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Table of contents for the manual
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Page 1
MO DE L G0 64 6 / G0 64 7 50 / 65 T O N IR ON W OR KE R O W NER'S MANU AL COPYRIGHT © APRIL , 20 08 BY GRIZ ZL Y INDUSTRIAL , INC. W AR NI NG : NO P ORT I ON OF T HI S MA NUAL MA Y BE R EPRO DUC ED I N A NY S HAPE OR FOR M W I THO UT T HE WR IT TE N A PPROV A L O F GR IZ Z L Y I N DUS TR IA L , IN C. #TS 1 0279 PRINTED IN T AIW AN[...]
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T able of Con tents SECTION 5: ACCESSORIES ......................... 35 Available Tooling ......................................... 36 SECTION 6: MAINTENANCE ......................... 37 Schedule ...................................................... 37 Cleaning & Protecting .................................. 37 Lubrication ....................[...]
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-2 - G0 646 /G0 647 50 / 65 T on Ironwork er INTR ODU CTION F ore wo rd We are proud to offer the Model G0646/G0647 50/65 Ton Ironworker. This machine is part of a growing Grizzly family of fine machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation and proof of Grizzly?[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -3 - Identi fi cat ion Figure 4. Control panel identification. Q R S T U V W X A. Punching Station Emergency Stop Button B. Punching Station C. Bar Stock Shearing Station D. Lifting Eye Bolt E. Angle Iron Shearing Station F. Flat Stock Shearing Station G. Control Panel H. Foot Actuator I. Limit Stop Access[...]
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- 4- G 064 6 / G06 4 7 50 / 6 5 T on Ironwork er [...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -5 - [...]
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- 6 - G0 646 / G0 64 7 50 / 65 T on Ironwork er ?[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 7 - [...]
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-8- G06 46 / G0 64 7 50 / 65 T o n Ironw orker Safe t y Instr ucti ons fo r M ac hi ner y ?[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -9 - ?[...]
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- 1 0 - G0 646 /G0 64 7 50 / 6 5 T on Ironwork er A ddit io nal S af et y Ins tru ctio ns for Iro n w or k ers Like al l machiner y ther e is potential danger whe n opera ting this machine. A ccide nts are fre - quently caused b y lack of familiarity or fai lure to p ay at tention. Use this machine wit h re spec t and caution to lesse n the possibi[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 1 1 - No list of safet y guid elines c an b e comple te. Every shop environment is dif fer ent . Alway s c on- sider safet y first, as it app lies to your individual working conditions. Use this an d othe r machin - er y with caution and re spec t . Failure to do so could result in serious p ersonal inju[...]
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- 1 2- G0646 / G0 64 7 50 / 65 T on Ironwork er S E C T I O N 2: C I R C U I T R E Q U I R E M E N T S Fu ll Loa d Amp Dra w G06 46 220V 3 -Phase ................................. 1 4.5 A G06 46 4 40 V 3 - Phase ................................... 7 .5A G06 4 7 2 20 V 3 -Phase .................................... 1 6A G06 4 7 4 40V 3 - Phase ......[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 1 3 - The Mod el G0 646 / G0 64 7 c an be c onv er ted for 440V operation. This conv ersion job c onsists of disconnect ing t he machine from the powe r source, changing the connec tions on the voltage transformer , replacing t he ove rload rela y , and rewi ring the motor for 4 40V operation. The necess[...]
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- 1 4- G0 646 / G0 64 7 50 / 65 T on Ironwork er W e ar safet y gl asses dur- ing t he entire setup pr o - cess ! Th is m ac hin e p r es e nt s se ri o us in jur y ha z ar d s to untrain ed users . Read through t his entire manu - al to becom e familiar with the controls and op era - tions befor e star ting the machine ! Set up Safe t y SE CTION 3[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 1 5 - In v ent or y The following is a descr iption of the main compo - nents shipped with your m achine. La y the compo - nents out to invent or y them. Note : If you can' t find an item o n this li st, chec k the mounting l ocation o n the machi ne or examine the packaging materials carefully . Oc[...]
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- 1 6 - G0 646 / G0 64 7 50 / 65 T on Ironwork er Fl oor Loa d Refe r to the Machine D ata Sh eets (beginning on Page 4 ) for the weight and footprint specifications of your machine . Some floors ma y require addi - tional reinfo rcement to suppor t both the machine and operator . Pl ace men t Loca tio n Consider existing and anticipated needs, siz[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 1 7 - Although not required, we recommend that you mount your new machine to the floor . Because this is an o ptional step and floor materials may va r y , floor mounting hardwa re is not includ ed. Generally , you can either bolt your machine to the floor or mount it on machine mounts. Both options a re[...]
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- 1 8- G 06 46 / G06 4 7 50 / 6 5 T on Ironwork er Before st ar ting this machine, make sure you hav e read through the res t of the manual and ar e fa miliar with t he various func tions and sa fety featur es on this machine. Fail ure to fol low this warni ng could result in serious per sonal injury or even deat h ! T est Ru n Test run your machin[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 1 9- 11. One at a time, perform the following steps for each of the emergency stop buttons. a. Press the emergency stop button in to turn the machine OFF . b. WITHOUT resetting the button, press the motor start button. The motor should not start. —If the motor does not start, the emergency stop button [...]
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-20- G 06 46 / G06 4 7 50 / 6 5 T on Ironwork er Damag e to your eyes, lungs, and e ars could re su lt fro m u sin g t his ma ch in e wi th ou t prope r prote ctive gea r . Alway s we ar safet y glasses , a respirator , and hearing prote ction when op erating this machine. Lo o s e h a ir an d c l ot h - ing could g et caught in machiner y a nd cau[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 21 - E. Motor Start Button: Turns the motor ON when there is power to the machine . F. Motor Stop Button: Turns the motor OFF . G. Normal/Inch Switch: In Normal position, the beam moves to the end of the arc in the direction selected, then returns to the opposite end of the arc. In Inch position, the bea[...]
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-22- G0646 / G0 64 7 50 / 65 T on Ironwork er 3. Brush one of the lubricants from Figure 18 or an equivalent onto the punch, die, and both sides of the workpiece. Brand T ype B.P . Ser vora 68 Castrol Ilobroach 2 1 9 Duckhams Adfornal EP7 Shell Garia 927 Figure 18. Recommended cutting lubricants. workpiece lubric ants 4. Position the workpiece unde[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -23- 4. Loosen the die set screws on both sides of the punch bolster, then lift the die from below and remove it (see Figure 20 ). 5. Use the spanner wrench to loosen and remove the punch retaining ring, then sepa - rate the punch adapter and die from the ring (see Figure 21 ). Figure 21. Punch assembly re[...]
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-2 4- G 064 6 / G06 4 7 50 / 6 5 T on Ironwork er 7. Use the spanner wrench to fully tighten the punch assembly onto the pressure plate. 8. Insert the die into the punch bolster with the larger opening down, but do not tighten the set screws (see Figure 22 ). 9. Set the controls to Punch and Inch , then reconnect the machine to power. 10. Turn the [...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -25- Not ch in g The notching station sets up to make notches of va r ying sizes and s hapes in flat bar mild steel stock. The limit stops are adjustable to set the most ef ficient stroke length for your operation (ref er to Page 33 ). Stay wit hin the following notching capacit ies for you r machine: Mod [...]
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-26- G0 64 6 /G 06 4 7 50 / 6 5 T on Ironwork er 4. Remove the table guides, unthread the three flat head cap screws securing the notch - ing table (see Figure 26 ), then remove the table. 5. Put on heavy leather gloves, hold the bottom dies (two side and one front) as you remove the cap screws that secure them to the bol - ster, then remove the di[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 27 - 5. Install the front die into the bolster and fully secure it with the two cap screws. 6. Thread the side die adjustment set screws on both sides out 2–3 turns (see Figure 29 ), position the side dies into the bolster, then thread and fully tighten the cap screws through the bolster and into the d[...]
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-28- G0 646 / G0 64 7 50 / 65 T on Ironwork er F lat St ock Shear in g The flat stock shearing station is desi gned to straight or angle cut flat stock or cut one flange of angle iron stock. Use the adjustable ho ld- down and table guides for safe and ac curate cuts. Stay within the following flat stock shearing c apac - ities for your machine: Mod[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -29- T o she ar flat stock : 1. Set the controls for Punch and Inch , use the foot actuator to raise the top shearing die and make room for the workpiece, then turn the motor OFF . 2. Brush one of the lubricants from Figure 18 on Page 22 or an equivalent onto both sides of the workpiece. 3. Loosen the lock[...]
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Page 32
-3 0 - G06 46 / G0 64 7 50 / 65 T on Ironwork er Ba r Stoc k Shear in g Use the bar stock shearing station to cut solid, mild steel round, squar e, and rectangular bar mate rial. Stay wit hin th e fo llowi ng b ar s toc k s hear ing capacities for your machine: Mod el G0 6 4 6 Maximum Round Bar Diameter ...... 1 3 ⁄ 16 " (30mm) Maximum Squar[...]
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Page 33
G06 46 / G0 64 7 50 / 65 T o n Ironw orker -3 1 - 6. Set the controls for Notch and Normal , then use the pedal actuator to perform the shear - ing operation. Note: Make sure the cut piece falls through the rear exit panel and away from the dies so that it does not interfere with the next opera - tion. Ex tens ion Ba r The in cluded extension bar a[...]
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-32- G06 46 / G06 4 7 50 / 65 T on Ironwork er 4. Rotate the support frame handwheel to align the angle iron opening in the frame with the opening in the dies, then re-tighten the lock knobs. 5. Thread the appropriate hold-down screw up, then feed the workpiece through the front of the support frame and beyond the dies (see Figure 40 ). Figure 40. [...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -33 - A dj ust in g Stro k e Len gth The stroke length of the beam and at tached tool- ing is adjusted by moving the position of t he limit stops. The t ypic al benefit of adjusting t he stroke length is to shor ten the distanc e t he tooling moves aw ay from t he workpiec e to decrease the amount of cycle[...]
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-3 4- G0 64 6 /G 06 4 7 50 / 6 5 T on Ironwork er 3. Loosen the limit stop set screw, move the limit stop along the limit bar, then re-tighten the set screw. Note: A small adjustment to the limit stop position makes a large difference in the stroke length. Make small adjustments, then test the results. 4. Set the controls to Inch and in the desired[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -35 - SE CTION 5 : A CC ESS ORIE S accessories G5562—SLIPIT ® 1 Qt. Gel G5563—SLIPIT ® 12 oz Spray G28 71— Boeshiel d ® T - 9 1 2 oz S pray G28 70 — Bo eshiel d ® T -9 4 oz S pray H3788—G96 ® Gun Treatment 12 oz Spray H3789—G96 ® Gun Treatment 4.5 oz Spray Figure 45. Recommended products [...]
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-3 6 - G06 46 / G06 4 7 50 / 65 T on Ironwork er T2 0571— 5 / 1 6” Round Punch T2 057 2 — 3 / 8” Round Punch T2 057 3 —7/ 1 6” Round Punch T2 057 4 —1/ 2” Round Punch T2 0575 — 5 / 8” Round Punch T2 0576 — 23 / 32” Round Punch T2 057 7—3 / 4” Round Punch T2 057 8 —7/ 8” Round Punch T2 057 9 — 1 ” Round Punch T2 0[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -37 - SE CTION 6 : MAINT ENAN CE Alwa ys disconnec t power to t h e m ac hi ne b ef or e per forming maintenance . Failure to do t his may result in s erious p erson - al injury . For optimum per formance from your machine , follow this maint enance schedule and refer to any specific instructions given in [...]
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-3 8- G0 64 6 /G 06 4 7 50 / 6 5 T on Ironwork er L ubr icati on There are four points on the ironwork er that require at least monthly lubric ation: 1 ) The beam pivot shaft, 2) the shearing hold - down adjustment rod, 3 ) the angle iron ho ld- down screw s, and 4) the shearing sup por t frame leadscrew and bev - eled gears. Before lubrication, wi[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -39 - Su ppo rt Fra me Lub ric at ion 1. DISCONNECT MACHINE FROM POWER! 2. Remove the three lock knobs and shearing support frame from the machine. 3. Turn the support frame over, remove the two hold-down screws, then thoroughly clean the threads of the screws, lock rings, and nuts (see Figure 51 ). Figure[...]
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- 40 - G0 646 /G0 647 50 / 65 T on Ironwork er Hy dr au lic Sy stem Fluid Ca pacity Hydraulic Reservoir ......... Approx. 15 gal. (60 L.) The hy draulic syst em must be maintained on a regular basis and kept in good operating cond ition so t hat the ironwork er can per form safely and at the rated c apacit y . If you have nev er maintained a hy dra[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 4 1 - Draining & Re-Filling Hydraulic Re ser voi r T ools N ee ded Qt y Wrench 10mm ................................................... 1 Large Adjustable Wrench .................................. 1 Oil Catch Pan .................................................... 1 To drain and re-fill the hydrauli[...]
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- 42 - G0 64 6 /G0 647 50 / 65 T on Ironwork er 6. Reach through the opening in the top of the reservoir left by the access plate and remove the outlet filter from the reservoir. 7. Thoroughly clean the filler cap, both filters, and the inside of the reservoir with solvent or mineral spirits. Make sure to wipe and dry all fluid residue from the par[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -43 - Revie w t he troubleshooting and proc edures in this sec tion to fix or adjust your machine if a problem dev el - ops. If you need replacement parts or y ou a re unsur e of your repair skills, then feel free t o call our T echnical Suppor t at (570) 5 46 -9 663. SE CTION 7 : SE R VIC E T rou bles hoo[...]
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- 44 - G0 646 / G0 64 7 50 / 65 T on Ironwork er Mo tor & Elec tri ca l Symptom Possible Cause Possible Solution Mac hine ha s vibr a- tio n or noi sy o pera - tio n. 1. Motor wired out of phase. 2. Motor or component is loose. 3. Motor mount loose/broken. 4. Machine is incorrectly mounted or sits unevenly. 5. Motor fan is rubbing on fan cover.[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -45 - F lat St ock Shear in g Dies The bottom die for the flat stock shearing sta- tion has fou r cut ting edges that c an b e u sed b y mounting it in dif ferent posit ions. The top die has one moun ting position and one cut ting edge. B oth dies can be face ground to sharpen the cut ting edges if nec ess[...]
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- 46 - G0 646 / G0 64 7 50 / 65 T on Ironwork er 6. Have an assistant hold the dies as you remove the flat head cap screws, then remove both dies from the machine. Note: To aid in re-installation, record the ori- entation of each die as your remove it. 7. Thoroughly clean the dies and mounting area with a solvent or mineral spirits to remove debris[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 4 7 - 4. Use the foot actuator to pivot the beam so that the cap screws of the top dies are acces - sible, as shown in Figure 61 , then release the pedal actuator to hold it in that position. Figure 61. Angle iron shearing station dies (front view) Adjustment Set Screws Top Dies 5. DISCONNECT MACHINE FRO[...]
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- 48 - G06 46 / G0 64 7 50 / 65 T on Ironwork er 5. DISCONNECT MACHINE FROM POWER! 6. Remove the two outer die brackets, then both dies. Note: The inner die has a cutout on the top edge that fits over a cap screw in the beam and must be re-installed in the same posi - tion (see Figure 63 ). To aid in re-installation, record the orientation of the d[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -49 - Shear in g T able Al ign ment The shearing table must be lev el alo ng the entire length wit h the bottom flat stock shearing die for accurate cut s. T ools N ee ded Qt y Straightedge ...................................................... 1 Hex Wrench 8mm .............................................[...]
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-50 - G06 46 / G0 64 7 50 / 65 T o n Ironw orker Figure 66. Hydraulic pressure relief and needle valves. Needle Valve Pressure Relief Valve L im it Rin gs When t he limit stops are se cured up against the limit rings, the ram and beam move at their ma xi - mum safe lengths to eit her side. The p osition of the limit rings (ref er to Page 33 ) ha ve[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 5 1 - Elect ri cal P anel Wir in g Figure 67. Electrical panel wiring (see Wiring Diagram on Page 53 ) Voltage Transformer Main Power Switch Fuses Contactor Overload Relay[...]
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-52- G06 46 / G06 4 7 50 / 6 5 T on Ironwork er Con trol Pa nel Wi ri ng Figure 68. Control panel wiring (see Wiring Diagram on Page 54 ) Emergency Stop Button Power Lamp Motor Stop Button Motor Start Button Punch/Notch Switch Normal/Inch Switch[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -53 - ?[...]
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-5 4- G 064 6 / G06 4 7 50 / 6 5 T on Ironwork er Con trol Pa nel Wi ri ng Dia gra m control panel wiring diagram ?[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -55 - ?[...]
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-56 - G 06 46 / G06 4 7 50 / 6 5 T on Ironwork er Mot or Wi r in g Dia gram motor wiring diagram ?[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -57 - Hy dr au lic Sy stem Ov er vie w ?[...]
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-58 - G0 64 6 /G 06 4 7 50 / 6 5 T on Ironwork er SE CTION 8 : P ARTS Upper F ro nt - Half ?[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -59 - G0 64 6 Upper F r on t- Half Pa r ts Li st REF PART # DESCRIPTION REF PART # DESCRIPTION 11 P0646011 PIVOT SHAFT 66 PW06M FLAT WASHER 12MM 12 P0646012 LOCK PLATE 67 PN09M HEX NUT M12-1.75 13 PSB61M CAP SCREW M10-1.5 X 20 70 P0646070 PUNCH TABLE 14 P0646014 PIVOT SHAFT BUSHING 71 PFH61M FLAT HD CAP SC[...]
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- 60 - G 06 46 / G06 4 7 50 / 6 5 T on Ironwork er G0 64 7 Upper F ro nt - Half Pa r ts L is t REF PART # DESCRIPTION REF PART # DESCRIPTION 11 P0647011 PIVOT SHAFT 66 PW06M FLAT WASHER 12MM 12 P0647012 LOCK PLATE 67 PN09M HEX NUT M12-1.75 13 PSB61M CAP SCREW M10-1.5 X 20 70 P0647070 PUNCH TABLE 14 P0647014 PIVOT SHAFT BUSHING 71 PFH61M FLAT HD CAP[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 6 1 - Upper Rear - Half ?[...]
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- 62- G064 6 /G 06 4 7 50 / 6 5 T on Ironwork er G0 64 6 Upper Rear - Hal f Pa r ts L is t REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P0646001 TOP PANEL FRONT 81 P0646081 LOCK HANDLE 1/2-13 2 P0646002 TOP PANEL REAR 82 PW01 FLAT WASHER 1/2 3 P0646003 HANGER FRAME 83 PCB32M CARRIAGE BOLT 1/2-13 X 1-3/4 4 P0646004 TOP COVER 84 P0646084 SECTION R[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -63 - G0 64 7 Upper Rear - Half Pa r ts Li st REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P0647001 TOP PANEL FRONT 81 P0647081 LOCK HANDLE 1/2-13 2 P0647002 TOP PANEL REAR 82 PW01 FLAT WASHER 1/2 3 P0647003 HANGER FRAME 83 PCB32M CARRIAGE BOLT 1/2-13 X 1-3/4 4 P0647004 TOP COVER 84 P0647084 SECTION REA[...]
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- 64 - G0 646 / G0 64 7 50 / 65 T on Ironwork er Cab ine t [...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -65 - G0 64 6 Cabi net REF PART # DESCRIPTION REF PART # DESCRIPTION 5 P0646005 FRONT ACCESS PANEL 190 P0646190 FOOT PEDAL 6 P0646006 SUB-PANEL 190-1 P0646190-1 FOOT PEDAL FLEXIBLE CONDUIT 7 P0646007 REAR ACCESS PANEL 190-2 P0646190-2 FOOT PEDAL ELECTRICAL CABLE 8 P0646008 LIMIT SWITCH ACCESS PANEL 191 P06[...]
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- 66 - G0 64 6 /G 06 4 7 50 / 6 5 T on Ironwork er REF PART # DESCRIPTION REF PART # DESCRIPTION 5 P0647005 FRONT ACCESS PANEL 190 P0646190 FOOT PEDAL 6 P0647006 SUB-PANEL 190-1 P0646190-1 FOOT PEDAL FLEXIBLE CONDUIT 7 P0647007 REAR ACCESS PANEL 190-2 P0646190-2 FOOT PEDAL ELECTRICAL CABLE 8 P0647008 LIMIT SWITCH ACCESS PANEL 191 P0646191 SIDE EMER[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker - 67 - Not ch in g Stati on REF PART # DESCRIPTION REF PART # DESCRIPTION 137 P0646137 NOTCH PUNCH 144 P0646144 NOTCH BOLSTER CLAMP 138 P0646138 CAP SCREW M20-2.5 X 90 145 PLW05[...]
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- 68 - G0 646 /G0 64 7 50 / 65 T on Ironwork er P unc hi n g St at ion REF[...]
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G06 46 / G0 64 7 50 / 65 T o n Ironw orker -69 - Ex tens ion Ba r & T ool s [...]
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- 70- G0 64 6 / G06 4 7 50 / 6 5 T on Ironwork er Lab el P lacemen t Safety labels warn about machine hazards and ways to prevent injury. The owner of[...]
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W AR RANT Y AND RET URNS ?[...]
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