Grizzly G0528 owner's manual

Grizzly

Industrial, Inc.

MODEL G0528

ROUTER TABLE

OWNER'S MANUAL

(For models manufactured since 03/17)

COPYRIGHT © SEPTEMBER, 2003 BY GRIZZLY INDUSTRIAL, INC. REVISED MARCH, 2017 (MN) WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. #CR11780 PRINTED IN TAIWAN

WARNING!

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 comprehension, 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.

WARNING!

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 equipment, 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

• Identification ........ 3

• Machine Data Sheet ........ 4

• SECTION 1: SAFETY ........ 5

• Safety Instructions for Machinery ........ 5

• Additional Safety Instructions for Sliding Router Tables ........ 7

• SECTION 2: CIRCUIT REQUIREMENTS ........ 8

• 110V Operation ........ 8

• SECTION 3: SETUP ........ 9

• Needed for Setup ........ 9

• Unpacking ........ 9

• Inventory ........ 10

• Hardware Recognition Chart ........ 11

• Cleanup ........ 12

• Site Considerations ........ 13

• Assembly ........ 14

• Miter ........ 17

• Router ........ 18

• Test Run ........ 19

• SECTION 4: OPERATIONS ........ 20

• Operation Overview ........ 20

• Workpiece Inspection ........ 21

• Routing ........ 21

• SECTION 5: ACCESSORIES ........ 24

• SECTION 6: MAINTENANCE ........ 25

• Schedule ........ 25

• Cleaning ........ 25

• Unpainted Cast Iron ........ 25

• SECTION 7: WIRING ........ 26

• Wiring Safety Instructions ........ 26

• Wiring Diagram ........ 27

• SECTION 8: PARTS ........ 28

• Main Breakdown ........ 28

• Parts List ........ 29

• Labels and Parts List ........ 30

• WARRANTY AND RETURNS ........ 33

INTRODUCTION

Manual Accuracy

We are proud to provide a high-quality owner’s manual with your new machine!

We made every effort to be exact with the instructions, specifications, drawings, and photographs in this manual. Sometimes we make mistakes, but our policy of continuous improvement also means that sometimes the machine you receive is slightly different than shown in the manual.

If you find this to be the case, and the difference between the manual and machine leaves you confused or unsure about something, check our website for an updated version. We post current manuals and manual updates for free on our website at www.grizzly.com.

Alternatively, you can call our Technical Support for help. Before calling, make sure you write down the Manufacture Date and Serial Number from the machine ID label (see below). This information is required for us to provide proper tech support, and it helps us determine if updated documentation is available for your machine.

Contact Info

We stand behind our machines! If you have questions or need help, contact us with the information below. Before contacting, make sure you get the serial number and manufacture date from the machine ID label. This will help us help you faster.

Grizzly Technical Support 1815 W. Battlefield Springfield, MO 65807 Phone: (570) 546-9663 Email: techsupport@grizzly.com

We want your feedback on this manual. What did you like about it? Where could it be improved? Please take a few minutes to give us feedback.

Grizzly Documentation Manager P.O. Box 2069 Bellingham, WA 98227-2069 Email: manuals@grizzly.com

Machine Description

The Model G0528 sliding router table allows the woodworker to mount most routers to the table underside with the spindle and cutter protruding upward from the table. Similar to a shaper, the workpiece is slid along an adjustable fence and into the cutter. Unlike a shaper, the Model G0528 has a sliding table feature where the table moves with the workpiece into the cutter. This design improves workpiece control, especially when routing the end grain of a workpiece. For support on both sides of the workpiece, the sliding router table is equipped with a split-rail type fence. For easy ON/OFF control, the table has been fitted with a router power switch.

Identification

Set up and operation instructions will be easier to understand if you become familiar with the location and names of the machine features shown in Figure 1.

Figure 1. Machine features.

Grizzly Industrial, Inc. MACHINE DATA SHEET

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

MODEL G0528 ROUTER TABLE

• Design Type ........ Floor Model

Overall Dimensions:

• Main Table ........ 31" W x 10" D x 1-3/4" T
• Sliding Table ........ 31" W x 12" D
• Total Table Surface ........ 31" W x 22" D
• Overall Height ........ 42" H
• Height From Table To Floor ........ 34" H
• Overall Width ........ 40"W
• Overall Length ........ 30" D
• Shipping Weight ........ 132 lbs.
• Net Machine Weight ........ 125 lbs.
• Box Size ........ 35-1/2" W x 26" D x 8" H
• Footprint ........ 40" W x 30" D

Capacities:

• Suitable Routers For Mounting ........ 3/4 HP - 5 HP
• Table Counterbore ........ 3-1/2"
• Table Insert Opening Sizes ........ 1-1/8" & 2-5/16"
• Fence Size ........ 3" x 12" (Each Piece)
• Maximum Fence Working Surface ........ 3" x 36"
• Dust Port ........ 2-1/2"

Construction:

• Main Table ........ Precision-Ground Cast Iron
• Sliding Table ........ Aluminum
• Fence Assembly ........ Aluminum & Steel
• Stand ........ Powder-Coated Steel
• Miter Body ........ Aluminum

Features:

• ........ Workpiece Hold-Downs
• ........ Clamping Miter Gauge
• ........ Toggle Switch W/Safety Key
• ........ Dual Power Outlets For Convenient Router/Accessory Plug-Ins
• ........ 45° Table Tilt For Easy Router Mounting
• ........ Sliding Table

SECTION 1: SAFETY

For Your Own Safety, Read Instruction Manual Before Operating This Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of 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. Always use common sense and good judgment.

DANGER Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

CAUTION 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.

NOTICE This symbol is used to alert the user to useful information about proper operation of the machine.

Safety Instructions for Machinery

WARNING

OWNER’S MANUAL. Read and understand this owner’s manual BEFORE using machine.

TRAINED OPERATORS ONLY. Untrained operators have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine. When machine is not being used, disconnect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make workshop kid proof!

DANGEROUS ENVIRONMENTS. Do not use machinery in areas that are wet, cluttered, or have poor lighting. Operating machinery in these areas greatly increases the risk of accidents and injury.

MENTAL ALERTNESS REQUIRED. Full mental alertness is required for safe operation of machinery. Never operate under the influence of drugs or alcohol, when tired, or when distracted.

ELECTRICAL EQUIPMENT INJURY RISKS. You can be shocked, burned, or killed by touching live electrical components or improperly grounded machinery. To reduce this risk, only allow qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment.

DISCONNECT POWER FIRST. Always disconnect machine from power supply BEFORE making adjustments, changing tooling, or servicing machine. This prevents an injury risk from unintended startup or contact with live electrical components.

EYE PROTECTION. Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are NOT approved safety glasses.

Model G0528 (Mfd. 3/17+) -5-

⚠WARNING

WEARING PROPER APPAREL. Do not wear clothing, apparel or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to avoid accidental slips, which could cause loss of work-piece control. Wear hard hat as needed.

HAZARDOUS DUST. Dust created while using tools may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece material, always wear a NIOSH-approved respirator, and connect tool to an appropriate dust collection device to reduce your risk.

HEARING PROTECTION. Always wear hearing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.

REMOVE ADJUSTING TOOLS. Never leave adjustment tools, chuck keys, wrenches, etc. in or on tool—especially near moving parts. Verify removal before starting!

INTENDED USAGE. Only use tool for its intended purpose. Never modify or alter tool for a purpose not intended by the manufacturer or serious injury or death may result!

AWKWARD POSITIONS. Keep proper footing and balance at all times when operating tool. Do not overreach! Avoid awkward hand positions that make tool control difficult or increase the risk of accidental injury.

SAFE HANDLING. Firmly grip tool. To avoid accidental firing, do not keep finger on switch or trigger while carrying.

SECURING WORKPIECE. When required, use clamps or vises to secure workpiece. A secured workpiece protects hands and frees both of them to operate the tool.

GUARDS & COVERS. Guards and covers reduce accidental contact with moving parts or flying debris. Make sure they are properly installed, undamaged, and working correctly.

CHILDREN & BYSTANDERS. Keep children and bystanders at a safe distance from the work area. Stop using machine if they become a distraction.

FORCING TOOLS. Use the right tool for the job, and do not force it. It will do the job safer and better at the rate for which it was designed.

USE RECOMMENDED ACCESSORIES. Consult this owner’s manual or the manufacturer for recommended accessories. Using improper accessories will increase the risk of serious injury.

MAINTAIN WITH CARE. Keep cutting tool edges sharp and clean. Follow all maintenance instructions and lubrication schedules to keep tool in good working condition. A tool that is improperly maintained could malfunction, leading to serious personal injury or death. Only have tool serviced by qualified service-personnel using matching replacement parts.

CHECK DAMAGED PARTS. Regularly inspect tool for any condition that may affect safe operation. Immediately repair or replace damaged or mis-adjusted parts before operating tool.

MAINTAIN POWER CORDS. When disconnecting cord-connected tools from power, grab and pull the plug—NOT the cord. Carrying or pulling the cord may damage wires inside. Do not handle cord/plug with wet hands. Avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, sharp edges, moving parts, and wet/damp locations. Damaged cords increase risk of electrocution.

UNATTENDED OPERATION. Never leave tool running while unattended. Turn tool off and ensure all moving parts completely stop before walking away.

EXPERIENCING DIFFICULTIES. If at any time you experience difficulties performing the intended operation, stop using the machine! Contact our Technical Support at (570) 546-9663.

Additional Safety Instructions for Sliding Router Tables

⚠WARNING

AVOIDING AMPUTATION. Never place hands directly over or in front of the cutter. As one hand approaches the cutter, move it away. Always keep hand at least 6" away from the cutter while operating.

SECURING LEVERS AND KNOBS. Never operate the router table without first making sure that all lock levers and knobs are tight, and that all fence hardware and guide rails are secure. Otherwise, the workpiece can slip out of alignment during cutting and be kicked back causing injury.

PREVENTING WORKPIECE DRAW-IN or KICKBACK. Always feed the workpiece against the rotation of the cutter. Never force materials through the machine. Let the cutter do the work. Excessive force is likely to result in poor cutting results and will cause dangerous kickback conditions.

APPROPRIATE WORKPIECES. The danger of kickback and injury is increased when the workpiece has knots, holes, or foreign objects in it. Warped stock should be run through a jointer before you run it through the router table.

BLIND CUTTING. Keep the cutter on the underside of the workpiece when making blind cuts, which decreases risk of accidental contact with the cutter.

TESTING ROTATION. With the machine disconnected from power, rotate the spindle to test any new setup to ensure proper cutter clearance before starting the machine.

CUTTING DEPTH. Never remove too much material in one pass. Several light cuts produce a cleaner finish and help prevent kickback.

CUTTING SUPPORT. NEVER cut a workpiece without using a fence, jig, or miter. Otherwise, the workpiece can be grabbed by the cutter causing severe injury. Whenever possible, use a fixture, jig, or clamping device to hold or guide the workpiece.

WORKPIECE SIZING. NEVER use a workpiece shorter than six inches without special fixtures or jigs. Otherwise, the workpiece can become trapped between the fence and cutter causing injury.

CUTTER HEIGHT. Keep any unused portion of the cutter below the table surface, or a workpiece can be grabbed by the cutter causing severe injury.

USING SAFETY GUARDS. To prevent amputation or other injuries, NEVER remove any guards or covers when machine is operating. Fabricate additional guards or jigs for special circumstances. Use an overhead guard when the fence is removed.

⚠WARNING

Like all machines there is danger associated with the Model G0528. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this machine with respect and caution to lessen the possibility of operator injury. If normal safety precautions are overlooked or ignored, serious personal injury may occur.

⚠CAUTION

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 personal injury, damage to equipment, or poor work results.

Model G0528 (Mfd. 3/17+) -7-

SECTION 2: CIRCUIT REQUIREMENTS

110V Operation

WARNING Serious personal injury could occur if you connect the machine to power before completing the setup process. DO NOT connect the machine to the power until instructed later in this manual.

Figure 2. Typical 5-15 plug and receptacle.

WARNING 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!

CAUTION 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.

Full Load Amperage Draw

This router table is equipped with a 5-15, 110V, 15 amp receptacle, power cord, and power switch. When selecting a router to use with this router table, do not use routers that draw more than 15 amps under a full load.

Power Supply Circuit Requirements

The power supply circuit for the router table MUST be grounded and rated for the amperage given below. Never replace a circuit breaker on an existing circuit with one of higher amperage without consulting a qualified electrician to ensure compliance with wiring codes. If you are unsure about the wiring codes in your area or you plan to connect your machine to a shared circuit, consult a qualified electrician.

• Minimum Circuit Size ........ 15 Amps

Power Connection Device

This machine comes with a plug, similar to Figure 2, to connect the machine to power.

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.

-8- Model G0528 (Mfd. 3/17+)

SECTION 3: SETUP

Needed for Setup

The following are needed to complete the setup process, but are not included with your machine.

Unpacking

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 immediately 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 condition of your shipment, inventory the contents.

Model G0528 (Mfd. 3/17+) -9-

Inventory

Please inventory your shipment with this list. 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.

Box 1: (Figure 3) Qty Note: Table and Shelf not Shown.

• A. Left Fence ........ 1
• B. Right Fence ........ 1
• C. Dust Hood ........ 1
• D. Power Cord ........ 1
• E. Switch ........ 1
• F. Switch Box ........ 1
• G. Workpiece Hold-Downs ........ 2
• H. Miter Plate ........ 1
• I. Miter Fence ........ 1
• J. Router Clamps ........ 4
• K. Table Insert 29MM ........ 1
• L. Table Insert 60MM ........ 1
• M. Fence Lock Handles ........ 2 N. Hardware Bag
• —Rubber Stops (Flange Brackets) ........ 2 —Phillips Screws 1/4"-20 x 1-1/2" (Lock Arm) 2
• —Flat Washers 1/4" (Lock Arm) ........ 4
• —Hex Nuts 1/4"-20 (Lock Arm) ........ 4
• —Hex Bolts 5/16"-18 x 1" (Table Pivot) ........ 2
• —Lock Nuts 5/16"-18 (Table Pivot) ........ 2
• —Flat Washers 5/16" (Table Pivot) ........ 4
• —Hex Nuts 5/16"-18 (Table/Stand) ........ 4
• —Flat Washers 5/16" (Table/Stand) ........ 8
• —Cap Screws 5/16"-18 x 1-1/2" (Stops) ........ 2
• —Spacers ........ 2 O. Hardware Bag
• —Carriage Bolts 5/16"-18 x 1/2" (Legs) ........ 32
• —Flat Washers 5/16" (Legs) ........ 32
• —Lock Washers 5/16" (Legs) ........ 32
• —Hex Nuts 5/16"-18 (Legs) ........ 32
• —Rubber Feet (Legs) ........ 4
• —Hex Nuts 5/16"-18 (Legs) ........ 4
• —Flat Washers 5/16" (Legs) ........ 4 —Phillips Screws 1/4"-20 x 1 (Stand Pad)... 4
• —Flat Washers 1/4" (Stand Pad) ........ 4
• —Hex Nuts 1/4"-20 (Stand Pad) ........ 4
• —Phillips Screws #10-24 x 3/4 (Switch) ........ 3
• —External Tooth Washers #10 (Switch) ........ 3
• —Hex Nuts #10-24 (Switch) ........ 3
• P. Diagonal Supports ........ 2
• Q. Stand Legs ........ 4
• R. Front Support ........ 1
• S. Strain Relief ........ 1
• T. Side Supports ........ 2
• U. Right and Left Flange Brackets ........ 1EA

Figure 3. G0528 Inventory.

-10- Model G0528 (Mfd. 3/17+)

Hardware Recognition Chart

USE THIS CHART TO MATCH UP HARDWARE DURING THE ASSEMBLY PROCESS.

MEASURE BOLT DIAMETER BY PLACING INSIDE CIRCLE

• #10
• 1/4"
• 5/16"
• 3/8"
• 7/16"
• 1/2"
• 4mm
• 5mm
• 6mm
• 8mm
• 10mm
• 12mm
• 16mm

LINES ARE 1MM APART

• 5mm
• 10mm
• 15mm
• 20mm
• 25mm
• 30mm
• 35mm
• 40mm
• 45mm
• 50mm
• 55mm
• 60mm
• 65mm
• 70mm
• 75mm

LINES ARE 1/16" INCH APART

• 1/4"
• 3/8"
• 1/2"
• 5/8"
• 5/16"
• 7/16"
• 9/16"
• 3/4"
• 7/8"
• 1"
• 1 1/4"
• 1 1/2"
• 1 3/4"
• 2
• 2 1/4"
• 2 1/2"
• 2 3/4"
• 3

WASHERS ARE MEASURED BY THE INSIDE DIAMETER

Cleanup

The unpainted surfaces of your machine are coated with a heavy-duty rust preventative that prevents corrosion during shipment and storage.

This rust preventative has been your machine's close ally and guardian since it left the factory. If your machine arrived to you free of rust, then be thankful that the rust preventative protected it during its journey and try to stay thankful as you clean it off, because it can be challenging to remove if you are unprepared and impatient.

Plan on spending some time cleaning your machine. The time you spend doing this will reward you with smooth sliding parts and a better appreciation for the proper care of your machine's unpainted surfaces.

Although there are many ways to successfully remove the rust preventative, these instructions walk you through what works well for us.

Before cleaning, gather the following:

• Disposable Rags
• Cleaner/degreaser (Figure 4)
• Safety glasses & disposable gloves

H9692—Orange Power Cleaner & Degreaser One of the best cleaners we've found for quickly and easily removing rust preventative.

Figure 4. Model H9692 Industrial Orange Power Cleaner/Degreaser (99.9% biodegradable).

Note: In a pinch, automotive degreasers, mineral spirits or WD•40 can be used to remove rust preventative. Before using these products, though, test them on an unnoticeable area of your paint to make sure they will not damage it.

!WARNING Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. Avoid using these products to clean machinery.

!CAUTION Many cleaning solvents are toxic if inhaled. Minimize your risk by only using these products in a well ventilated area.

NOTICE 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.

Basic steps for removing Rust preventative:

1. Put on safety glasses and disposable gloves.

2. Coat all surfaces that have rust preventative with a liberal amount of your cleaner/ degreaser and let them soak for few minutes.

3. Wipe off the surfaces. If your cleaner/ degreaser is effective, the rust preventative will wipe off easily.

   Note: To clean off thick coats of rust preventative on flat surfaces, such as tables, use a PLASTIC paint scraper to scrape off the majority of the coating before wiping it off with your rag. (Do not use a metal scraper or you may scratch your machine).

4. Repeat Steps 2–3 as necessary until clean, then coat all unpainted surfaces with a quality metal protectant to prevent rust.

Site Considerations

Weight Load

Refer to the Machine Data Sheet for the weight of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.

Space Allocation

Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual. See below for required space allocation.

Physical Environment

The physical environment where the machine is operated is important for safe operation and longevity of machine components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions. Extreme conditions for this type of machinery are generally those where the ambient temperature range exceeds 41°–104°F; the relative humidity range exceeds 20%–95% (non-condensing); or the environment is subject to vibration, shocks, or bumps.

Electrical Installation

Place this machine near an existing power source. Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or other hazards. Make sure to leave enough space around machine to disconnect power supply or apply a lockout/tagout device, if required.

Lighting

Lighting around the machine must be adequate enough that operations can be performed safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated.

Dust Collection Hose Port

31"

40"

Figure 5. Minimum working clearances.

Assembly

To assemble the machine:

1. Secure the rubber feet to the stand legs with the four 1/4"-20 x 1" Phillips screws, 1/4"-20 hex nuts, and 1/4" flat washers (Figure 6).

Figure 6. Rubber feet installation.

2. Arrange the front support, side supports, and the "L" and "R" flange brackets in the order shown in Figures 7–8. Be sure that the pivot holes in the flange brackets are located at the orientation shown in Figure 7.

Figure 7. Table support and bracket order.

3. Fasten the brackets together at both ends of the front support (Figure 8) with one 5/16"-18 x 1" hex bolt, two 5/16" flat washers, and one 5/16"-18 hex nut.

4. Using two 5/16"-18 x 1-1/2" cap screws, 5/16" flat washers, and 5/16"-18 hex nuts, install the rubber stops at the end of the flange brackets (Figure 8).

Figure 8. Table support assembly.

5. At the pivot bolt locations (Figure 7), attach the flange bracket to the table with two 5/16"-18 x 1" hex bolts, six 5/16" flat washers, and two 5/16"-18 lock nuts.

Figure 9. Table pivot installation.

Note: For the next few steps, do not completely tighten the fasteners until instructed.

6. Position the legs on the outside of the side supports, and secure the legs to the supports with (12) 5/16"-18 x 1/2" carriage bolts, 5/16" flat washers, 5/16" lock washers, and 5/16"-18 hex nuts.

Note: In the normal upright view if looking at the machine from the front, the leg with the switch cut-out should be on the right hand side to allow for switch mounting clearance.

7. Secure the shelf to the stand legs with (16) 5/16"-18 x 1/2" carriage bolts, 5/16" flat washers, 5/16" lock washers, and 5/16"-18 hex nuts.

8. Secure the diagonal supports (Figure 10) to the legs and the shelf with (4) 5/16"-18 x 1/2" carriage bolts, 5/16" flat washers, 5/16" lock washers, and 5/16"-18 hex nuts.

Figure 10. Table diagonal support positions.

WARNING Hands and fingers can become seriously injured if they are pinched between the stand edge and the table. DO NOT place hands or fingers near the stand edge while the table is in the raised position.

9. In the order shown in Figure 11, slide a washer onto each screw, and insert the screws through the holes in each brace, then thread the screws through the spacers.

Note: Allow just enough of a gap between the washers and spacers for the table braces to slide freely.

Figure 11. Assembling the table braces.

10. Secure with the washers and hex nuts.

11. Secure the left and right fence assemblies to the table with the fence lock handles in the holes located closest to the edge of the cast iron table.

12. Secure the dust hood to the top of each fence assembly with the pre-installed lock nuts (Figure 12).

Figure 12. Installed fence and dust hood.

Model G0528 (Mfd. 3/17+) -15-

13. Verify fence face alignment shown in Figure 12 using a straightedge. If the fence faces are out of alignment when fully retracted into their housings, loosen the fence housing lock nuts and slide the fence face back into alignment.

14. Remove one of the hex nuts from each of the hold-down brackets.

15. Slide the hold-down brackets through the mounting holes on the dust cover and secure them from the underside of the dust cover with the hex nuts removed in Step 14.

16. Tighten the hex nuts until the hold-down brackets are secure.

17. Secure the hold-down fingers to the hold-down brackets by tightening the threaded star knob (Figure 13).

Note: Do not worry about precise placement of the hold-down brackets or fingers at this time.

Figure 13. Installed hold-down assemblies.

18. Install the strain relief on the outside of the switch, using the plastic nut from the inside to secure the strain relief to the switch box.

19. Feed the power wires through the strain relief and tighten the strain relief screw against the main cord jacket.

20. Secure the green ground wires to the ground screw (Figure 14) from the power cord, and attach the switch box to the stand leg, using the Phillips head screw and hex nut already installed in the frame.

Figure 14. Switch installation.

21. Push the switch through the cut-out on the stand leg, and plug-in the black and white power wires to the back of the switch, refer to wiring diagram on Page 27 for connection locations.

22. Place the loom clamp around the power cord and mount it in the lower mounting hole (Figure 14) using the #10-24 x 3/4" Phillips head screw, #10 flat washer, and #10-24 nut.

23. Secure the switch box to the back of the switch using the remaining phillips head screws, the external toothed washers, and the hex nuts already installed in the frame.

24. Fit a 2-1/2" dust collection hose over the dust port and secure it in place with a hose clamp.

CAUTION

DO NOT operate the Model G0528 without an adequate dust collection system. This saw creates substantial amounts of wood dust while operating. Failure to use a dust collection system can result in short and long-term respiratory illness.

25. Tug the hose to make sure it does not come off.

Note: A tight fit is necessary for proper performance.

Recommended CFM at Dust Port: 150 CFM
Do not confuse this CFM recommendation with the rating of the dust collector. To determine the CFM at the dust port, you must consider these variables: (1) CFM rating of the dust collector, (2) hose type and length between the dust collector and the machine, (3) number of branches or wyes, and (4) amount of other open lines throughout the system. Explaining how to calculate these variables is beyond the scope of this manual. Consult an expert or purchase a good dust collection "how-to" book.

Miter

To attach the miter to the sliding table:

1. Secure the miter plate to the sliding table by sliding the T-bolts into the table T-track.

2. Position the miter plate in the desired position and tighten the threaded star knobs.

Note: Do not worry about precise placement of the miter plate at this time.

3. Secure the miter fence to the miter plate with the threaded star knobs (Figure 15).

Figure 15. Installed sliding table fence.

Model G0528 (Mfd. 3/17+) -17-

Router

To attach the router to the table:

1. Lift the table assembly up and engage the table braces on each side. Ensure that the table brace lock tabs are engaged completely around the lock screws (Figure 16).

WARNING Hands and fingers can become seriously injured if they are pinched between the stand edge and the table. DO NOT place hands or fingers near the stand edge while the table is in the raised position.

Lock Screw Table Brace Lock Tab Locked Position Figure 16. Locked table brace.

2. Move the jack bolt lock nut (Figure 17) on the router clamp to the table side of the router clamp if the router base mounting is 1/2" or thinner.

Jack Bolt Lock Nut Thick-Base Routers Thin-Base Routers Figure 17. Router clamp lock nut positions.

3. Slide each of the four router clamps into the T-slots on the underside of the cast iron table (Figure 18).

Router Clamps Figure 18. Installing the four router clamps.

4. Loosen the router clamps enough to allow the base of the router to press flat against the underside of the cast iron table.

Note: The router spindle should be centered under the cut out in the cast iron table.

5. Adjust the jack bolts and the lock nuts on each of the router clamps to allow the router base to be secured against the table (Figure 19).

Jack Bolt Figure 19. Router clamp jack bolts.

6. Tighten the router clamps to secure the router base into position.

Test Run

Once the assembly is complete, test run your machine to make sure it runs properly.

If, during the test run, you cannot easily locate the source of an unusual noise or vibration, stop using the machine immediately and refer to your router manual for troubleshooting.

If you still cannot remedy a problem with the Model G0528 router table, contact our Tech Support at (570) 546-9663 for assistance.

To test run the machine:

1. Put on safety glasses and hearing protection.
2. Make sure the router table is turned OFF and disconnected from power.
3. Make sure the router collet nut is secure on the router spindle and will not come off during the test run.
4. Make sure the router is firmly secured to the table, and plug the router power cord into the router table outlet.
5. On the router, turn the power switch ON.
6. Connect the router table to power.
7. Make sure you have read the safety instructions at the beginning of the manual and that the machine is setup properly.
8. Make sure all tools and objects used during setup are cleared away from the machine.
9. Turn the router table switch ON.
10. Listen to and watch for abnormal noises or actions. The router should run smoothly with little or no vibration or rubbing noises.

—Strange or unusual noises must be investigated and corrected before operating the machine further. Always disconnect the machine from power when investigating or correcting potential problems.

11. Turn the router table OFF.

Model G0528 (Mfd. 3/17+) -19-

SECTION 4: OPERATIONS

WARNING To reduce your risk of serious injury, read this entire manual BEFORE using machine.

Operation Overview

This overview gives you the basic process that happens during an operation with this machine. Familiarize yourself with this process to better understand the remaining parts of the Operation section.

To complete a typical operation, the operator does the following:

1. Examines the workpiece to make sure it is suitable for cutting.
2. Adjusts the fence close to the cutter for maximum workpiece support near the cutter, and then locks the infeed and outfeed fence in place.
3. Adjusts the cutter height for the desired cutting profile location.
4. Adjusts the fence depth for the depth of cut.
5. Wears safety glasses and a respirator, and locates push sticks if needed.
6. If using a reversible router, the woodworker verifies the direction router operation is correct, and then starts the router.
7. Holds the workpiece firmly and flatly against both the sliding table and fence, and then pushes the workpiece into the cutter at a steady and controlled rate until the workpiece moves completely beyond the cutter.

The operator is very careful to keep the workpiece firmly against the table and fence during the entire cut. For smaller workpieces or odd-shaped workpieces, the miter and clamp can be used, or a special jig can be made to hold the workpiece.

8. Stops the machine.

WARNING 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.

WARNING Loose hair, clothing, or jewelry could get caught in machinery and cause serious personal injury. Keep these items away from moving parts at all times to reduce this risk.

NOTICE If you have never used this type of machine or equipment before, WE STRONGLY RECOMMEND that you read books, review industry trade magazines, or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.

-20- Model G0528 (Mfd. 3/17+)

Workpiece Inspection

Some workpieces are not safe to cut or may require modification before routing. Before routing, inspect all workpieces for the following:

• Material Type
  This machine is intended for cutting natural and man-made wood products, laminate covered wood products, and some plastics. This machine is NOT designed to cut metal, glass, stone, tile, etc.

• Foreign Objects
  Nails, staples, dirt, rocks and other foreign objects are often embedded in wood. While shaping, these objects can become dislodged and hit the operator, cause kickback, or break the blade, which might then fly apart. Always visually inspect your workpiece for these items. If they can't be removed, DO NOT cut the workpiece.

• Large/Loose Knots
  Loose knots may dislodge during a cutting operation. Knots can cause kickback and machine damage. Choose workpieces that do not have large/loose knots or plan ahead to avoid shaping through them.

• Wet or "Green" Stock
  Shaping wood with a moisture content over 20% causes unnecessary wear on the cutters, increases the risk of kickback, and yields poor results.

• Excessive Warping
  Workpieces with excessive cupping, bowing, or twisting are dangerous to cut because they are unstable and often unpredictable when being shaped. DO NOT process workpieces with these characteristics!

• Minor Warping
  Workpieces with slight cupping can be safely supported if the cupped side is facing the table or the fence. On the contrary, a workpiece supported on the bowed side will rock during a cut and could cause kickback or severe injury.

Routing

Routing operations on your Model G0528 are grouped into three main techniques:

• Edge Jointing
• Groove Cutting
• Profile Cutting

Edge Jointing

Jointing the edge of a board involves using a straight cutting router bit to remove wood from the edge face of a board. The result is a perfectly flat and square edge.

To joint the edge of a workpiece:

1. Secure a straight cutting router bit into your router according to the router manufacturer’s instructions.

2. Snap the smallest table insert into the recessed hole that still allows the router bit to freely rotate.

3. Adjust the outfeed fence even with the left edge of the router bit (Figure 20).

Figure 20. Jointing setup (Top View).

Model G0528 (Mfd. 3/17+) -21-

4. Raise the bit to a height slightly higher than that of the board thickness.

5. Adjust the infeed fence to the right of the outfeed fence, so that the distance is equal to the desired depth of cut (Figure 21).

Figure 21. Jointing setup (Top View).

Groove Cutting

Beading is commonly defined as cutting a groove or bead in the face of a board.

To cut a groove in a workpiece:

1. Mount a router bit into your router according to the router manufacturer's instructions.
2. Snap the smallest table insert into the recessed hole that still allows the router bit to freely rotate.
3. Raise the router bit to the desired height.
4. Adjust the main fence until the center of the V-groove bit is the desired distance away, as shown in Figures 22 & 23.

Figure 22. Groove cutting setup (Top View).

Figure 23. Groove cutting setup (Side View).

Profile Cutting

Profile cutting is usually performed using a bit with a ball bearing. The ball bearing is used to control the depth of cut into the edge face of a board. A good example would be a chamfer cut. The bearing rides along the uncut edge of the board while the cutter removes the wood.

To cut a profile in a workpiece:

1. Mount a router bit into your router according to the router manufacturer's instructions.
2. Snap the smallest table insert into the recessed hole that still allows the router bit to freely rotate.

-22- Model G0528 (Mfd. 3/17+)

3. Raise the router bit to the desired height.

4. Adjust the fence back and away from the bit only enough to allow the ball bearing to control the depth of cut, as shown in Figures 24 & 25.

Figure 24. Proper setup for profile cutting (Top View).

Figure 25. Proper setup for profile cutting (Side View).

5. Adjust the fence as close as possible to the bearing. The fence will serve as a back-up support, reducing the chance of an accident.

SECTION 5: ACCESSORIES

G1163P—1HP Dust Collector Effective dust collection not only keeps your shop cleaner and more pleasant to work in, it can also keep you healthier. Our systems feature powerful motors and convenient collection bags - so they're ideal for just about any-sized woodworking operation.

Figure 26. G1163P 1HP dust collector.

G2370—SHOP FOX® Board Buddies These unique holdowns only turn in one direction to prevent kickback. Adjustable height, spring loaded wheels are designed to hold your workpiece tight against the table and rip fence and are made of a special composition that will not mark your work.

Figure 27. G2370 SHOP FOX® Board Buddies.

H3168—30 Pc. Carbide 1/4" Router Bit Set

Figure 28. Model H3168 30 pc. 1/4" shank router bit set.

G8983—Tilting Roller Stand Adjusts from 26" to 44", 0°-45°. 150 lb. capacity. G8984—Single Roller Stand Adjusts from 26-5/8" to 45". 250 lb. capacity. G8985—5 Roller Stand Adjusts from 26" to 44-5/8". 250 lb. capacity. These super heavy-duty roller stands feature convenient hand knobs for fast height adjustment.

Figure 29. SHOP FOX® Roller Stands.

Call 1-800-523-4777 To Order

SECTION 6: MAINTENANCE

WARNING Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious personal injury.

Schedule

For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.

Daily Check:

• Loose router mounting clamps.
• Damaged router bits.
• Worn or damaged power cords.
• Loose fence mounting or hardware.
• Any other unsafe condition.

Cleaning

Cleaning the Model G0528 is relatively easy. Vacuum excess wood chips and sawdust, and wipe off the remaining dust with a dry cloth. If any resin has built up, use a resin dissolving cleaner to remove it. Treat all unpainted cast iron and steel with a non-staining lubricant after cleaning.

Unpainted Cast Iron

Protect the unpainted cast iron surfaces on the table by wiping the table clean after every use—this ensures moisture from wood dust does not remain on bare metal surfaces.

Keep tables rust-free with regular applications of products like G96® Gun Treatment, SLIPIT®, or Boeshield® T-9.

SECTION 8: WIRING

These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Compare the manufacture date of your machine to the one stated in this manual, and study this section carefully.

If there are differences between your machine and what is shown in this section, call Technical Support at (570) 546-9663 for assistance BEFORE making any changes to the wiring on your machine. An updated wiring diagram may be available. Note: Please gather the serial number and manufacture date of your machine before calling. This information can be found on the main machine label.

WARNING

Wiring Safety Instructions

SHOCK HAZARD. Working on wiring that is connected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical components!

MODIFICATIONS. Modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire. This includes the installation of unapproved aftermarket parts.

WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections.

CIRCUIT REQUIREMENTS. You MUST follow the requirements at the beginning of this manual when connecting your machine to a power source.

WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components.

MOTOR WIRING. The motor wiring shown in these diagrams is current at the time of printing but may not match your machine. If you find this to be the case, use the wiring diagram inside the motor junction box.

CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors.

EXPERIENCING DIFFICULTIES. If you are experiencing difficulties understanding the information included in this section, contact our Technical Support at (570) 546-9663.

NOTICE

The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.grizzly.com.

COLOR KEY

Wiring Diagram

WARNING! SHOCK HAZARD! Disconnect power before working on wiring.

View this page in color at www.grizzly.com.

Figure 30. Switch box.

STOP READ ELECTRICAL SAFETY ON Page 26! -27-

SECTION 8: PARTS

Main Breakdown

-28- Model G0528 (Mfd. 3/17+)

Parts List

Labels and Parts List

WARNING

Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine MUST maintain the original location and readability of the labels on the machine. If any label is removed or becomes unreadable, REPLACE that label before using the machine again. Contact Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.

Grizzly WARRANTY CARD

Name ___________________________________________________________________________________ Street ___________________________________________________________________________________ City __________________________________________ State _________________________________ Zip ________________________ Phone #_____________________________________ Email ___________________________________________________ Model #_____________________________________ Order #________________________________ Serial #_______________________________

The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop better products and services. Of course, all information is strictly confidential.

1. How did you learn about us? ____ Advertisement ____ Friend ____ Catalog ____ Card Deck ____ Website ____ Other:

2. Which of the following magazines do you subscribe to? ____ Cabinetmaker & FDM ____ Popular Science ____ Wooden Boat ____ Family Handyman ____ Popular Woodworking ____ Woodshop News ____ Hand Loader ____ Precision Shooter ____ Woodsmith ____ Handy ____ Projects in Metal ____ Woodwork ____ Home Shop Machinist ____ RC Modeler ____ Woodworker West ____ Journal of Light Cont. ____ Rifle ____ Woodworker’s Journal ____ Live Steam ____ Shop Notes ____ Other: ____ Model Airplane News ____ Shotgun News ____ Old House Journal ____ Today’s Homeowner ____ Popular Mechanics ____ Wood

3. What is your annual household income? ____ $20,000-$29,000 ____ $30,000-$39,000 ____ $40,000-$49,000 ____ $50,000-$59,000 ____ $60,000-$69,000 ____ $70,000+

4. What is your age group? ____ 20-29 ____ 30-39 ____ 40-49 ____ 50-59 ____ 60-69 ____ 70+

5. How long have you been a woodworker/metalworker? ____ 0-2 Years ____ 2-8 Years ____ 8-20 Years ____ 20+ Years

6. How many of your machines or tools are Grizzly? ____ 0-2 ____ 3-5 ____ 6-9 ____ 10+

7. Do you think your machine represents a good value? ____ Yes ____ No

8. Would you recommend Grizzly Industrial to a friend? ____ Yes ____ No

9. Would you allow us to use your name as a reference for Grizzly customers in your area? Note: We never use names more than 3 times. ____ Yes ____ No

10. Comments: ___________________________________________________________________________________

CUT ALONG DOTTED LINE

FOLD ALONG DOTTED LINE

Place Stamp Here

Grizzly Industrial, Inc.®

GRIZZLY INDUSTRIAL, INC. P.O. BOX 2069 BELLINGHAM, WA 98227-2069

FOLD ALONG DOTTED LINE

Send a Grizzly Catalog to a friend:

Name______________________________ Street_____________________________ City________________ State______ Zip______

TAPE ALONG EDGES--PLEASE DO NOT STAPLE

WARRANTY AND RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants. In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special, or consequential damages arising from the use of our products.

To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue you a “Return Number,” which must be clearly posted on the outside as well as the inside of the carton. We will not accept any item back without this number. Proof of purchase must accompany the merchandise.

The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment. We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.

grizzly.com®

TOOL WEBSITE

Buy Direct and Save with Grizzly® – Trusted, Proven and a Great Value! Since 1983

Visit Our Website Today For Current Specials!

ORDER 24 HOURS A DAY! 1-800-523-4777