Grizzly G0645 User manual
MODEL G0645
BENCHTOP MORTISING
MACHINE
OWNER'S MANUAL
COPYRIGHT © NOVEMBER, 2007 BY GRIZZLY INDUSTRIAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
#BL10079 PRINTED IN CHINA
Table of Contents
INTRODUCTION ............................................... 2
Foreword ........................................................ 2
Contact Info ................................................... 2
Machine Data Sheet ...................................... 3
Identification ................................................... 5
SECTION 1: SAFETY ....................................... 6
Safety Instructions for Machinery .................. 6
Additional Safety for Mortising Machines ...... 8
SECTION 2: CIRCUIT REQUIREMENTS ........ 9
110V Operation .............................................. 9
SECTION 3: SETUP ....................................... 10
Setup Safety ................................................ 10
Items Needed for Setup ............................... 10
Unpacking .................................................... 10
Inventory ...................................................... 11
Hardware Recognition Chart ....................... 12
Clean Up ...................................................... 13
Site Considerations ...................................... 13
Mounting ...................................................... 14
Assembly ..................................................... 14
Test Run ...................................................... 16
SECTION 4: OPERATIONS ........................... 17
Operation Safety .......................................... 17
Basic Operations ......................................... 17
Basic Controls .............................................. 17
Installing Mortising Chisel ............................ 18
Adjusting Depth Stop Rod ........................... 19
Adjusting Fence ........................................... 20
Hold Down ................................................... 20
Basic Mortising Operations .......................... 21
Rotating Column .......................................... 22
SECTION 5: ACCESSORIES ......................... 23
SECTION 6: MAINTENANCE ......................... 24
Schedule ...................................................... 24
Cleaning ....................................................... 24
Unpainted Cast Iron ..................................... 24
Drill Bits & Mortising Chisels ........................ 24
SECTION 7: SERVICE ................................... 25
Troubleshooting ........................................... 25
Adjusting Gibs .............................................. 26
Replacing Gas Spring .................................. 26
Electrical Components & Wiring Diagram ... 27
Parts Breakdown ......................................... 28
Parts List ...................................................... 29
Label Placement .......................................... 29
WARRANTY AND RETURNS ........................ 33
-2- G0645 Benchtop Mortising Machine
INTRODUCTION
Foreword
We are proud to offer the Model G0645 Benchtop
Mortising Machine. This machine is part of a grow-
ing Grizzly family of fine woodworking machinery.
When used according to the guidelines set forth in
this manual, you can expect years of trouble-free,
enjoyable operation and proof of Grizzly’s com-
mitment to customer satisfaction.
The specifications, drawings, and photographs
illustrated in this manual represent the Model
G0645 when the manual was prepared. However,
owing to Grizzly’s policy of continuous improve-
ment, changes may be made at any time with no
obligation on the part of Grizzly.
For your convenience, we always keep current
Grizzly manuals available on our website at www.
grizzly.com. Any updates to your machine will be
reflected in these manuals as soon as they are
complete. Visit our site often to check for the lat-
est updates to this manual!
If you have any comments regarding this manual,
please write to us at the address below:
Grizzly Industrial, Inc.
C/O Technical Documentation Manager
P.O. Box 2069
Bellingham, WA 98227-2069
Email: [email protected]
We stand behind our machines. If you have any
service questions or parts requests, please call or
write us at the location listed below.
Grizzly Industrial, Inc.
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: (570) 546-9663
Fax: (800) 438-5901
E-Mail: [email protected]
Web Site: http://www.grizzly.com
Contact Info
G0645 Benchtop Mortising Machine -3-
Machine Data Sheet
-4- G0645 Benchtop Mortising Machine
G0645 Benchtop Mortising Machine -5-
Figure 1. Model G0645 features.
A. Tool Storage Rack
B. Chuck Access Cover
C. Chisel and Drill Bit Set
D. Hold Down Lock Lever
E. Fence
F. Base
G. Fence Lock Lever
H. Extension Block
I. Gas Spring
J. Depth Stop Lock Lever
K. Hand Lever
L. Column
M. Fence Adjustment Knob
N. Hold Down
O. Depth Stop Rod
P. ON/OFF Switch
Identification
A
B
C
D
E
F
G
H
I
K
L
M
N
O
J
P
-6- G0645 Benchtop Mortising Machine
Safety Instructions for Machinery
G0645 Benchtop Mortising Machine -7-
-8- G0645 Benchtop Mortising Machine
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.
Additional Safety for Mortising Machines
5. ADJUSTMENTS. Hands may be seriously
injured if they come in contact with the
chisel and drill bit during operation. Do not
adjust the machine or workpiece while the
mortising machine is running. Wait for the
spindle to come to a complete stop and
unplug the machine before continuing.
6. INSPECTING MACHINE. Loose chisels
and bits can be ejected at the operator,
or the headstock can fall if not properly
secured, causing serious personal injury.
Inspect the machine for smooth head cast-
ing movement, loose drill bits/chisel hous-
ing, loose nuts/bolts and lock levers before
connecting the machine to power and oper-
ating. Correct any problems before use.
7. EXPERIENCING DIFFICULTIES. If at any
time you are experiencing difficulties per-
forming the intended operation, stop using
the machine! Contact Tech Support at
(570) 546-9663.
1. HAND PROTECTION. Do not place your
hands under an installed chisel at any
time or near the chisel while the spindle
is in motion. Chisels may become hot dur-
ing operation! Allow chisels to cool before
handling. Chisels are sharp! Always use
caution when handling, especially when
installing or removing.
2. USING CORRECT MATERIALS. Mortising
materials such as metals, plastics, and
glass can result in serious personal injury
and machine damage. Do not use the
machine for anything except mortising in
wood.
3. RESPIRATOR AND SAFETY GLASSES.
Dust and chips created from mortising and
may be ejected, becoming hazards to the
eyes and lungs. Always wear a respira-
tor and safety glasses while operating the
machine.
4. CHISEL COMPATIBILITY. Mortising bits
can fly out of chuck at the operator if not
properly secured, causing serious personal
injury. Make sure the mortising bit fits a
minimum of 1/2" into the chuck.
G0645 Benchtop Mortising Machine -9-
Figure 2. Typical 5-15 plug and receptacle.
110V Operation
Full Load Amperage Draw
Motor Draw ..............................................6 Amps
Minimum Circuit Requirements
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 cir-
cuit with one of higher amperage without consult-
ing a qualified electrician to ensure compliance
with wiring codes. If you are unsure about the
wiring codes in your area or you plan to con-
nect your machine to a shared circuit, consult
a qualified electrician.
110V Circuit ...........................................15 Amps
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.
Extension Cords
We do not recommend using extension cords, but
if you find it absolutely necessary:
• Use at least a 14 gauge cord that does not
exceed 50 feet in length!
• The extension cord must have a ground wire
and plug pin.
• A qualified electrician MUST size cords over
50 feet long to prevent motor damage.
SECTION 2: CIRCUIT REQUIREMENTS
Serious personal injury could occur if you
connect the machine to power before com-
pleting the setup process. DO NOT connect
the machine to the power until instructed
later in this manual.
Electrocution or fire could
result if machine is not
grounded and installed in
compliance with electrical
codes. Compliance MUST
be verified by a qualified
electrician!
Power Connection Device
The Model G0645 comes with a 5-15 plug, similar
to Figure 2, to connect the machine to power.
-10- G0645 Benchtop Mortising Machine
Wear safety glasses dur-
ing the entire setup pro-
cess!
This machine presents
serious injury hazards
to untrained users. Read
through this entire manu-
al to become familiar with
the controls and opera-
tions before starting the
machine!
Setup Safety
SECTION 3: SETUP
The following items are needed to complete the
setup process, but are not included with your
machine:
Description Qty
• Safety Glasses (for each person) .............. 1
• Hex Wrench 8mm ...................................... 1
• Mounting Hardware ................... As Needed
• Shop Rags for Cleaning ............. As Needed
• Solvent Cleaner/Degreaser ........ As Needed
• Assistant for Lifting Help ............................ 1
• Flat Head Screwdriver ................................ 1
• Phillips Head Screwdriver .......................... 1
• Wrench/Socket 13mm
(optional, for extension block) .................... 1
Items Needed for
Setup
Your machine was carefully packaged for safe
transportation. Remove the packaging materials
from around your machine and inspect it. If you
discover the machine is damaged, please imme-
diately call Customer Service at (570) 546-9663
for advice.
Save the containers and all packing materials for
possible inspection by the carrier or its agent.
Otherwise, filing a freight claim can be difficult.
When you are completely satisfied with the condi-
tion of your shipment, inventory the contents.
Unpacking
This machine and its
components are heavy.
Get lifting help to move
heavy items.
G0645 Benchtop Mortising Machine -11-
Inventory
The following is a description of the main compo-
nents shipped with your machine. Lay the compo-
nents out to inventory them.
Note: If you can't find an item on this list, check
the mounting location on the machine or examine
the packaging materials carefully. Occasionally
we pre-install certain components for shipping
purposes.
Box 1: (Figure 3) Qty
A. Hand Lever ................................................. 1
B. Gas Spring ................................................. 1
C. Tool Storage Rack ...................................... 1
D. Hold Down .................................................. 1
E. Mortising Chisel and Bit 1⁄4" ........................ 1
F. Mortising Chisel and Bit 5⁄16" ....................... 1
G. Mortising Chisel and Bit 3⁄8" ........................ 1
H. Mortising Chisel and Bit 1⁄2" ........................ 1
I. Extension Block .......................................... 1
J. Hardware & Tools (Not Shown) ................. 1
— Chuck Key/ Hex Wrench 4mm ............... 1
— Hex Wrench 4mm .................................. 1
— Hex Bolts M8-1.25 x 80 (Extension) ...... 4
SUFFOCATION HAZARD!
Immediately discard all plas-
tic bags and packing materi-
als to eliminate choking/suf-
focation hazards for children
and animals.
If any nonproprietary parts are missing (e.g. a
nut or a washer), we will gladly replace them; or
for the sake of expediency, replacements can be
obtained at your local hardware store.
Figure 3. G0645 inventory.
A
B
C
D
EH
I
FG
-12- G0645 Benchtop Mortising Machine
Hardware Recognition Chart
G0645 Benchtop Mortising Machine -13-
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 the
workpiece.
Placement Location
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 5 for the minimum
working clearances. The workbench should be
located where plenty of working clearance exists
for larger workpieces.
Children and visitors may be
seriously injured if unsuper-
vised around this machine.
Lock entrances to the shop
or disable start switch or
power connection to prevent
unsupervised use.
The unpainted surfaces are coated with a waxy
oil to prevent corrosion during shipment. Remove
this protective coating with a solvent cleaner or
citrus-based degreaser such as Grizzly’s G7895
Citrus Degreaser. To clean thoroughly, some parts
must be removed. For optimum performance
from your machine, clean all moving parts or
sliding contact surfaces. Avoid chlorine-based
solvents, such as acetone or brake parts cleaner
that may damage painted surfaces. Always follow
the manufacturer’s instructions when using any
type of cleaning product.
Site ConsiderationsClean Up
Figure 5. Minimum working clearances.
Gasoline and petroleum
products have low flash
points and can explode
or cause fire if used to
clean machinery. DO
NOT use these products
to clean the machinery.
Many cleaning solvents
are toxic if inhaled.
Minimize your risk by only
using these products in a
well ventilated area.
Figure 4. Grizzly citrus degreaser.
G7895—Grizzly Citrus Degreaser
This natural, citrus-based degreaser is a great
solution for removing export grease, and it’s much
safer to work around than nasty solvents.
-14- G0645 Benchtop Mortising Machine
AssemblyMounting
Mount the mortising machine to a workbench
through the two holes in the base.
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 mortising machine to
the workbench.
Figure 6. Example of a through mount setup.
Figure 7. Example of a direct mount setup.
Another option for mounting is a "Direct Mount"
where the machine is simply secured to the work-
bench with a lag screw. Figure 8. Hand lever installed.
Spring
Shoulder
Bolt
Hand Lever
Figure 9. Depth stop rod installed.
Depth
Stop
Rod
The included extension block will extend the col-
umn an additional 13⁄4", so workpieces up to 6"
thick can be mortised. You will not be able to use
the fence adjustment knob when the extension
block is installed. If you do not want to install the
extension block, skip Steps 6-8.
To assemble the Model G0645:
1. Secure the handle onto the hub using the
spring and shoulder bolt already attached to
the headstock, as shown in Figure 8.
2. Loosen the lock lever and insert the depth
stop rod into the hole on the headstock, as
shown in Figure 9.
Hub
Lock Lever
G0645 Benchtop Mortising Machine -15-
Figure 13. Tool storage rack installed.
5. Install the tool storage rack, as shown in
Figure 13, with the M6-1 x 15 Phillips head
screws already attached to the headstock.
Figure 12. Gas spring attached to bottom of
column.
Depth Stop
The headstock must be locked in place
before the gas spring is installed. Serious
personal injury can occur if the headstock
drops during installation.
3. Lift the headstock to the top position using
the hand lever. Position the depth stop so it
contacts the top of the headstock, as shown
in Figure 10, and secure the lock knob so the
headstock does not move.
Figure 10. Depth stop contacting headstock.
Ball Stud
Figure 11. Gas spring attached to top of
headstock.
4. Snap the gas spring ball sockets onto the ball
studs, as shown in Figures 11 & 12.
Tip: It may help to use a flat head screwdriver
to leverage the bottom gas spring ball socket
onto the ball stud.
Ball Stud
6. Remove the four M8-1.25 x 25 hex bolts,
flat washers and lock washers securing the
column to the base, shown in Figure 14, and
temporarily lay the headstock on its side on
the workbench.
Figure 14. Hex bolts and washers securing
column to base.
CRUSHING HAZARD!
Have an assistant hold the headstock during
the following step. The headstock is heavy
and could cause serious personal injury if
not supported.
-16- G0645 Benchtop Mortising Machine
7. Place the extension block over the rack and
base, and align the mounting holes, as shown
in Figure 15.
Test Run
Once the assembly is complete, test run your
machine.
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 25.
If you still cannot remedy a problem, contact our
Tech Support at (570) 546-9663 for assistance.
To test run the machine:
1. Make sure you have read the safety instruc-
tions at the beginning of the manual and that
the machine is setup properly.
2. Verify that there is not a drill bit or chisel
installed, and that all tools are cleared away
from the machine.
3. Connect the machine to the power source.
4. Turn the machine ON.
5. 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.
6. Turn the machine OFF.
Figure 16. Extension block installed.
8. Place the column over the extension block,
align the mounting holes, have an assistant
hold the headstock upright, and secure the
column to the base with the M8-1.25 x 80 hex
bolts and the washers removed in Step 6, as
shown in Figure 16.
Figure 15. Extension block positioned on base.
Extension Block
Rack
G0645 Benchtop Mortising Machine -17-
Operation Safety
SECTION 4: OPERATIONS
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.
Basic Controls
Below is a summary of the basic controls used
during mortising operations. Use the list with
Figure 17 to become familiar with your mortising
machine.
ON/OFF Switch: Starts or stops motor.
Depth Stop Rod: Controls the mortise depth.
Hand Lever: Raises or lowers headstock.
Fence Lock Handles: Locks fence. When loos-
ened, allows fence to move.
Fence Adjustment Knob: Moves fence back and
forth on the table—is disabled when the exten-
sion block is installed.
Hold Down Lock Lever: Locks hold down.
Hold Down: Holds workpiece down when chisel
is raised after mortise is cut.
Damage to your eyes and lungs could result
from using this machine without proper pro-
tective gear. Always wear safety glasses and
a respirator when operating this machine.
Figure 17. Model G0645 basic controls.
Hand
Lever
ON/OFF
Switch
Depth Stop
Rod
Fence Lock
Handle
Fence
Adjustment
Knob
Hold Down
Lock Lever
Hold Down
Basic Operations
This machine uses a hollow chisel with a drill bit to
cut square holes called mortises. After setting the
fence, depth stop, and hold down, use the hand
lever to lower the chisel and bit into the workpiece,
then raise the hand lever to remove the chisel and
bit from the workpiece.
Never mortise treated lumber—the smoke is
extremely poisonous.
-18- G0645 Benchtop Mortising Machine
Installing Mortising
Chisel
8. Rotate the chuck by hand and make sure no
binding occurs.
—If binding occurs, loosen the chisel lock set
screw and rotate the chisel 90°.
Figure 20. Drill bit extension.
Wrong Correct
1⁄16–3⁄16"
4. Slide the bit into the chisel and loosen the
chisel lock set screw (Figure 19) on the
headstock.
5. Insert the chisel into the bushing shown in
Figure 19, and tighten the chisel lock set
screw.
Figure 19. Inserting chisel into bushing.
This mortising machine uses 5⁄8" shank chisels
ranging from 1⁄4"–1⁄2". If you want to use chisels
that did not come with this machine, make sure
they conform to the dimensions in the Figure 18.
Chisel
Chuck
6. Open the chuck access cover.
7. Using the chuck key, tighten the drill bit into
the drill chuck so the tip extends 1⁄16"—3⁄16"
beyond the chisel, as shown in Figure 20.
The correct distance depends on the wood
type and operation.
To install a mortising chisel:
1. DISCONNECT THE MORTISING MACHINE
FROM POWER!
2. Lock the headstock in the fully raised posi-
tion.
3. Put on a pair of leather gloves to protect
your hands, or wrap a shop towel around the
sharp end of the chisel. Place a wood scrap
on the table to protect it during chisel and bit
installation.
Figure 18. G0645 chisel and drill bit dimensions.
Bit
Bushing
A
C
3" Cut Depth
1⁄2" Minimum Chuck Grab
5/8" Max. Dia.
B Lock Set
Screw
Chisel Min.
Overall
Bit
Length
(A)
Max
Drill Bit
Dia.
(B)
Min.
Overall
Chisel
Length
(C)
1⁄4" 61⁄4"11⁄64" 41⁄4"
5⁄16" 61⁄4"7⁄32" 41⁄4"
3⁄8" 75⁄16"17⁄64" 51⁄2"
1⁄2" 75⁄16"3⁄8" 51⁄2"
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