOLS If the tool is equipped with a three prong plug it should be plugged into a three hole grounded outlet If an adapter is used to accommodate a two prong receptacle the adapter plug must be attached to a known ground Never remove the grounding prong 4 REMOVE ADJUSTING KEYS AND WRENCHES Make it a habit to check that keys and adjust ing wrenches are removed from the machine before turning it on 5 KEEP WORK AREA CLEAN Cluttered areas and benches invite accidents 6 AVOID DANGEROUS ENVIRONMENTS Do not use power tools in damp or wet locations or expose them to rain Keep your work area well lighted 2 10 11 12 13 14 15 16 17 18 19 20 21 22 23 KEEP CHILDREN AND VISITORS AWAY All children and visitors should be kept a safe dis tance away from your work area MAKE WORKSHOP CHILD PROOF with padlocks master switches or by removing starter keys DO NOT FORCE TOOL Tools work better and more safely when they are allowed to work at their own speed USE THE RIGHT TOOL Do not use a tool or an attachment to do a job it wasn t intended for WEAR PROPER APPAR
16. eel 4 Set the wheel height between 7 16 and t s below the height of the material you intend to mill The wheels when properly adjusted will put consistent downward pressure on your workpiece See Figure 7 Figure 7 Figure 8 The power feeder can also be set to support your work against a fence as shown in Figure 8 As with the previous arrangement the rollers should be slightly angled to hold the workpiece against your cutting surface This arrangement is ideal for milling edges and when using the power feeder with a jointer When using the power feeder this way it is essential to make sure that the fence is fastened tightly in place As before you will want to set the distance between the rollers and in this case the fence about 16 to s under the thickness of the material to be milled When used on its side you will want to adjust the rollers so the leading wheel is about s closer to the table than the trailing wheel There are three important factors to consider when using the power feeder with a table saw pinch ing binding and blade height If you are ripping boards 4 or wider place the power feeder between the fence and blade with the rollers turned slightly toward the fence If you are ripping materials less than 4 set the rollers as close as possible to the fence It is important in this case that you don t set the rollers so the waste side of your material binds or pinches the blade The rollers should be ang
17. ion Once the holes are drilled and the base is mounted with appropriate hardware loosen the clamp ing lever on the base and attach the column assembly Tighten the clamping lever when the columns are in place The next step is to attach the angular joints to the motor and roller assembly and attach that entire unit to the outboard end of the horizontal column To begin connect the two angular joints The 45 joint is fitted with a threaded knob which is inserted into the 90 joint Tighten the locking lever on the 90 joint with the two joints aligned as shown in Figure 5 Attach the motor and roller assembly 27 to the angled joints The roller casing mounts in an identical fashion as described for the angle joints Attach the knob on the roller casing to the 45 angle joint and tighten the locking lever Once the motor and roller assembly is attached to the angle joints attach the entire unit to the col umn assembly The column clamp may need to be spread slightly to attach it to the horizontal col umn Use extreme care when spreading the clamp Too much force could break the casting Figure 5 Figure 6 It s essential for proper power feeder operation that the feed rollers be parallel to the machine s table To adjust the power feeder lower the horizontal column using the handwheel at the top of the vertical column until the rollers contact the table If the rollers touch unevenly loosen the locking lever on the 45 angula
18. le saw Feed speed is controlled by interchangeable gear systems which allow you to customize the motor to drive wheel ratio giving you six possible speeds to choose from ranging from 16 to 52 feet per minute FPM We recommend that your keep a current copy of the Grizzly catalog for complete information regard ing Grizzly warranty and return policy Should you need additional technical information relating to this machine parts or general assistance please contact the appropriate regional service depart ment We also believe that additional information sources are very important to help you realize the full potential of your woodworking equipment Trade journals woodworking magazines woodworking clubs and your local library all excellent sources of information lll SAFETY RULES FOR ALL TOOLS WARNING As with all power tools there is a certain amount of inherent danger associated with the Model G1778 Power Feeder Using the tool with respect and caution will considerably lessen the possibility of mechanical damage or operator injury However if normal safety precautions are over looked or ignored injury to the operator or others in the area is possible There are certain applications for which this tool was designed We strongly emphasize that this tool should never be modified and or used for any application other than that for which it was designed If you are confused about any aspect of this machine do not use it until you hav
19. led with no more than t s of variation between the leading and trailing wheels IMPORTANT It is essential when ripping narrow materials that the blade height on your table saw be at or just slightly below the bottom of your rollers See Figure 9 If the material you are cutting requires you to place the saw blade directly below you rollers set your saw blade slightly below the full thickness of your workpiece Figure 9 9 B FEED RATES The optimum feed rate for the Model G1778 Power Feed will vary depending on a number of fac tors including the thickness of the material to be cut the hardness of the workpiece the speed of the cutting tool and the configuration of the cutting tool number of teeth shape of cutter etc Generally the following rules can be followed with a good level of success The thicker the material to be cut the slower the feed rate The harder the material the slower the feed rate The faster the cutter speed the faster the feed rate The greater the number of teeth or cutting surfaces the faster the feed rate X GEARING The Model G1778 Power Feed gearbox allows you to tailor your feed rate to match individual pro jects Feed rates range from 16 to 52 feet per minute See Figure 11 To change gears 1 2 Remove the gearbox cover by unscrewing the knurled knob on the front of the power head Determine the speed you desire based on your material and cutter configuration Loc
20. r joint and continue to lower the horizontal column until all of the rollers are touching the table evenly Re tighten the locking lever IX ADJUSTMENTS The effectiveness of your Model G1778 Power Feeder depends on proper placement of the rollers and the speed at which they turn In this section we will look at the the adjustments that will opti mize power feeder performance A ROLLER PLACEMENT If you look at the rollers as shown in Figure 6 you will notice that the gap between the leading and middle roller is larger than that between the middle and trailing roller That arrangement allows you to place the rollers so the first wheel is slightly ahead of your cutting tool while the middle and third wheels are behind Thus the rollers feed your workpiece into through and past the cutting surface without contact between the wheels and cutter Positioning the roller assembly this way not only pro vides a consistent application of power to the workpiece it also acts to keep your hands away from cutting surfaces To position the rollers correctly 1 Raise the horizontal column so the rollers are just above the table 2 Swing the motor and roller assembly so the rollers are just slightly away from the cutter with the leading roller slightly forward of the cutting surface 8 3 Turn the feed rollers so they are angled just slightly toward the fence The leading wheel should be just about s closer to the fence than the trailing wh
21. scription Ref Part Description Cord 1778204 O Ring p1778111_ Switch Cover P1778205 Screw M3 5 0 6x13mm P1778212 Handle 1778206 Wire Clamp P1778213 P1778207 Strain Relief RS DE 17
22. wever if you operate the power feeder on a circuit that is already close to capacity it could overload that circuit If an unusual load does not exist and a power failure still occurs have the circuit inspected by a qualified electrician This equipment must be grounded The Model G1778 is equipped with a grounded cord and plug Please ensure that the outlet and circuit you select is wired for 110 120V and is properly grounded If the circuit isn t grounded it will be necessary to run a separate 12 AWG copper wire from the out let to a known ground If adding a new circuit please ensure that the circuit is connected to the grounding terminal in your electrical service panel Under no circumstances should the grounding pin be removed from the three pronged plug A 15 amp fuse or circuit breaker should be used when fusing the power feeder Circuits rated any higher are not adequate to protect the motor from power surges If you find it necessary to use an extension cord with the Model G1778 make sure the cord is rated Hard Service grade S or better Cords up to 50 feet should contain 14 AWG wire The extension cord must also contain a ground wire and plug pin Always repair or replace extension cords when they become worn or damaged CAUTION In this section we have covered some basic electrical requirements for the safe opera tion of your G1778 Power Feeder As with the safety rules in the preceding section these require ments are not ne
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