Grizzly G8689 User manual

COPYRIGHT © MAY, 2005 BY GRIZZLY INDUSTRIAL, INC., REVISED MARCH, 2009 (TS)
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
(FOR MODELS MANUFACTURED SINCE 8/06) #PC7203 PRINTED IN CHINA
MODEL G8689
MINI MILL
OWNER'S MANUAL

This manual provides critical safety instructions on the proper setup,
operation, maintenance, and service of this machine/tool. Save this
document, refer to it often, and use it to instruct other operators.
Failure to read, understand and follow the instructions in this manual
may result in fire or serious personal injury—including amputation,
electrocution, or death.
The owner of this machine/tool is solely responsible for its safe use.
This responsibility includes but is not limited to proper installation in
a safe environment, personnel training and usage authorization,
proper inspection and maintenance, manual availability and compre-
hension, application of safety devices, cutting/sanding/grinding tool
integrity, and the usage of personal protective equipment.
The manufacturer will not be held liable for injury or property damage
from negligence, improper training, machine modifications or misuse.
Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive
harm. Some examples of these chemicals are:
• Lead from lead-based paints.
• Crystalline silica from bricks, cement and other masonry products.
• Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
Work in a well ventilated area, and work with approved safety equip-
ment, such as those dust masks that are specially designed to filter
out microscopic particles.

Table of Contents
INTRODUCTION............................................... 2
Manual Accuracy ........................................... 2
Contact Info.................................................... 2
Machine Description ...................................... 2
Machine Data Sheet ...................................... 3
Identification ................................................... 5
SECTION 1: SAFETY....................................... 6
Safety Instructions for Machinery .................. 6
Additional Safety Instructions for Mini Mill ..... 8
Glossary Of Terms ......................................... 9
SECTION 2: CIRCUIT REQUIREMENTS ...... 10
110V Operation ............................................ 10
SECTION 3: SET UP ...................................... 11
Needed for Set Up ....................................... 11
Unpacking .................................................... 11
Inventory ...................................................... 12
Hardware Recognition Chart ....................... 13
Clean Up ...................................................... 14
Site Considerations ...................................... 14
Mounting to Workbench ............................... 15
Installing Handwheel Handles ..................... 15
Drill Chuck Removal .................................... 16
SECTION 4: OPERATIONS ........................... 17
Control Panel ............................................... 17
Test Run and Spindle Break-in .................... 18
Power Shutdown .......................................... 19
Rapid & Micro Downfeed Controls .............. 19
Limit Block.................................................... 20
Table Travel ................................................. 20
Graduated Dials ........................................... 21
Backlash ...................................................... 21
Column Angle Adjustment ........................... 21
MT#3 Collets ................................................ 22
Setting RPM ................................................. 23
SECTION 5: ACCESSORIES ......................... 24
SECTION 6: MAINTENANCE......................... 27
Schedule ...................................................... 27
Cleaning ....................................................... 27
Unpainted Cast Iron ..................................... 27
Lubrication ................................................... 28
SECTION 7: SERVICE ................................... 29
About Service............................................... 29
Troubleshooting ........................................... 29
Adjusting Gibs .............................................. 30
Replacing Motor Brushes ............................ 30
Fuse Replacement ....................................... 31
Head Counterbalance Spring ...................... 31
Electrical Components ................................. 32
Parts Breakdown.......................................... 33
G8689 Table Assembly ............................... 33
G8689 Head Assembly ................................ 35
G8689 Column Assembly ............................ 37
WARRANTY AND RETURNS ........................ 41

-2- G8689 Mini Mill (Mfg. 8/06+)
INTRODUCTION
We stand behind our machines. If you have any
service questions, parts requests or general ques-
tions about the machine, please call or write us at
the location listed below.
Grizzly Industrial, Inc.
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
If you have any comments regarding this manual,
please write to us at the address below:
Grizzly Industrial, Inc.
C/O Technical Documentation Manager
P.O. Box 2069
Bellingham, WA 98227-2069
Email: [email protected]
Contact Info
Machine Description
Manual Accuracy
We are proud to offer this manual with your new
machine! We've made every effort to be exact
with the instructions, specifications, drawings, and
photographs of the machine we used when writ-
ing this manual. However, sometimes errors do
happen and we apologize for them.
Also, owing to our policy of continuous improve-
ment, your machine may not exactly match the
manual. If you find this to be the case, and the dif-
ference between the manual and machine leaves
you in doubt, check our website for the latest
manual update or call technical support for help.
Before calling, find the manufacture date of your
machine by looking at the date stamped into the
machine ID label (see below). This will help us
determine if the manual version you received
matches the manufacture date of your machine.
For your convenience, we post all available man-
uals and manual updates for free on our website
at www.grizzly.com. Any updates to your model
of machine will be reflected in these documents
as soon as they are complete.
Manufacture Date
of Your Machine The mill is used to remove material from metal
workpieces to form shapes. Tooling is inserted
into the spindle of the head, which is positioned
above the table and workpiece.
During most operations, the tooling rotates in the
spindle above the workpiece while the opera-
tor moves the workpiece, which is clamped to
the table, in any combination of two paths of
table movement—longitudinal (X-axis) and cross
(Y-axis). Vertical travel of the spindle is controlled
with the micro and rapid downfeed controls.

G8689 Mini Mill (Mfg. 8/06+) -3-
Machine Data Sheet
The information contained herein is deemed accurate as of 2/18/2015 and represents our most recent product specifications.
Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased. PAGE 1 OF 2Model G8689
MACHINE DATA
SHEET
Customer Service #: [phone] · To Order Call: [phone] · Fax #: [phone]
MODEL G8689 MINI MILLING MACHINE
Product Dimensions:
Weight.............................................................................................................................................................. 101 lbs.
Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 20 x 20 x 30-1/4 in.
Footprint (Length x Width)................................................................................................................. 12-1/2 x 8-1/2 in.
Space Required for Full Range of Movement (Width x Depth).................................................................... 20 x 20 in.
Shipping Dimensions:
Type.......................................................................................................................................................... Wood Crate
Content........................................................................................................................................................... Machine
Weight.............................................................................................................................................................. 149 lbs.
Length x Width x Height....................................................................................................................... 20 x 21 x 30 in.
Must Ship Upright................................................................................................................................................... Yes
Electrical:
Power Requirement........................................................................................................... 110V, Single-Phase, 60 Hz
Prewired Voltage.................................................................................................................................................. 110V
Full-Load Current Rating....................................................................................................................................... 4.5A
Minimum Circuit Size.............................................................................................................................................. 15A
Connection Type....................................................................................................................................... Cord & Plug
Power Cord Included.............................................................................................................................................. Yes
Power Cord Length................................................................................................................................................. 6 ft.
Power Cord Gauge......................................................................................................................................... 18 AWG
Plug Included.......................................................................................................................................................... Yes
Included Plug Type................................................................................................................................................ 5-15
Switch Type........................................................................................... ON/OFF Push Button Switch w/Safety Cover
Motors:
Main
Type..................................................................................................................................................... Universal
Horsepower............................................................................................................................................. 3/4 HP
Phase............................................................................................................................................ Single-Phase
Amps........................................................................................................................................................... 4.5A
Speed................................................................................................................................................ 6000 RPM
Power Transfer ................................................................................................................................. Gear Drive
Bearings..................................................................................................... Shielded & Permanently Lubricated
Main Specifications:
Operation Info
Max Distance Spindle to Column.......................................................................................................... 6-3/8 in.
Max Distance Spindle to Table............................................................................................................ 11-1/2 in.
Longitudinal Table Travel (X-Axis)...................................................................................................... 7-5/16 in.
Cross Table Travel (Y-Axis)......................................................................................................................... 4 in.
Vertical Head Travel (Z-Axis)................................................................................................................ 7-1/2 in.
Head Tilt (Left/Right).............................................................................................................................. 45 deg.
Drilling Capacity for Cast Iron................................................................................................................... 1/2 in.
Drilling Capacity for Steel......................................................................................................................... 1/2 in.
End Milling Capacity................................................................................................................................. 1/2 in.
Face Milling Capacity................................................................................................................................... 1 in.

-4- G8689 Mini Mill (Mfg. 8/06+)
The information contained herein is deemed accurate as of 2/18/2015 and represents our most recent product specifications.
Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased. PAGE 2 OF 2Model G8689
Table Info
Table Length........................................................................................................................................ 15-3/4 in.
Table Width........................................................................................................................................... 3-5/8 in.
Table Thickness.................................................................................................................................... 1-1/4 in.
Number of T-Slots............................................................................................................................................ 3
T-Slot Size.............................................................................................................................................. 7/16 in.
T-Slots Centers...................................................................................................................................... 1-1/8 in.
X/Y-Axis Travel per Handwheel Revolution.......................................................................................... 0.062 in.
Spindle Info
Spindle Taper............................................................................................................................................ MT#3
Number of Vertical Spindle Speeds...................................................................................................... Variable
Range of Vertical Spindle Speeds............................................................................................... 0 – 2500 RPM
Quill Diameter....................................................................................................................................... 1.580 in.
Drawbar Thread Size.......................................................................................................................... M12-1.75
Drawbar Length........................................................................................................................................... 4 in.
Spindle Bearings........................................................................................................................... Ball Bearings
Construction
Spindle Housing/Quill........................................................................................................................... Cast Iron
Table....................................................................................................................................... Ground Cast Iron
Head.................................................................................................................................................... Cast Iron
Column/Base....................................................................................................................................... Cast Iron
Base..................................................................................................................................................... Cast Iron
Paint Type/Finish.................................................................................................................................... Enamel
Other Specifications:
Country of Origin ................................................................................................................................................ China
Warranty ........................................................................................................................................................... 1 Year
Approximate Assembly & Setup Time ........................................................................................................ 30 Minutes
ISO 9001 Factory .................................................................................................................................................. Yes
CSA, ETL, or UL Certified/Listed ............................................................................................................................ No
Features:
Two Speed Ranges on Geared Drive
Spring Head Return
Safety Shutoff Switch
Adjustable Depth Stop
Fine Feed Head Control
Clear Guard on Spindle
Rubber Chip Guards on Ways
Zero Setting Dials
Dials Read in Inches
Adjustable Dovetailed Ways on Column
Accessories Included:
1/2" Drill Chuck
2 T-Nuts
3/8" and 1/2" Collets

G8689 Mini Mill (Mfg. 8/06+) -5-
Figure 1. The Model G8689 Mini Mill.
A. Motor
B. Micro Downfeed Knob
C. Rapid Downfeed Lever
D. Headstock
E. Longitudinal Handwheel
F. Table
G. Scale & Pointer
H. Table Lock
I. Way Cover
J. Cross Feed Handwheel
K. Column Pivot & Scale
Identification
L. Column
M. Limit Block
N. Chip Shield
O. Spindle Cover
P. System Power Light
Q. Spindle Power Light
R. Column Lock
S. Electrical Box
T. Head Counterbalance Spring
U. Cooling Fan
V. Emergency Stop Button
J
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-6- G8689 Mini Mill (Mfg. 8/06+)
4. ALWAYS USE HEARING PROTECTION
WHEN OPERATING MACHINERY.
Machinery noise can cause permanent
hearing damage.
5. WEAR PROPER APPAREL. DO NOT
wear loose clothing, gloves, neckties, rings,
or jewelry which may get caught in moving
parts. Wear protective hair covering to con-
tain long hair and wear non-slip footwear.
6. NEVER OPERATE MACHINERY WHEN
TIRED, OR UNDER THE INFLUENCE OF
DRUGS OR ALCOHOL. Be mentally alert
at all times when running machinery.
1. READ THROUGH THE ENTIRE MANUAL
BEFORE STARTING MACHINERY.
Machinery presents serious injury hazards
to untrained users.
2. ALWAYS USE ANSI APPROVED
SAFETY GLASSES WHEN OPERATING
MACHINERY. Everyday eyeglasses only
have impact resistant lenses, they are
NOT safety glasses.
3. ALWAYS WEAR AN ANSI APPROVED
RESPIRATOR WHEN OPERATING
MACHINERY THAT PRODUCES DUST.
Wood dust is a carcinogen and can cause
cancer and severe respiratory illnesses.
For Your Own Safety, Read Instruction
Manual Before Operating this Machine
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This
manual uses a series of symbols and signal words which are intended to convey the level of
importance of the safety messages. The progression of symbols is described below. Remember
that safety messages by themselves do not eliminate danger and are not a substitute for proper
accident prevention measures.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
This symbol is used to alert the user to useful information about
proper operation of the machine.
NOTICE
Safety Instructions for Machinery
SECTION 1: SAFETY

G8689 Mini Mill (Mfg. 8/06+) -7-
7. ONLY ALLOW TRAINED AND PROP-
ERLY SUPERVISED PERSONNEL TO
OPERATE MACHINERY. Make sure
operation instructions are safe and clearly
understood.
8. KEEP CHILDREN AND VISITORS AWAY.
Keep all children and visitors a safe dis-
tance from the work area.
9. MAKE WORKSHOP CHILD PROOF. Use
padlocks, master switches, and remove
start switch keys.
10. NEVER LEAVE WHEN MACHINE IS
RUNNING. Turn power OFF and allow all
moving parts to come to a complete stop
before leaving machine unattended.
11. DO NOT USE IN DANGEROUS
ENVIRONMENTS. DO NOT use machin-
ery in damp, wet locations, or where any
flammable or noxious fumes may exist.
12. KEEP WORK AREA CLEAN AND WELL
LIT. Clutter and dark shadows may cause
accidents.
13. USE A GROUNDED EXTENSION
CORD RATED FOR THE MACHINE
AMPERAGE. Undersized cords overheat
and lose power. Replace extension cords
if they become damaged. DO NOT use
extension cords for 220V machinery.
14.
ALWAYS DISCONNECT FROM POWER
SOURCE BEFORE SERVICING
MACHINERY. Make sure switch is in
OFF
position before reconnecting.
15. MAINTAIN MACHINERY WITH CARE.
Keep blades sharp and clean for best and
safest performance. Follow instructions for
lubricating and changing accessories.
16. MAKE SURE GUARDS ARE IN PLACE
AND WORK CORRECTLY BEFORE
USING MACHINERY.
Safety Instructions for Machinery
17. REMOVE ADJUSTING KEYS AND
WRENCHES. Make a habit of checking for
keys and adjusting wrenches before turn-
ing machinery ON.
18. CHECK FOR DAMAGED PARTS
BEFORE USING MACHINERY. Check
for binding and alignment of parts, broken
parts, part mounting, loose bolts, and any
other conditions that may affect machine
operation. Repair or replace damaged
parts.
19. USE RECOMMENDED ACCESSORIES.
Refer to the instruction manual for recom-
mended accessories. The use of improper
accessories may cause risk of injury.
20. DO NOT FORCE MACHINERY. Work at
the speed for which the machine or acces-
sory was designed.
21. SECURE WORKPIECE. Use clamps or
a vise to hold the workpiece when practi-
cal. A secured workpiece protects your
hands and frees both hands to operate the
machine.
22. DO NOT OVERREACH. Keep proper foot-
ing and balance at all times.
23. MANY MACHINES WILL EJECT
THE WORKPIECE TOWARD THE
OPERATOR. Know and avoid conditions
that cause the workpiece to "kickback."
24. ALWAYS LOCK MOBILE BASES
(IF USED) BEFORE OPERATING
MACHINERY.
25. ALLERGIC REACTIONS. Be aware that
certain metal shavings and cutting fluids
may cause an allergic reaction in people
and animals, especially when cutting fumes
can be inhaled. Make sure you know what
type of metal and cutting fluid you will be
exposed to and how to avoid contamina-
tion.

-8- G8689 Mini Mill (Mfg. 8/06+)
Additional Safety Instructions for Mini Mill
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 machines there is danger associ-
ated with the Model G8689. 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.
1. UNDERSTANDING CONTROLS. Make
sure you understand the use and operation
of all controls.
2. SAFETY ACCESSORIES. Always use the
chip guard in addition to your safety glasses
when milling to prevent bodily injury.
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.
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 which is appropriate for the type of
work and material. Allow the mill to gain its
full speed before beginning a cut.
6. 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.
7. SPINDLE DIRECTION CHANGES. Never
reverse motor direction while the mill is in
motion.
8. STOPPING SPINDLE. DO NOT stop the
mill using your hand against the chuck.
9. BE ATTENTIVE. DO NOT leave mill run-
ning unattended for any reason.
10. MACHINE CARE AND MAINTENANCE.
Never operate the mill with damaged or
worn parts. Maintain your mill in proper
working condition. Perform routine inspec-
tions and maintenance promptly. Put away
adjustment tools after use.
11. DISCONNECT POWER. Make sure the mill
is turned OFF, disconnected from its power
source and all moving parts have come to
a complete stop before starting any inspec-
tion, adjustment, or maintenance proce-
dure.
12. AVOIDING ENTANGLEMENT. Keep loose
clothing articles such as sleeves, belts or
jewelry items away from the mill spindle.
13. TOOL HOLDING. Always use the proper
tools for the material you are milling. Make
sure they are held firmly in the proper tool
holder for the job.
14. CLEAN-UP. DO NOT clear chips by hand.
Use a brush, and never clear chips while the
mill is turning.
15. CUTTING TOOL INSPECTION. Inspect
drills and end mills for sharpness, chips,
or cracks before each use. Replace dull,
chipped, or cracked cutting tools immedi-
ately. Handle new cutting tools with care.
Leading edges are very sharp and can
cause lacerations.

G8689 Mini Mill (Mfg. 8/06+) -9-
The following is a list of common definitions, terms and phrases used throughout this manual as they relate
to this mill and metalworking in general. Become familiar with these terms for assembling, adjusting or
operating this machine. Your safety is VERY important to us at Grizzly!
Arbor: A machine shaft that supports a cutting
tool.
Backlash: Wear in a screw or gear mechanism
that may result in slippage, vibration and loss
of tolerance.
Collet: A conical shaped split-sleeve bushing
which holds round or rectangular tool and/or
workpieces by their outside diameter.
Cross Feed: The movement of the table toward
or away from the column.
Cross Slide: A fixture attached to the lathe car-
riage that holds the compound rest and can be
moved in and out.
Cutting Speed: The distance a point on a cutter
moves in one minute, expressed in meters or
feet per minute.
Dial Indicator: An instrument used in setup
and inspection work that shows on a dial the
amount of error in size or alignment of a part.
Dividing Head: A milling machine accessory
used to divide a circular object into a number
of equal parts.
Down Milling or Climb Milling: Feeding the
workpiece in the same direction as the cutter
rotation.
End Mill: A cutter with cutting surfaces on both
its circumference and end.
Facing: cutting across the face of a workpiece,
usually to machine a flat surface.
Feed: The movement of a cutting tool into a
workpiece.
Fixture: A device that securely holds the
workpiece in place during cutting operation as
opposed to a Jig which is used to hold and
guide a workpiece through an operation.
Gib: A tapered wedge located along a sliding
member to take up wear or to ensure a proper
fit.
Headstock: The major component that houses
the spindle and motor drive system to turn the
workpiece.
Leadscrew: The screws that move the table in
longitudinal, transverse, or vertical directions.
Spindle: The revolving shaft that holds and
drives the workpiece or cutting tool.
Turret : The part of a mill which rotates on the
column and can be set to a specific degree.
Ways: The precision machined and flat tracks on
a lathe or mill on which the carriage, tailstock
and the mill table and knee slide.
Glossary Of Terms

-10- G8689 Mini Mill (Mfg. 8/06+)
SECTION 2: CIRCUIT REQUIREMENTS
Figure 2. Typical 5-15 plug and receptacle.
Grounding Prong
Neutral Hot
5-15 PLUG
GROUNDED
5-15 RECEPTACLE
110V Operation
Full Load Amperage Draw
This machine draws the following amps under
maximum load:
Amp Draw ............................................. 4.5 Amps
Power Supply Circuit Requirements
The power supply circuit for your machine MUST
be grounded and rated for the amperage given
below. Never replace a circuit breaker on an exist-
ing circuit with one of higher amperage without
consulting a qualified electrician to ensure compli-
ance 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, con-
sult a qualified electrician.
Minimum Circuit Size ............................. 15 Amps
Extension Cords
We do not recommend using extension cords, but
if you find it absolutely necessary:
• Use at least a 16 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.
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
This machine comes with a plug, similar to
Figure 2, to connect the machine to power.
SHOCK HAZARD!
Two-prong outlets do not meet the grounding
requirements for this machine. Do not modify
or use an adapter on the plug provided—if
it will not fit the outlet, have a qualified
electrician install the proper outlet with a
verified ground.

G8689 Mini Mill (Mfg. 8/06+) -11-
The Model G8689 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
[phone] 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 con-
dition of your shipment, you should inventory the
contents.
Wear safety glasses dur-
ing the entire set up 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!
Unpacking
SECTION 3: SET UP
The Model G8689 is a
heavy machine. Get assis-
tance and use safe lifting
methods when moving
heavy machinery.
The following are needed to complete the set up
process, but are not included with your machine:
Description Qty
• Precision Level ........................................... 1
• Safety Glasses (for each person) ............... 1
• Solvent ........................................................ 1
• Shop Rags .................................................. 1
• Mounting Hardware ................................... 1
• Machinist Square ........................................ 1
• Metal Shim Stock ....................................... 1
• Wrench or Socket 9⁄16" ................................ 1
• Brass Hammer ........................................... 1
• Flat Head Screwdriver ................................ 1
• Drill and 3⁄8" Bit ........................................... 1
Needed for Set Up

-12- G8689 Mini Mill (Mfg. 8/06+)
Inventory
After all the parts have been removed from the
two boxes, you should have the following items:
Box 1: (Figure 3) Qty
A. Mini Mill ...................................................... 1
B. Chip Shield ................................................. 1
Figure 3. Model G8689 Mini Mill.
A
B
Bag Contents: (Figure 4)
C. Hex Key Set 3, 4, 5 & 6mm ........................ 1
D. Wrench 8/10mm ......................................... 1
E. Wrench 14/17mm ........................................ 1
F. Wrench 17/19mm ........................................ 1
G. Spanner Wrench ........................................ 1
H. Wrench 36mm ............................................ 1
I. Drill Chuck 1⁄2"-B16 ..................................... 1
J. Spare Fuse 5 Amp ..................................... 1
K. Collet MT#3 x 3⁄8" ........................................ 1
L. Collet MT#3 x 1⁄2" ........................................ 1
M. Chuck Key .................................................. 1
N. T-Nuts M10-1.5 ........................................... 1
O. Oil Bottle ..................................................... 1
P. Handwheel Handles ................................... 2
Q. Spindle Locking Pin .................................... 1
R. Drawbar ...................................................... 1
S. Arbor MT#3-B16 ......................................... 1
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.
C
D
Figure 4. Bag contents.
E
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G8689 Mini Mill (Mfg. 8/06+) -13-
Hardware Recognition Chart

-14- G8689 Mini Mill (Mfg. 8/06+)
Workbench Load
The Model G8689 weighs 101 lbs. and has a
base footprint of 81⁄2" W x 12" D. Make sure the
workbench you mount the Model G8689 Mini Mill
to is sturdy enough to support its weight and rigid
enough so it will not tip over during use.
Working 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 mill. See Figure 6 for the minimum working
clearances of the Model G8689.
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!
Site Considerations
Figure 6. Working clearances.
20"
20"
The unpainted surfaces are coated with a waxy
oil to prevent corrosion during shipment. Remove
this protective coating with a solvent cleaner or
degreaser, such as shown in Figure 5. For thor-
ough cleaning, some parts must be removed.
For optimum performance, clean all moving
parts or sliding contact surfaces. Avoid chlo-
rine-based solvents, such as acetone or brake
parts cleaner that may damage painted surfac-
es. Always follow the manufacturer’s instructions
when using any type of cleaning product.
Clean Up
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.
G2544—Solvent Cleaner & Degreaser
H9692—Orange Power Degreaser
Great products for removing shipping grease.
Figure 5. Cleaner/degreasers available from
Grizzly.

G8689 Mini Mill (Mfg. 8/06+) -15-
Mounting to
Workbench
The Model G8689 should be bolted to a work-
bench to provide maximum rigidity and safety.
Components and Hardware Needed: Qty
Hex Bolts 3⁄8-16 x (length needed)......................4
Flat Washers 3⁄8" .................................................8
Hex Nuts 3⁄8"-16 ..................................................4
Tools Needed: Qty
9⁄16" Wrench or Socket ....................................... 1
Drill with 3⁄8" Bit .................................................. 1
To mount the mini mill to the workbench:
1. Determine the best position for the mill on the
workbench.
Note: For the best performance, make sure
the cross feed and the longitudinal hand-
wheels extend out beyond the edge of the
table surface. This will allow unrestricted
handwheel operation.
2. Mark your hole locations using the mounting
holes in the base as a guide.
3. Drill the holes needed in the workbench.
4. Place a precision level on the mill table and
shim the mill until it is level side to side and
front to back.
5. Mount the mill to the workbench using four
3⁄8"-16 carriage bolts with washers and hex
nuts.
The handwheels on the Model G8689 come
installed, you will only need to install the handwheel
handles.
Components and Hardware Needed: Qty
Handwheel Handles .......................................... 2
Tools Needed: Qty
Flat Head Screwdriver ....................................... 1
To attach the handles to the handwheels:
1. Using the screwdriver, screw the thread of
the handles into the cross feed and longitudi-
nal handwheels.
Installing Handwheel
Handles

-16- G8689 Mini Mill (Mfg. 8/06+)
Drill Chuck Removal
The Model G8689 may have shipped with the chip
guard in place and the drill chuck installed in the
spindle. If this is the case, go ahead and remove
them at this time.
Tools Needed: Qty
Brass Hammer .................................................. 1
Spindle Locking Pin ........................................... 1
Wrench 17/19mm ............................................... 1
To remove the chuck and arbor from the
spindle:
1. DISCONNECT MILL FROM POWER!
2. Remove the chip guard for easier access to
the chuck.
3. Remove the plastic cap that covers the
drawbar.
4. Insert the spindle locking pin into the hole
on the side of the head. Rotate the chuck by
hand until the pin falls into the notch on the
spindle shaft, preventing the spindle from
turning (see Figure 7).
NOTICE
DO NOT completely unscrew the drawbar
before striking it with the hammer. You will
damage the threads on the drawbar and the
arbor.
6. Tap the top of the drawbar with the brass
hammer. This will unseat the taper of the
arbor and the spindle (see Figure 8).
5. Using the 17mm wrench, loosen the drawbar
but DO NOT remove it.
Figure 8. Striking the drawbar.
7. Hold one hand under the chuck and finish
loosening the drawbar by hand until it falls out
of the spindle (see Figure 9).
Figure 9. Removing the arbor.
Figure 7. Loosening the drawbar.
Spindle Locking Pin

G8689 Mini Mill (Mfg. 8/06+) -17-
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.
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.
Control Panel
It is vital that you become familiar with the control
panel before operating the Model G8689. Three
separate switches control the power on the mill
(see Figure 10).
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.
1. POWER INDICATOR Light: Shines when the
system power is ON.
2. SPINDLE ON & RPM Control Knob: Turns
the spindle ON and controls the spindle
RPM.
3. SYSTEM ON Toggle Switch: This toggle
switch delivers power to the system.
4. Fuse Socket: Houses a 5 Amp system fuse.
5. EMERGENCY STOP Button: Immediately
disconnects power to the system. Once
pressed, this button must be released to allow
use of the SYSTEM ON Toggle Switch.
Note: After using the EMERGENCY STOP
Button it will be necessary to reset the
SPINDLE ON & RPM Control Knob and the
SYSTEM ON Toggle Switch.
Figure 10. Control panel components.
12
3
4
5

-18- G8689 Mini Mill (Mfg. 8/06+)
Test Run and
Spindle Break-in
The Model G8689 has two speed ranges: Low
range is 0–1100; high range is 0–2500 RPM.
It is essential to closely follow the proper break-in
procedures to ensure trouble free performance.
Complete this process once you have familiarized
yourself with all instructions in this manual.
To begin the start up and break-in procedure:
1. Follow all lubrication procedures highlighted
in Lubrication in Section 6: MAINTENANCE
on Page 28.
2. Make sure there are no obstructions around or
underneath the spindle. Remove the drawbar
if there is no arbor or collet in the spindle.
3. With the spindle at a complete stop, shift the
speed range lever into the low range (see
Figure 11).
Note: If the lever will not drop into gear at
first, rotate the spindle by hand while holding
light pressure on the lever. When the gears
engage, the lever will fall into place.
4. Turn the SPINDLE ON & RPM CONTROL
KNOB ON and let the mill run for a minimum
of 10 minutes on a low speed. The mill should
run smoothly with minimal noise and vibra-
tion.
—If you suspect the mill is not working cor-
rectly, shut the mill OFF and correct the
problem before proceeding further.
—If the mill is running smoothly, proceed.
Figure 11. Speed range lever.
5. Slowly increase the RPM and allow it to run
at a medium RPM for another ten minutes.
6. Slowly increase the RPM and allow it to run
at a high RPM for another ten minutes.
7. Turn the mill OFF. Switch to the high range
and repeat Steps 4–6.
NOTICE
DO NOT attempt to change speed ranges
with the spindle ON. Damage to the spindle
gearing will occur.
NOTICE
Failure to follow start up and spindle break-
in procedures will likely cause rapid dete-
rioration of spindle and other related parts.