Grizzly 50/65 Ton Ironworker G0646 Owner's Manual

50/65 ton ironworker

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

MODEL G0646/G0647

50/65 TON IRONWORKER

OWNER'S MANUAL

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#TS10279 PRINTED IN TAIWAN

Table of Contents

Summary of Contents for Grizzly 50/65 Ton Ironworker G0646

Page 1 MODEL G0646/G0647 50/65 TON IRONWORKER OWNER'S MANUAL COPYRIGHT © APRIL, 2008 BY GRIZZLY INDUSTRIAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. #TS10279 PRINTED IN TAIWAN...
Page 2 �� ...
Page 3: Table Of Contents
INTRODUCTION ... 2 Foreword ... 2 Contact Info ... 2 Functional Overview ... 2 Identification ... 3 G0646 Machine Data Sheet ... 4 G0647 Machine Data Sheet ... 6 SECTION 1: SAFETY ... 8 Safety Instructions for Machinery ... 8 Additional Safety Instructions for Ironworkers ...
Page 4: Introduction
G0646/G0647 when the manual was prepared. However, owing to Grizzly’s policy of continuous improvement, changes may be made at any time with no obligation on the part of Grizzly. For your convenience, we always keep current Grizzly manuals available on our website at www.grizzly.com.
Page 5: Identification
Figure 2. Front view identification. Figure 3. Rear view identification. G0646/G0647 50/65 Ton Ironworker Identification Figure 4. Control panel identification. A. Punching Station Emergency Stop Button B. Punching Station C. Bar Stock Shearing Station D. Lifting Eye Bolt E. Angle Iron Shearing Station Flat Stock Shearing Station G.
Page 6: G0646 Machine Data Sheet
G0646 Machine Data Sheet �� ...
Page 7 �� ...
Page 8: G0647 Machine Data Sheet
G0647 Machine Data Sheet �� ...
Page 9 �� ...
Page 10: Section 1: Safety
�� ...
Page 11 �� ...
Page 12: Additional Safety Instructions For Ironworkers
Additional Safety Instructions for HYDRAULIC INJECTION INJURIES. Be familiar with the hydraulic system of this machine and with the hydraulic safety sec- tion in this manual. Until you have a clear understanding about hydraulic injection inju- ries, how they occur, and how to avoid them, DO NOT use this machine.
Page 13: Additional Safety Instructions For Hydraulics
Additional Safety Instructions for Hydraulics HYDRAULIC INJECTION INJURY. Leaking hydraulic fluid may have enough pressure to penetrate the skin. Hydraulic fluid that is injected into the body represents a medical emergency that could cause infection, dis- ability, amputation, or death. SEEK MEDICAL ATTENTION.
Page 14: Section 2: Circuit Requirements
circuit requirements SECTION 2: CIRCUIT REQUIREMENTS 220/440V Operation Serious personal injury could occur if you connect the machine to the power source before you have completed the setup pro- cess. DO NOT connect the machine to the power source until instructed after setup. Electrocution or fire could result if this machine is not installed to code.
Page 15: 440V Conversion
All wiring changes must be inspected by a quali- fied electrician before the machine is connected to the power source. If, at any time during this pro- cedure you need help, call Grizzly Tech Support at (570) 546-9663. To rewire the Model G0646/G0647 for 440V...
Page 16: Section 3: Setup
SECTION 3: SETUP Setup Safety 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! Wear safety glasses dur- ing the entire setup pro- cess! The Model G0646/G0647 is a heavy machine.
Page 17: Inventory
NOT use these products to clean the machinery. Many cleaning solvents toxic inhaled. Minimize your risk by only using these products in a well ventilated area. Grizzly. -15-...
Page 18: Site Considerations
Site Considerations Floor Load Refer to the Machine Data Sheets (beginning on Page 4) for the weight and footprint specifications of your machine. Some floors may require addi- tional reinforcement to support both the machine and operator. Placement Location Consider existing and anticipated needs, size of material to be processed through each machine, and space for auxiliary stands, work tables or other machinery when establishing a location for...
Page 19: Mounting To Shop Floor
Mounting to Shop Floor Although not required, we recommend that you mount your new machine to the floor. Because this is an optional step and floor materials may vary, floor mounting hardware is not included. Generally, you can either bolt your machine to the floor or mount it on machine mounts.
Page 20: Test Run
Test Run Test run your machine to make sure it runs prop- erly and is ready for regular operation. The test run consists of verifying the following: 1) The motor powers up and runs correctly, 2) the motor turns the correct direction (machine is not wired out of phase), and 3) the emergency stop button safety feature works correctly.
Page 21: Recommended Adjustments
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.
Page 22: Section 4: Operations
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. -20-...
Page 23: Operation Tips
E. Motor Start Button: Turns the motor ON when there is power to the machine. 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.
Page 24 workpiece lubricants Brush one of the lubricants from Figure 18 or an equivalent onto the punch, die, and both sides of the workpiece. Brand Type B.P. Servora 68 Castrol Ilobroach 219 Duckhams Adfornal EP7 Shell Garia 927 Figure 18. Recommended cutting lubricants. Poison Hazard! Use prop- er protection equipment when handling cutting...
Page 25 Loosen the die set screws on both sides of the punch bolster, then lift the die from below and remove it (see Figure 20). Bolster Punching Die Figure 20. Punching die removed. 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).
Page 26 Use the spanner wrench to fully tighten the punch assembly onto the pressure plate. Insert the die into the punch bolster with the larger opening down, but do not tighten the set screws (see Figure 22). Set the controls to Punch and Inch, then reconnect the machine to power.
Page 27: Notching
notching station tips Notching The notching station sets up to make notches of varying sizes and shapes in flat bar mild steel stock. The limit stops are adjustable to set the most efficient stroke length for your operation (refer to Page 33). Stay within the following notching capacities for your machine: Model G0646...
Page 28 The edges of ironwork- er tooling are very sharp and can quickly cut fin- gers and hands. Always wear heavy leather gloves when handling tooling to avoid injury. Remove the table guides, unthread the three flat head cap screws securing the notch- ing table (see Figure 26), then remove the table.
Page 29 Install the front die into the bolster and fully secure it with the two cap screws. 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 die to hold them firmly against the bolster.
Page 30: Flat Stock Shearing
flat shearing tips Flat Stock Shearing The flat stock shearing station is designed to straight or angle cut flat stock or cut one flange of angle iron stock. Use the adjustable hold-down and table guides for safe and accurate cuts. Stay within the following flat stock shearing capac- ities for your machine: Model G0646...
Page 31 To shear flat stock: 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. Brush one of the lubricants from Figure 18 on Page 22 or an equivalent onto both sides of the workpiece.
Page 32: Bar Stock Shearing
Bar Stock Shearing Use the bar stock shearing station to cut solid, mild steel round, square, and rectangular bar material. Stay within the following bar stock shearing capacities for your machine: Model G0646 Maximum Round Bar Diameter ... 1 Maximum Square Bar Dimensions ...
Page 33: Extension Bar
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.
Page 34 Loosen the three lock knobs of the shearing support frame (see Figure 39). Support Frame Lock Knobs Figure 39. Front support frame lock knobs. 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.
Page 35: Adjusting Stroke Length
adjusting stroke length Adjusting Stroke Length The stroke length of the beam and attached tool- ing is adjusted by moving the position of the limit stops. The typical benefit of adjusting the stroke length is to shorten the distance the tooling moves away from the workpiece to decrease the amount of cycle time needed between cuts.
Page 36: Beam Lubrication
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.
Page 37: Section 5: Accessories
accessories SECTION 5: ACCESSORIES G5562—SLIPIT 1 Qt. Gel ® G5563—SLIPIT 12 oz Spray ® G2871—Boeshield T-9 12 oz Spray ® G2870—Boeshield T-9 4 oz Spray ® H3788—G96 Gun Treatment 12 oz Spray ® H3789—G96 Gun Treatment 4.5 oz Spray ® Figure 45.
Page 38: Available Tooling
T20571—5/16” Round Punch T20572—3/8” Round Punch T20573—7/16” Round Punch T20574—1/2” Round Punch T20575—5/8” Round Punch T20576—23/32” Round Punch T20577—3/4” Round Punch T20578—7/8” Round Punch T20579—1” Round Punch T20580—11/32” Round Die T20581—13/32” Round Die T20582—15/32” Round Die T20583—17/32” Round Die T20584—21/32” Round Die T20585—3/4”...
Page 39: Section 6: Maintenance
Wipe away built-up grime and debris from all sta- tions, tables, and tooling. Clean away any remain- ing material with a solvent or mineral spirits prod- uct such as the cleaner/degreaser from Grizzly shown in Figure 9 on Page 15. When thoroughly clean and dry, protect the...
Page 40: Lubrication
Clean away any remaining material with a solvent or min- eral spirits product such as the cleaner/degreaser from Grizzly shown in Figure 9 on Page 15. Beam Pivot Shaft Use a grease gun to add 1–2 pumps of multi-pur-...
Page 41 Support Frame Lubrication DISCONNECT MACHINE FROM POWER! Remove the three lock knobs and shearing support frame from the machine. 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).
Page 42: Hydraulic System
hydraulic system Hydraulic System Fluid Capacity Hydraulic Reservoir ... Approx. 15 gal. (60 L.) The hydraulic system must be maintained on a regular basis and kept in good operating condition so that the ironworker can perform safely and at the rated capacity. If you have never maintained a hydraulic system before, WE STRONGLY RECOMMEND that you read books, get formal training, or seek the help of...
Page 43 Draining & Re-Filling Hydraulic Reservoir Tools Needed Wrench 10mm ... 1 Large Adjustable Wrench ... 1 Oil Catch Pan ... 1 To drain and re-fill the hydraulic reservoir: DISCONNECT MACHINE FROM POWER! Remove the rear access panel. Unscrew the filler cap, and take out the filter from the filler neck (see Figure 55).
Page 44: Beam Alignment
beam alignment Reach through the opening in the top of the reservoir left by the access plate and remove the outlet filter from the reservoir. Thoroughly clean the filler cap, both filters, and the inside of the reservoir with solvent or mineral spirits.
Page 45: Section 7: Service
troubleshooting SECTION 7: SERVICE Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel- ops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical Support at (570) 546-9663.
Page 46 Motor & Electrical Symptom Possible Cause Machine has vibra- 1. Motor wired out of phase. tion or noisy opera- tion. 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. 6.
Page 47: Flat Stock Shearing Dies
shearing blades installing flat blades Flat Stock Shearing Dies The bottom die for the flat stock shearing sta- tion has four cutting edges that can be used by mounting it in different positions. The top die has one mounting position and one cutting edge. Both dies can be face ground to sharpen the cutting edges if necessary.
Page 48: Angle Iron Shearing Dies
Because of the critical positioning in relation to each other, these dies cannot be sharpened. When they become damaged or dull, call Grizzly Tech Support at (570) 546-9663 to order new ones. To re-install the angle iron shearing dies, use the...
Page 49: Bar Stock Shearing Dies
When they become damaged or dull, call Grizzly Tech Support at (570) 546-9663 to order new ones. Tools Needed Hex Wrench 8mm ...
Page 50 DISCONNECT MACHINE FROM POWER! 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).
Page 51: Shearing Table Alignment
shearing table alignment Shearing Table Alignment The shearing table must be level along the entire length with the bottom flat stock shearing die for accurate cuts. Tools Needed Straightedge ... 1 Hex Wrench 8mm ... 1 Adjustable Wrench ... 1 To adjust the shearing table to the bottom flat stock shearing die: DISCONNECT MACHINE FROM POWER!
Page 52: Limit Rings
limit rings Limit Rings When the limit stops are secured up against the limit rings, the ram and beam move at their maxi- mum safe lengths to either side. The position of the limit rings (refer to Page 33) have been set at the factory and should not be moved.
Page 53: Electrical Panel Wiring
Electrical Panel Wiring Voltage Transformer Main Power Switch Fuses Contactor Overload Relay Figure 67. Electrical panel wiring (see Wiring Diagram on Page 53) -51- G0646/G0647 50/65 Ton Ironworker...
Page 54: Control Panel Wiring
Control Panel Wiring Emergency Stop Power Button Lamp Motor Motor Stop Start Button Button Normal/Inch Switch Punch/Notch Switch Figure 68. Control panel wiring (see Wiring Diagram on Page 54) -52- G0646/G0647 50/65 Ton Ironworker...
Page 55: Electrical Panel Wiring Diagram
electrical wiring diagram Electrical Panel Wiring Diagram � � � �� ...
Page 56: Control Panel Wiring Diagram
control panel wiring diagram Control Panel Wiring Diagram �� To Electrical Panel �� (see Wiring Diagram � on Page 53) �� -54- � � �� ...
Page 57: Electrical Components Wiring Diagram
components wiring diagram Electrical Components Wiring Diagram �� To Electrical Panel (see Wiring Diagram on Page 53) G0646/G0647 50/65 Ton Ironworker �� ...
Page 58: Motor Wiring Diagram
motor wiring diagram Motor Wiring Diagram Figure 73. 220V motor wiring. �� -56- �� ...
Page 59: Hydraulic System Overview
Hydraulic System Overview -57- G0646/G0647 50/65 Ton Ironworker...
Page 60: Section 8: Parts
SECTION 8: PARTS Upper Front-Half -58- G0646/G0647 50/65 Ton Ironworker...
Page 61 G0646 Upper Front-Half Parts List REF PART # DESCRIPTION P0646011 PIVOT SHAFT P0646012 LOCK PLATE PSB61M CAP SCREW M10-1.5 X 20 P0646014 PIVOT SHAFT BUSHING P0646015 HEX BOLT M20-2.5 X 140 P0646018 SET SCREW M24-3 X 50 PN44M HEX NUT M24-3 P0646021 HEX BOLT M24-3 X 65 PN44M...
Page 62 G0647 Upper Front-Half Parts List REF PART # DESCRIPTION P0647011 PIVOT SHAFT P0647012 LOCK PLATE PSB61M CAP SCREW M10-1.5 X 20 P0647014 PIVOT SHAFT BUSHING P0646015 HEX BOLT M20-2.5 X 140 P0646018 SET SCREW M24-3 X 50 PN44M HEX NUT M24-3 P0646021 HEX BOLT M24-3 X 65 PN44M...
Page 63: Upper Rear-Half
Upper Rear-Half -61- G0646/G0647 50/65 Ton Ironworker...
Page 64 G0646 Upper Rear-Half Parts List REF PART # DESCRIPTION P0646001 TOP PANEL FRONT P0646002 TOP PANEL REAR P0646003 HANGER FRAME P0646004 TOP COVER P0646009 LIFTING EYE BOLT MOUNT P0646010 LIFTING EYE BOLT PN28M HEX NUT M20-2.5 P0646017 HEX BOLT M20-2.5 X 125 P0646020 PRESSURE PAD P0646052...
Page 65 G0647 Upper Rear-Half Parts List REF PART # DESCRIPTION P0647001 TOP PANEL FRONT P0647002 TOP PANEL REAR P0647003 HANGER FRAME P0647004 TOP COVER P0647009 LIFTING EYE BOLT MOUNT P0646010 LIFTING EYE BOLT PN28M HEX NUT M20-2.5 P0646017 HEX BOLT M20-2.5 X 125 P0647020 PRESSURE PAD P0647052...
Page 66: Cabinet
Cabinet -64- G0646/G0647 50/65 Ton Ironworker...
Page 67 REF PART # DESCRIPTION P0646005 FRONT ACCESS PANEL P0646006 SUB-PANEL P0646007 REAR ACCESS PANEL P0646008 LIMIT SWITCH ACCESS PANEL PB04M HEX BOLT M6-1 X 10 PW03M FLAT WASHER 6MM P0646153 RAM LIMIT SWITCH P0646168 HYDRAULIC CYLINDER P0646169 P0646173 HYD. LINE MANIFOLD-CYLINDER P0646174 HYD.
Page 68 REF PART # DESCRIPTION P0647005 FRONT ACCESS PANEL P0647006 SUB-PANEL P0647007 REAR ACCESS PANEL P0647008 LIMIT SWITCH ACCESS PANEL PB04M HEX BOLT M6-1 X 10 PW03M FLAT WASHER 6MM P0646153 RAM LIMIT SWITCH P0647168 HYDRAULIC CYLINDER P0647169 P0646173 HYD. LINE MANIFOLD-CYLINDER P0646174 HYD.
Page 69: Notching Station
�� REF PART # DESCRIPTION P0646137 NOTCH PUNCH P0646138 CAP SCREW M20-2.5 X 90 P0646139 NOTCH SIDE DIE P0646140 NOTCH END DIE P0646141 NOTCH BOLSTER PSB64M CAP SCREW M10-1.5 X 25 PSS21M SET SCREW M8-1.25 X 25 G0646/G0647 50/65 Ton Ironworker Notching Station ��...
Page 70: Punching Station
�� REF PART # DESCRIPTION P0646102 SPECIAL SET SCREW P0646103 PUNCH STRIPPER TOP PLATE P0646104 PUNCH PRESSURE PLATE P0646105 KNURLED KNOB PSB31M CAP SCREW M8-1.25 X 25 P0646107 COMPRESSION SPRING P0646108 BUSHING PW04M FLAT WASHER 10MM PSB47M...
Page 71: Extension Bar & Tools
extension bar Extension Bar & Tools �� REF PART # DESCRIPTION P0646215 GUIDE BAR P0646216 SCALE 1M P0646217 MOUNTING BRACKET PSB70M CAP SCREW M10-1.5 X 45 PLW06M LOCK WASHER 10MM P0646220 END CAP PSB17M CAP SCREW M4-.7 X 10 P0646222...
Page 72: Label Placement
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. -70- Label Placement ��...
Page 73 �� ...
Page 74 �� ...
Page 75: Warranty And Returns
WARRANTY AND RETURNS �� ...
Page 76 �� ...

This manual is also suitable for:

G0647

Grizzly 50/65 Ton Ironworker G0646 Owner's Manual

Introduction

Section 1: Safety

Section 2: Circuit Requirements

Section 3: Setup

Section 4: Operations

Section 5: Accessories

Section 6: Maintenance

Section 7: Service

Section 8: Parts

Warranty and Returns

Quick Links

Related Manuals for Grizzly 50/65 Ton Ironworker G0646

Summary of Contents for Grizzly 50/65 Ton Ironworker G0646

This manual is also suitable for:

Table of Contents