Grizzly Saw G0646 User 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

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Table of Contents

INTRODUCTION............................................... 2

SECTION 5: ACCESSORIES......................... 35

Foreword........................................................ 2

Contact Info ................................................... 2

Functional Overview ...................................... 2

Identification................................................... 3

G0646 Machine Data Sheet .......................... 4

G0647 Machine Data Sheet .......................... 6

Available Tooling ......................................... 36

SECTION 6: MAINTENANCE......................... 37

Schedule...................................................... 37

Cleaning & Protecting.................................. 37

Lubrication ................................................... 38

Hydraulic System......................................... 40

Beam Alignment .......................................... 42

SECTION 1: SAFETY....................................... 8

Safety Instructions for Machinery .................. 8

Additional Safety Instructions

SECTION 7: SERVICE ................................... 43

Troubleshooting ........................................... 43

Flat Stock Shearing Dies............................. 45

Angle Iron Shearing Dies............................. 46

Bar Stock Shearing Dies ............................. 47

Shearing Table Alignment ........................... 49

Limit Rings................................................... 50

Hydraulic Fluid Pressure.............................. 50

Electrical Panel Wiring................................. 51

Control Panel Wiring.................................... 52

Electrical Panel Wiring Diagram .................. 53

Control Panel Wiring Diagram..................... 54

Electrical Components Wiring Diagram....... 55

Motor Wiring Diagram.................................. 56

Hydraulic System Overview......................... 57

for Ironworkers............................................. 10

Additional Safety Instructions

for Hydraulics............................................... 11

SECTION 2: CIRCUIT REQUIREMENTS ...... 12

220/440V Operation..................................... 12

440V Conversion ......................................... 13

SECTION 3: SETUP ....................................... 14

Setup Safety ................................................ 14

Items Needed for Setup............................... 14

Unpacking.................................................... 14

Inventory ...................................................... 15

Clean Up...................................................... 15

Site Considerations...................................... 16

Moving & Placing Base Unit ........................ 16

Mounting to Shop Floor ............................... 17

Test Run ...................................................... 18

Recommended Adjustments........................ 19

SECTION 8: PARTS....................................... 58

Upper Front-Half.......................................... 58

Upper Rear-Half........................................... 61

Cabinet......................................................... 64

Notching Station .......................................... 67

Punching Station.......................................... 68

Extension Bar & Tools................................. 69

Label Placement.......................................... 70

SECTION 4: OPERATIONS ........................... 20

Operation Safety.......................................... 20

Basic Controls.............................................. 20

Operation Tips ............................................. 21

Punching...................................................... 21

Notching....................................................... 25

Flat Stock Shearing ..................................... 28

Bar Stock Shearing...................................... 30

Extension Bar .............................................. 31

Angle Iron Shearing..................................... 31

Adjusting Stroke Length............................... 33

Beam Lubrication......................................... 34

WARRANTY AND RETURNS ........................ 73

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INTRODUCTION

Foreword

Functional Overview

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’s com-

mitment to customer satisfaction.

The Model G0646/G0647 Ironworker is a versatile

metal-cutting machine that cuts mild steel stock at

five separate stations: 1) punching, 2) notching, 3)

bar stock shearing, 4) angle iron shearing, and 5)

flat stock shearing.

This machine uses a single, large beam that

moves through an arc from side-to-side and is

driven by the hydraulic ram (see Figure 1).

The specifications, drawings, and photographs

illustrated in this manual represent the Model

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.

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For your convenience, we always keep current

Grizzly manuals available on our website at

www.grizzly.com. Any updates to your machine

will be reflected in these manuals as soon as they

are complete.

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Contact Info

Figure 1. Movement of the beam.

We stand behind our machines. If you have any

service questions, parts requests or general ques-

tions about the machine, please call or write us at

the location listed below.

The beam is mounted with the appropriate dies

for each station. As the beam reaches the end of

the arc, limit switches automatically reverse the

hydraulic flow and move the beam back. A pres-

sure relief valve protects the hydraulic system

if the operation exceeds the capabilities of the

machine.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901

E-Mail: [email protected]

The workpiece is held in place with hold-downs,

table guides, or strippers that are designed spe-

cifically for each station. All stations accept a wide

variety of punch and die configurations.

If you have any comments regarding this manual,

please write to us at the address below:

Exit panels on the rear of the machine allow for

long workpieces to be processed at the shear-

ing and cutting stations. In addition, an extension

assembly mounts above the exit panels of the bar

and angle iron shearing stations for measured

repetitive work.

Grizzly Industrial, Inc.

Technical Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: [email protected]

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Identification

Figure 2. Front view 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

F. Flat Stock Shearing Station

G. Control Panel

H. Foot Actuator

I. Limit Stop Access Panel

J. Notching Station

K. One-Shot Beam Lubricator

L. Flat Stock, Angle Iron, and Bar Stock Rear

Exit Panels

M. Extension Bar

N. Hydraulic Reservoir Sight Glass and

Thermometer

O. Power Cord

P. Mounting Flange

Q. Main Power Switch

R. Power Lamp

S. Emergency Stop Button

T. Motor Stop Button

Figure 3. Rear view identification.

U. Punch/Notch Switch

V. Normal/Inch Switch and Key

W. Motor Start Button

X. Electrical Panel Door Lock

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G0646 Machine Data Sheet

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G0647 Machine Data Sheet

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Safety Instructions for Machinery

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Additional Safety Instructions for

Ironworkers

6. KEEP HANDS AND BODY CLEAR. Each

1. 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.

station of the Ironworker is designed to cut

or shear metal, NOT body parts. Always

keep your hands and body clear of the cut-

ting operation when activating the machine

with the foot actuator.

7. IRONWORKER TOOLS. The tremendous

force this machine bears on each workpiece

can break or shatter tooling if not properly

setup. Make sure that all tooling, even in

stations that are not currently in use, is prop-

erly mounted and secured before beginning

operations.

2. OPERATOR PROTECTION. Processed

workpieces can be hot and sharp. Wear

heavy leather gloves when handling the

workpieces. Metal chips or debris can be

rapidly thrown toward the operator during

operations. Always wear an ANSI approved

full face shield, and heavy leather body,

arm, and foot protection when using this

machine.

8. UNATTENDED OPERATION. To avoid the

risk of injury from unexpected movement

of the beam and tooling, always turn the

motor OFF before walking away from this

machine. When leaving the machine for an

extended period, disconnect it from power.

3. SINGLE OPERATOR. When in operation,

multiple stations are active at the same time

but there is only one set of controls. This

machine was designed for use by only one

operator at a time.

9. SECURE WORKPIECE. Workpieces that

are not properly supported and secured

can rapidly move toward the operator when

force is applied. Always firmly secure the

workpiece with the devices provided. Make

sure workpieces are firmly supported on

both sides of the punch/cut. For long stock,

use additional support at both ends.

4. DISCONNECT POWER. Unexpected acti-

vation of the machine while hands are near

any processing station could cause serious

personal injury. Disconnect the machine

from power before making adjustments to

tooling or performing setup, maintenance, or

service to this machine.

10. EXPERIENCING DIFFICULTY. If at any

time you are experiencing difficulties per-

forming the intended operation, stop using

the machine! Contact our Technical Support

Department at (570) 546-9663.

5. GUARDS AND PANELS. The guards and

access panels are designed to protect the

operator from injury when the machine is

in operation. Always keep all guards and

access panels in place and secured before

beginning operations.

Like all machinery there is potential danger when operating this machine. Accidents are fre-

quently 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.

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Additional Safety Instructions for Hydraulics

1. 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.

5. DEPRESSURIZE THE SYSTEM. Working

on a pressurized hydraulic system can

cause a pressure explosion, resulting in

serious personal injury. To reduce the risk of

this hazard, stop the motor, disconnect the

machine from power, and fully depressurize

the hydraulic system before attempting to fix

or service the system.

2. SEEK MEDICAL ATTENTION. A hydraulic

injection injury may be a small wound that

has barely broken the skin. DO NOT be

fooled by this type of injury. Get professional

medical attention immediately! Minimizing

the time between the injury and when the

injected material is removed is critical to

reducing the seriousness of the injury.

6. CLEAN ENVIRONMENT. To reduce the

risk of hydraulic fluid contamination or dam-

age to internal components, remove debris,

grime, or water from the hydraulic hoses,

connections, and openings before mainte-

nance. Always use lint-free rags when wip-

ing components.

3. SUSPECTED

HYDRAULIC

LEAKS.

Leaking hydraulic fluid may be under

extreme pressure and hot. Use a piece of

clean cardboard—not hands—to check for

suspected hydraulic leaks.

7. HOSES AND FITTINGS. The hydraulic

system is under extreme pressure—typi-

cally 3000 PSI. Always use high-pressure

hydraulic hose and steel hydraulic fittings

when replacing system components. Never

use brass or aluminum.

4. OPERATOR PROTECTION. Always wear

an ANSI approved face shield and heavy

leather gloves and clothing when working

around hydraulic leaks. The best way to pro-

tect yourself is to stay away from the leaks

until you can depressurize the system.

8. REGULARINSPECTION. Awell-maintained

hydraulic system will have much fewer prob-

lems and hazards than a neglected system.

Regularly inspect the hydraulic system for

contamination or leaks, and keep the reser-

voir filters clean.

No list of safety guidelines can be complete. Every shop environment is different. Always con-

sider safety first, as it applies to your individual working conditions. Use this and other machin-

ery with caution and respect. Failure to do so could result in serious personal injury, damage to

equipment, or poor work results.

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circuit requirements

SECTION 2: CIRCUIT REQUIREMENTS

Power Supply Circuit Requirements

220/440V Operation

You MUST connect your machine to a grounded

circuit that is rated for the amperage given below.

Never replace a circuit breaker on an existing cir-

cuit with one of higher amperage without consult-

ing a qualiﬁed electrician to ensure compliance

Serious personal injury could occur if you

connect the machine to the power source

with wiring codes.

before you have completed the setup pro-

If you are unsure about the wiring codes in

cess. DO NOT connect the machine to the

your area or you plan to connect your machine

power source until instructed after setup.

to a shared circuit, consult a qualified electri-

cian.

G0646/G0647 220V Minimum Circuit ...........20A

G0646/G0647 440V Minimum Circuit ...........15A

Electrocution or fire could

result if this machine is

not installed to code. You

MUST ensure compliance

by checking with a quali-

fied electrician!

Power Connection Device

The power connection device depends on the

type of installed or planned service. We recom-

mend using one of the devices shown in Figure 5,

depending on the model and voltage being used.

NOTICE

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The Model G0646/G0647 is prewired for

220V operation. If you plan to use your

machine at 440V, you MUST have a quali-

fied electrician perform the 440V conver-

sion described on Page 13.

220V

NEMA 15-20

Plug & Receptacle

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Full Load Amp Draw

G0646 220V 3-Phase................................. 14.5A

G0646 440V 3-Phase................................... 7.5A

Hardwired Locking

Disconnect Switch

for 440V, 3-Phase

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G0647 220V 3-Phase....................................16A

G0647 440V 3-Phase......................................8A

Figure 5. Recommended connection types.

NOTICE

Using extension cords may reduce the life

of the motor. Instead, place the machine

near a power source. If you must use an

extension cord:

NOTICE

Extension Cords (220V Only)

Phase Converter Precaution

The power from the manufactured leg of

a phase converter may damage electrical

components if connected to the wrong

incoming power terminal on your machine.

Only connect the manufactured leg to the

T3 terminal of the main power switch (see

Page 53 for identification).

•

Use at least a 12 gauge cord that does

not exceed 50 feet in length.

Ensure that the extension cord contains

a ground wire and plug pin.

•

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440v conversion

3. At the voltage transformer, remove the wire

labeled "S" that leads to the “220” terminal,

and connect that wire to the “440” terminal

(see Figure 7).

440V Conversion

The Model G0646/G0647 can be converted for

440V operation. This conversion job consists

of disconnecting the machine from the power

source, changing the connections on the voltage

transformer, replacing the overload relay, and

rewiring the motor for 440V operation.

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The necessary overload relay for this procedure

can be purchased by calling Grizzly Customer

Service at (800) 523-4777 and ordering Part

Number P0646209-1.

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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.

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Figure 7. "S" wire connected to the 440V

terminal of the voltage transformer.

To rewire the Model G0646/G0647 for 440V

operation:

4. Remove the overload relay and replace it with

the 440V version (Part Number P0646209-1).

Set the overload relay dial (see Figure 6) to

the value for your model:

1. DISCONNECT MACHINE FROM POWER!

2. Rotate the main power switch to OFF or "0"

and the electrical cabinet door lock to the

horizontal, then open the door to access the

voltage transformer (see Figure 6).

Model G0646.........................................7.5A

Model G0647............................................8A

5. Open the junction box on the motor, and

rewire the motor as shown on the diagram

located inside the motor junction box.

Note: The reference motor wiring diagram on

Page 56 was current at the time of printing,

but always use the wiring diagram provided

inside the motor junction box, as it will reflect

any changes to the motor shipped with your

machine.

Voltage

Transformer

Overload

Relay

NOTICE

For 440V connections, an electrician MUST

hardwire the machine (using a metal con-

duit setup) directly to a locking disconnect

switch, which is directly connected to the

power source.

Figure 6. Voltage transformer and overload relay

inside electrical cabinet.

Note: It may be necessary to put pressure

on the upper left corner of the electrical cabi-

net door to engage and turn the main power

switch.

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SECTION 3: SETUP

Setup Safety

Items Needed for

Setup

The following items are needed to complete the

setup process, but are not included with your

machine:

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!

Description

Qty

•

Assistants.....................................At Least 2

Safety Glasses (for each person) .............. 1

Lifting Chain and Safety Hook

(rated for at least 3500 lbs.)....................... 1

Power Lifting Equipment

(rated for at least 3500 lbs.)....................... 1

Floor Mounting Hardware........... As Needed

•

Wear safety glasses dur-

ing the entire setup pro-

cess!

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 imme-

diately call Customer Service at (570) 546-9663

for advice.

TheModelG0646/G0647is

a heavy machine. Serious

personal injury may occur

if safe moving methods

are not used. To be safe,

get assistance and use

power equipment rated

for at least 3500 lbs. to

move the shipping crate

and remove the machine

from the crate.

Save the containers and all packing materials for

possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the condi-

tion of your shipment, inventory the contents.

Children and visitors may be

seriously injured if unsuper-

vised around this machine.

Lock entrances to the shop

or disable start switch or

power connection to prevent

unsupervised use.

SUFFOCATION HAZARD!

Immediately discard all plas-

tic bags and packing materi-

als to eliminate choking/suf-

focation hazards for children

and animals.

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Inventory

Clean Up

The following is a description of the main compo-

nents shipped with your machine. Lay the compo-

nents out to inventory them.

The unpainted surfaces are coated with a waxy

oil to prevent corrosion during shipment. Remove

this protective coating with a solvent cleaner or

degreaser, such as shown in Figure 9. For thor-

ough cleaning, some parts must be removed.

For optimum performance, clean all moving

parts or sliding contact surfaces. Avoid chlo-

rine-based solvents, such as acetone or brake

parts cleaner that may damage painted surfac-

es. Always follow the manufacturer’s instructions

when using any type of cleaning product.

Note: If you can't find an item on this list, check

the mounting location on the machine or examine

the packaging materials carefully. Occasionally

we pre-install certain components for shipping

purposes.

Inventory: (Figure 8)

Qty

A. Ironworker (not shown)............................... 1

B. Guide Bar Assembly .................................. 1

C. Extension Bar Assembly ............................ 1

D. Toolbox....................................................... 1

E. Cap Screws M10-1.5 x 50 (Guide Bar)....... 3

F. Lock Washers (Guide Bar)......................... 3

G. Punch Adapter 9036 .................................. 1

H. Punch Adapter 81031................................. 1

I. Punch Adapter 81029................................. 1

J. Spanner Wrench ........................................ 1

K. Adjustable Wrench ..................................... 1

L. Grease Gun................................................ 1

M. Hex Wrench 17mm..................................... 1

N. Hex Wrench 14mm..................................... 1

O. Hex Wrench 12mm..................................... 1

P. Hex Wrench Set 2.5–10mm ....................... 1

Gasoline and petroleum

products have low flash

points and can explode

or cause fire if used to

clean machinery. DO

NOT use these products

to clean the machinery.

Many cleaning solvents

are toxic if inhaled.

Minimize your risk by only

using these products in a

well ventilated area.

G2544—Solvent Cleaner & Degreaser

A great product for removing the waxy shipping

grease from your machine during clean up.

Figure 8. Model G0646/G0647 inventory.

If any nonproprietary parts are missing (e.g. a

nut or a washer), we will gladly replace them; or

for the sake of expediency, replacements can be

obtained at your local hardware store.

Figure 9. Cleaner/degreaser available from

Grizzly.

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Site Considerations

Moving & Placing

Base Unit

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.

TheModelG0646/G0647is

a heavy machine. Serious

personal injury may occur

if safe moving methods

are not used. To be safe,

get assistance and use

power equipment rated

for at least 3500 lbs. to

move the shipping crate

and remove the machine

from the crate.

Placement Location

Consider existing and anticipated needs, size of

material to be processed through each machine,

and space for auxiliary stands, work tables or

other machinery when establishing a location for

your new machine. See Figures 10–11 for the

minimum working clearances.

To move the machine:

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1. Remove the crating and plastic wrap, then

unbolt the machine from the shipping pallet.

2. Attach the safety hook and lifting chain to the

lifting eye bolt (see Figure 12).

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Eye Bolt

Figure 10. Model G0646 minimum working

clearances.

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Figure 12. Safety hook and lifting chain attached

to the eye bolt of the machine.

3. With assistance to steady the machine, care-

fully lift it enough to clear the pallet and floor

obstacles, then move it to the prepared loca-

tion.

Figure 11. Model G0647 minimum working

clearances.

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Using Machine Mounts

Mounting to Shop

Floor

Using machine mounts, shown in Figure 14, gives

the advantage of fast leveling and vibration reduc-

tion. The large size of the foot pads distributes

the weight of the machine to reduce strain on the

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. Both

options are described below. Whichever option

you choose, it is necessary to level your machine

with a precision level.

Bolting to Concrete Floors

Lag shield anchors with lag bolts (Figure 13) and

anchor studs are two popular methods for anchor-

ing an object to a concrete floor. We suggest

you research the many options and methods for

mounting your machine and choose the best that

fits your specific application.

Figure 14. Machine mount example.

NOTICE

We strongly recommend securing your

machine to the floor if it is hardwired to the

power source. Consult with your electrician

to ensure compliance with local codes.

NOTICE

Anchor studs are stronger and more per-

manent alternatives to lag shield anchors;

however, they will stick out of the floor,

which may cause a tripping hazard if you

decide to move your machine.

Anchor Stud

Lag Shield

& Bolt

Figure 13. Typical fasteners for mounting to

concrete floors.

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6. Connect the machine to the power source.

Test Run

7. There are two emergency stop buttons—on

the front control panel and below the punch-

ing station on the left of the machine. One at

a time, push the buttons in, then twist them

clockwise so they pop out (see Figure 15).

When both buttons pop out, the switches are

reset and ready for operation.

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.

If, during the test run, you cannot easily locate

the source of an unusual noise or vibration,

stop using the machine immediately, then review

Troubleshooting on Page 43.

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If you still cannot remedy a problem, contact our

Tech Support at (570) 546-9663 for assistance.

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Figure 15. Resetting the Emergency Stop

button.

8. Turn the main power switch to the ON or "l"

position—the power lamp should light.

Before starting this machine, make sure you

have read through the rest of the manual

and are familiar with the various functions

and safety features on this machine. Failure

to follow this warning could result in serious

personal injury or even death!

9. Set the controls to Normal, and press the

motor start button to turn the machine ON.

10. Verify that the machine is operating correctly

by pressing the foot pedal actuator.

When the steps below are successful, your iron-

worker is ready for operation.

—When operating correctly, the machine

runs smoothly with little or no vibration or

rubbing noises.

To test run the machine:

—If the motor is running but the beam does

not move, the power may be connected

out of phase, and the motor will emit a

loud, high-pitched whine. Stop the machine

IMMEDIATELY, shut off the power source,

then swap any two of the three power wires

that connect to the motor (refer to Page

56). Repeat Steps 5–9.

1. Make sure you understand the safety instruc-

tions at the beginning of the manual and that

the machine is setup properly.

2. Make sure all tools and objects used during

setup are cleared away from the machine.

3. Check the hydraulic fluid level in the reser-

voir and fill it if necessary (refer to Hydraulic

System on Page 40 for detailed instruc-

tions).

—Investigate and correct strange or unusual

noises or vibrations before operating the

machine further. Always stop the machine

and disconnect it from power before inves-

tigating or correcting potential problems.

4. Lubricatethebeam(refertoBeamLubrication

on Page 34 for detailed instructions).

5. Understand the basic controls and how to

use them (refer to Basic Controls on Page

20 for detailed instructions).

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11. One at a time, perform the following steps for

Recommended

Adjustments

each of the emergency stop buttons.

a. Press the emergency stop button in to

turn the machine OFF.

For your convenience, the adjustments listed

below have been performed at the factory.

b. WITHOUT resetting the button, press the

motor start button. The motor should not

start.

However, because of the many variables involved

with shipping, we recommend that you at least

verify the following adjustments to ensure the best

possible results from your new machine.

—If the motor does not start, the emergency

stop button safety feature is working cor-

rectly.

Step-by-step instructions for these adjustments

can be found in the SERVICE section starting on

Page 43.

—If the motor does start (with the emer-

gency stop button pushed in), immediately

disconnect power to the machine. The

emergency stop button safety feature is not

working correctly. This safety feature must

work properly before proceeding with regu-

lar operations. Call Tech Support for help.

Factory adjustments that should be verified:

•

Shearing die clearances (beginning on Page

45).

12. Reset both emergency stop buttons and

press the motor start button to turn the motor

ON.

•

Shearing table alignment (Page 49).

Limit ring and stop positions (Page 50).

Hydraulic fluid pressure (Page 50).

13. Set the controls to Punch and Normal, then

press the foot actuator—the beam should

come down on the punching station.

14. Set the controls to Notch and press the pedal

actuator—the beam should come down on

the notching station.

15. Set the controls to Inch, and repeat Step 12

and 13. Lift your foot from the actuator as the

beam moves—it should stop and stay in that

position.

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SECTION 4: OPERATIONS

Operation Safety

Basic Controls

Refer to Figure 16 and the descriptions below to

become familiar with the basic controls of your

ironworker.

Damage to your eyes, lungs, and ears could

result from using this machine without

proper protective gear. Always wear safety

glasses, a respirator, and hearing protection

when operating this machine.

Loose hair and cloth-

ing could get caught in

machinery and cause seri-

ous personal injury. Keep

loose clothing and long

hair away from moving

machinery.

Figure 16. Basic controls.

NOTICE

If you have never used this type of machine

or equipment before, WE STRONGLY REC-

OMMEND that you read books, trade maga-

zines, or get formal training before begin-

ning any projects. Regardless of the con-

tent in this section, Grizzly Industrial will

not be held liable for accidents caused by

lack of training.

A. Main Power Switch: Allows power to flow to

the machine—"l" is ON, and "O" is OFF.

B. Power Lamp: Lights when power flows to the

machine.

C. Emergency Stop Button: Turns power OFF

to the machine, but does not disconnect the

machine from power. There are two emer-

gency stop buttons—on the main control

panel and on the left side of the machine.

D. Electrical Cabinet Door Latch: Allows entry

to the electrical cabinet when the main power

switch is in the OFF position.

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punching station tips

E. Motor Start Button: Turns the motor ON

Punching

when there is power to the machine.

F. Motor Stop Button: Turns the motor OFF.

Use the punching station to perform general die

work, bar bending, corner notching, and tube

notching (additional tooling may be required for

some processes). The punching table and guides

accept a wide variety of workpiece shapes, and

the front portion of the table is removable for

flange punching. The limit stops are adjustable to

set the most efficient stroke length for your opera-

tion (refer to Page 33).

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

beam stops where it is when the foot actuator

is released or it has reached the end of the

arc—use this to "jog" the beam.

H. Punch/Notch Switch: Selects which direc-

tion the beam moves when the foot actuator

is depressed.

Use the following formula to calculate the maxi-

mum punch diameter for the workpiece (all values

are in millimeters):

I. Foot Actuator: Initiates the beam move-

��

�

ment.

The machine constants are:

Model G0646................................................. 330

Model G0647................................................. 420

Operation Tips

Using the Punching Station

1. Set the controls to Notch and Inch, then

raise the punching die up so that you can

insert the workpiece.

•

To produce quality cuts and avoid damage

to your machine, stay within the operational

capacities of your machine.

Adjust the table guides, strippers, or hold-

downs to keep the workpiece from unexpect-

edly moving up during the operation without

restricting movement of the workpiece when

required for the next cut.

2. Rotate both knurled stripper adjustment

shafts together (see Figure 17) to raise the

hold-down slightly higher than the thickness

of the workpiece.

•

Use liberal lubrication on the dies and

workpiece to reduce friction and wear on the

tooling.

Stripper Adjustment Shafts

The quality of the cut edges are an immediate

indicator of the die condition. keep the dies

clean of debris and mill scale. Sharp tool-

ing cuts cleaner and with less wear on the

machine.

•

To avoid damage to the machine or tooling,

cut completely through the workpiece unless

you are using tooling designed for partial cut-

ting.

Table Guides

Figure 17. Typical punch station setup with a

Dies are sharp! Always wear heavy leather

gloves when handling the dies to protect your

hands.

workpiece mounted on the table.

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workpiece lubricants

3. Brush one of the lubricants from Figure 18 or

an equivalent onto the punch, die, and both

sides of the workpiece.

Tooling and workpiece

could break apart under

pressure, sending metal

debris toward the opera-

tor at a high rate of speed.

Always keep all safety

guards and access panels

in the correct position and

secured when perform-

ing cutting operations

to reduce the risk of this

hazard.

Brand

B.P.

Type

Servora 68

Ilobroach 219

Adfornal EP7

Garia 927

Castrol

Duckhams

Shell

Figure 18. Recommended cutting lubricants.

Poison Hazard! Use prop-

er protection equipment

when handling cutting

fluid and only dispose by

following federal, state,

and fluid manufacturer

requirements.

Removing/Installing Punch Tooling

Tools Needed

Qty

Hex Wrench 6mm.............................................. 1

Spanner Wrench (included)............................... 1

To remove punch tooling:

1. Set the controls to Notch and Inch, use the

foot actuator to raise the punch to the upper-

most position, then stop the motor.

4. Position the workpiece under the punch and

secure it in position with the table guides.

5. Set the controls to Punch and Normal,

then use the foot actuator to punch the

workpiece.

2. DISCONNECT MACHINE FROM POWER!

3. Loosen the knurled knob securing the right

side of the stripper and safety guard assem-

bly, then swing it away from the punch and

die, as shown in Figure 19.

Note: When the punching operation is com-

plete, the punch will automatically raise up

out of the workpiece.

Safety Guard

The force of this ironwork-

er can quickly smash or

remove fingers or hands.

Always keep clear of all

cutting stations before

using the foot actuator to

begin the operation.

Knurled Knob

Stripper Base

Figure 19. Punch stripper and safety guard

assembly positioned away from the punch and

die.

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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).

To install punch tooling:

1. Set the controls to Notch and Inch, use the

foot actuator to raise the punch to the upper-

most position, then stop the motor.

2. DISCONNECT MACHINE FROM POWER!

Bolster

3. Move the stripper and safety guard assembly

Punching Die

out of the way.

4. Thoroughly clean the punch, die, pressure

plate, and bolster, then re-lubricate them to

prevent rust.

5. Place the adapter into the retaining ring, then

the punch into the adapter (see Figure 21).

Set Screw

(1 of 2 shown)

6. Center the assembly up against the punch

pressure plate, then hand-tighten the retain-

ing ring to secure it in place (see Figure 22).

Figure 20. Punching die removed.

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).

Punch

Assembly

Adapter

Retaining Ring

Die

Pressure

Plate

Figure 22. Punch, adapter, retaining ring, and

Punch

die installed.

Figure 21. Punch assembly removed and

separated.

NOTICE

To reduce the risk of tooling breakage, the

recommended side clearance between the

punch and die is approximately 10% of the

material thickness.

6. Thoroughly clean any metal debris or grime

off the punch, die, pressure plate, and bol-

ster.

Note: If you are storing the punch and

die, protect them with a light coat of an

anti-rust product like G96® Gun Treatment,

SLIPIT®, or Boeshield® T-9 (see Section 5:

Accessories on Page 35 for more details).

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7. Use the spanner wrench to fully tighten the

13. Properly re-position the stripper and safety

guard assembly, reset the emergency stop

button, then continue to jog the punch toward

the die.

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).

Note: Be prepared to quickly lift your foot

from the pedal actuator to stop the punch if

you suspect a mis-alignment or other prob-

lem.

9. Set the controls to Punch and Inch, then

reconnect the machine to power.

10. Turn the machine ON, press the foot actua-

tor to bring the punch near—but not into—the

die, then stop the motor.

14. Set the controls to Normal, then move the

punch in and out of the die several times to

ensure proper operation of the tooling before

mounting a workpiece onto the table.

11. Press the emergency stop button to avoid

unexpected movement of the tooling.

12. Align the die with the punch, then tighten the

set screws on both sides of the punch bolster

to hold the die in place.

To avoid tooling or workpiece breakage and

the risk of possible injury to the operator,

never attempt to cut a workpiece that is not

adequately supported and held in place.

Never attempt a cutting operation that is

beyond the capacity of your machine.

Note: If you have difficulty aligning the punch

with the die, you may have to reposition the

punch bolster. Use a 19mm wrench to loosen

the bolster mounting hex bolts (see Figure

23), move the bolster and die into alignment

with the punch, then re-tighten the hex bolts.

Bolster

Mounting Hex Bolts

(2 of 4 shown)

Figure 23. Punching bolster mounting hex bolts.

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notching station tips

4. Set the controls to Notch and Normal, then

turn the motor ON.

Notching

5. Stand clear of the machine and use the pedal

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).

actuator to perform the notching operation.

Note: When the notching operation is com-

plete, the die will automatically raise up out

of the workpiece.

Stay within the following notching capacities for

your machine:

Removing & Installing Notch Dies

Tools Needed

Qty

Model G0646

Hex Wrenches 4, 5, 6, 8, 14mm ..............1 Each

Wrench 19mm................................................... 1

Feeler Gauges 1mm, 3mm ......................1 Each

Maximum Thickness........................... ⁵⁄16" (8mm)

Maximum Notch Width .................... 1³⁄8" (35mm)

Maximum Notch Depth....................... 3" (75mm)

To remove the notch dies:

Model G0647

Maximum Thickness.......................... ³⁄8" (10mm)

Maximum Notch Width .................... 1⁵⁄8" (42mm)

Maximum Notch Depth..................... 4" (100mm)

1. Set the controls to Punch and Inch, raise the

die to its uppermost position above the notch-

ing station, then turn the motor OFF.

2. DISCONNECT MACHINE FROM POWER!

Using the Notching Station

1. Set the controls to Punch and Inch, then

raise the notching die so that you can insert

the workpiece.

3. Remove the stripper plates from both sides

of the notching station and the front safety

guard (see Figure 25).

2. Brush one of the lubricants from Figure 18 on

Page 22 or an equivalent onto both sides of

the workpiece.

Front

Safety

Guard

3. Position the workpiece on the table and

under the tooling, then use the table guides

and other devices to support the workpiece

(see Figure 24).

Stripper

Plate

Figure 25. Notching station stripper plate and

front safety guard.

Table Guide

Figure 24. Typical workpiece positioning for the

notching station.

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6. Support the top die as you remove the two

cap screws that secure it from the underside

of the die.

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.

7. Thoroughly clean any metal debris or grime

off the dies and bolster.

Note: Before storing the punch and dies, pro-

tect them with a light coat of an anti-rust prod-

uct like G96® Gun Treatment, SLIPIT®, or

Boeshield® T-9 (see Section 5: Accessories

on Page 35 for more details).

4. Remove the table guides, unthread the three

flat head cap screws securing the notch-

ing table (see Figure 26), then remove the

table.

Notch Die Clearances

Bottom Front Die and Top Die .................... 3mm

Bottom Side Dies and Top Die.................... 1mm

To install the notch dies:

1. Set the controls to Punch and Inch, raise the

top die to its uppermost position above the

notching station, then turn the motor OFF.

2. DISCONNECT MACHINE FROM POWER!

3. Remove the stripper plates, front safety

guard, and table, as described in the previ-

ous subsection.

4. Put on heavy leather gloves, support the top

die up against the beam, then secure it with

the two cap screws.

Figure 26. Flat head cap screws that secure the

notching table.

Note: Make sure the bottom flange (see

Figure 28) of the included top die is posi-

tioned to the back and next to the beam.

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 dies (see Figure 27).

Top

Die

Side Dies

��

Bolster

Cap

Front Die

Screws

��

Figure 28. Top notching die orientation.

Figure 27. Notching dies.

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5. Install the front die into the bolster and fully

10. Loosen the bolster hex bolts (see Figure 29),

adjust the bolster so that there is a clearance

of 3mm between the top and front dies, then

re-tighten the bolster hex bolts.

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 die to hold

them firmly against the bolster.

Note: During this step, attempt to evenly dis-

tribute the gaps on the sides.

11. Alternately loosen the side die cap screws

and adjustment set screws until there is a

1mm gap evenly between the top and side

dies (see Figure 30).

Set Screws

Cap

Screws

��

Bolster Hex Bolts

Figure 29. Notching side die set screw, cap

screws, and bolster hex bolts.

Figure 30. Notching die clearances.

7. Set the controls to Notch and Inch, then

reconnect the machine to power.

12. Fully tighten the side die cap screws, then

Note: The goal of the next set of procedures

is to bring the top die down through the

bottom dies so that the clearance between

them can be adjusted. It may be necessary

to move the bolster forward, as described in

Step 10 below, so that the punch can clear

the front die.

recheck all clearances.

13. Re-install the table, front safety guard, and

the side stripper plates.

14. Set the controls to Normal, then move the

top die in and out of the bottom dies several

times to check for correct positioning before

continuing with operations.

8. Turn the machine ON, then use the foot actu-

ator to bring the top die down into the bottom

dies.

Note: When in the Inch mode, lifting your

foot from the foot actuator will stop the beam

and hold it in that position.

9. Press the emergency stop button to avoid

unexpected movement of the tooling.

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flat shearing tips

The workpiece MUST extend through the hold-

down and through the dies, as shown in Figure 31,

to avoid sudden unexpected upward movement of

the workpiece during the cutting operation.

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

Maximum Thickness w/8" (200mm)

Workpiece Width ............................... ⁵⁄8" (15mm)

Maximum Thickness w/12" (300mm)

Workpiece Width ............................... ¹⁄2" (12mm)

Maximum Thickness for Single Flange

Cut w/3" x 3" (80mm x 80mm)

��

Angle Iron.......................................... ³⁄8" (10mm)

Model G0647

Maximum Shearing

��

Thickness w/8" (200mm)

Workpiece Width ............................... ³⁄4" (20mm)

Maximum Shearing

��

Thickness w/12" (300mm)

Workpiece Width ............................... ⁵⁄8" (15mm)

Maximum Thickness for Single Flange

Cut w/ 3" x 3" (80mm x 80mm)

Angle Iron.......................................... ³⁄8" (10mm)

��

Figure 31. Flat stock shearing workpiece

position.

To avoid tooling or workpiece breakage and

the risk of possible injury to the operator,

never attempt to cut a workpiece that is not

adequately supported and held in place.

Never attempt a cutting operation that is

beyond the capacity of your machine.

NOTICE

To make accurate and safe flat stock cuts,

be sure the table and bottom shearing die

are level and even with each other (refer to

Shearing Table Alignment on Page 49).

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To shear flat stock:

5. Tighten the adjustment rod so that the hold-

down clamps the workpiece against the

shearing table, then re-tighten the lock knobs

(see Figure 33).

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.

Note: Use the scored lines in the table to

align the workpiece.

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 knobs on the flat stock hold-

down (see Figure 32), then rotate the shear-

ing hold-down adjustment rod to lift the hold-

down up enough to clear the workpiece.

Adjustment Rod

Flat Stock

Hold-Down

Figure 33. Example of flat bar shearing setup.

6. Set the controls for Normal and Notch, start

the motor, then use the foot actuator to shear

the workpiece.

Lock Knobs

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.

Figure 32. Flat stock hold-down, lock knobs, and

adjustment rod.

4. Position the workpiece under the hold-down

and beyond the shearing dies (refer to Figure

31 on Page 28).

Tooling and workpiece

could break apart under

pressure, sending metal

debris toward the opera-

tor at a high rate of speed.

Always keep all safety

guards and access panels

in the correct position and

secured when perform-

ing cutting operations

to reduce the risk of this

hazard.

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4. Rotate the support frame handwheel to align

the bar stock openings in the support frame

with the openings in the dies (see Figure 35),

then re-tighten the lock knobs.

Bar Stock Shearing

Use the bar stock shearing station to cut solid,

mild steel round, square, and rectangular bar

material.

Bar Stock

Support Frame

Stay within the following bar stock shearing

capacities for your machine:

Model G0646

Maximum Round Bar Diameter...... 1³⁄16" (30mm)

Maximum Square Bar

Handwheel

Dimensions............1³⁄16" x 1³⁄16" (25mm x 25mm)

Model G0647

Maximum Round Bar Diameter...... 1⁹⁄16" (40mm)

Maximum Square Bar

Shearing Support Frame

Dimensions.............. 1³⁄8" x 1³⁄8" (35mm x 35mm)

Figure 35. Bar stock support frame openings

aligned with die openings.

To shear bar stock:

5. Feed the workpiece through the appropriate

opening (see Figures 36–37).

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 three lock knobs of the shearing

support frame (see Figure 34).

Support Frame Lock Knobs

Figure 36. Example of round bar shearing setup.

Figure 34. Front support frame lock knobs.

Figure 37. Example of square bar shearing

setup.

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6. Set the controls for Notch and Normal, then

use the pedal actuator to perform the shear-

ing operation.

Angle Iron Shearing

Use the angle iron shearing station to make 45°–

90° cuts in mild steel angle iron.

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.

Stay within the following bar stock shearing

capacities for your machine:

Model G0646

90° Cut:

The workpiece MUST extend through the

support frame and beyond the dies to

avoid sudden unexpected movement of the

workpiece when cutting (refer to the illustra-

tion in Figure 31 on Page 28). Fully support

and flag long workpieces to reduce the risk

of hazards.

Maximum Width......................... 4" (100mm)

Maximum Thickness................... ³⁄8" (10mm)

45° Cut:

Maximum Width........................ 2³⁄4" (70mm)

Maximum Thickness..................... ¹⁄4" (6mm)

Model G0647

90° Cut:

Maximum Width...................... 4³⁄4" (120mm)

Maximum Thickness................... ¹⁄2" (12mm)

45° Cut:

Extension Bar

Maximum Width........................ 3¹⁄8" (80mm)

Maximum Thickness.................... ⁵⁄16" (8mm)

The included extension bar assembly mounts on

the rear of the machine above the bar stock exit

panel (see Figure 38), and provides a method of

repetitive measure production bar stock cutting.

The guide bar and extension bar pivot and adjust

to accommodate various lengths of bar stock. The

support shaft receives the end of the bar stack as

it is fed through the front and beyond the rear exit

panel.

Making a 90° Cut

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.

Extension Bar

Figure 38. Example of bar stock setup with the

extension bar.

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3. Loosen the three lock knobs of the shearing

support frame (see Figure 39).

6. Tighten the hold-down screw close enough

to the workpiece so that it will not move up

during the shearing operation.

Support Frame Lock Knobs

7. Set the controls to Notch and Normal, then

use the foot actuator to perform the shearing

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.

Making a Less Than 90° Cut

Follow the same steps for making a 90° cut in

angle iron except position the workpiece at an

angle to the dies. To accomplish this, insert the

workpiece and move the support frame until the

workpiece reaches the desired angle, as shown in

Figure 41, then tighten the hold-down screw.

Figure 39. Front support frame lock knobs.

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.

Upper

Angle

Opening

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).

Lower

Angle

Opening

Hold-Down

Screws

Figure 41. Example of angle iron setup to make

Handwheel

an inner 45° cut.

Note: To make an inner angled cut, use the bot-

tom angle opening (see Figure 41). Conversely,

to make an outer angled cut, use the upper angle

opening.

Figure 40. Example of angle iron shearing setup

to make a 90° cut.

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adjusting stroke length

Adjusting Stroke

Length

NOTICE

Damage to the machine, tooling, or stock

that is a result of incorrect settings made

to the limit stops will not be covered under

warranty. DO NOT change the factory set-

tings of the limit rings.

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.

C. Limit Bar: Moves with the beam and enables

the limit stops to engage the limit switches.

D. Limit Stop Set Screw: When loosened,

Keep in mind that most tooling requires that the die

or punch passes entirely through the workpiece.

allows the limit stop to be re-positioned.

E. Limit Stop: Engages the limit switch as the

Turn the machine off, then use a 10mm wrench to

remove the hex bolts and the access panel to the

limit stop assembly. Become familiar with the dif-

ferent parts of the assembly, as shown in Figure

42, and their descriptions listed below.

limit bar moves with the beam.

F. Punch Limit Switch: When engaged by the

left limit stop, reverses the beam movement

and lifts the punch up and away from the

punching station (in Punch mode), or stops

the beam (in Notch mode).

G. Notch Limit Switch: When activated by the

right limit stop, reverses the beam movement

and lifts the top die up and away from the

notching station (in Notch mode), or stops

the beam (in Punch mode).

H. Limit Bar Support Bracket: Provides sup-

port for the limit bar as it moves from side to

side.

Tools Needed

Qty

Hex Wrench 4mm.............................................. 1

Figure 42. Limit stop assembly.

Wrench 10mm................................................... 1

To adjust the stroke length:

A. Beam Attachment: Moves the limit bar and

limit stops from side-to-side with the move-

ment of the beam.

1. Turn the motor OFF, and press the emer-

gency stop button to prevent unexpected

movement of the beam.

B. Limit Ring: Stops the limit stop from moving

past the maximum outbound setting. The limit

ring is set at the factory and should not be

moved.

2. Remove the limit stop assembly access panel

from the front of the machine.

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beam lubrication

3. Loosen the limit stop set screw, move the

limit stop along the limit bar, then re-tighten

the set screw.

Beam Lubrication

To keep the beam movement smooth, use the

one-shot beam oiler (see Figure 43) before

beginning operation and at least once every 4-

hours of operation.

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

direction, reset the emergency stop button,

then turn the machine ON.

Fill Cap

5. Keep clear of the machine and use the pedal

actuator to test the adjustment.

Note: Be ready to immediately lift your foot

from the pedal actuator to stop the beam in

the case of a problem.

Handle

6. When you are satisfied with the adjustment

and results, re-install the limit stop assembly

access panel.

Figure 43. One-shot beam oiler on the rear

panel.

Merely pull the handle of the oiler out, then let it

go. The oiler will force the lubricant through the oil

lines to points between the beam and the front/

rear panels that are subject to friction.

Tooling and workpiece

could break apart under

pressure, sending metal

debris toward the opera-

tor at a high rate of speed.

Always keep all safety

guards and access panels

in the correct position and

secured when perform-

ing cutting operations

to reduce the risk of this

hazard.

Fill the oiler with one of the lubricants from Figure

44 or an equivalent.

Brand

B. P.

Type

Energol GHL 220

Magna CF 220

Febis K220

Vactra Oil #4

Tomma T220

Drosera 150

Castrol

Esso

Mobil

Shell

Total

Figure 44. Recommended beam one-shot oiler

lubricants.

-34-

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accessories

SECTION 5: ACCESSORIES

G5562—SLIPIT^®1 Qt. Gel

G5330—Cobra™ Fluid Dispensing System

Step into the future of hands-free lubrication with

the Cobra™ Fluid Dispensing System. This fully

adjustable, foot controlled system holds a pint of

lubricating fluid and requires no compressed air or

electricity. Perfect for milling, drilling, tapping, or

cutting, this portable system features a 7-foot sup-

ply line, flexible magnetic base needle dispenser,

and five replaceable nozzle tips.

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. Recommended products for protect-

ing unpainted cast iron/steel part on machinery.

Figure 47. Cobra™ Fluid Dispensing System.

H7379—Tapmatic^®#1 Gold 16 oz.

T20501—Face Shield, 4" Crown, Clear

T20502—Face Shield, 7" Crown, Clear

T20448—Economy Clear Safety Glasses

T20452—"Kirova" Anti-Reflective Glasses

T20456—"Dakura" Clear Safety Glasses

H0736—Shop Fox^®Safety Glasses

These glasses meet ANSI Z87.1-2003 specifica-

tions. Buy extras for visitors or employees. You

can't be too careful with shop safety!

H7380—Tapmatic^®#1 Gold 1 Gal.

This superb cutting fluid is great for both steel and

aluminum, is excellent for low speed, high pres-

sure applications, minimizes torque increases,

does not contain chlorinated paraffins, water, sol-

vents or inactive fillers.

T20448

T20452

T20501

Figure 48. Tapmatic^®#1 Gold cutting fluid.

T20456

H0736

Figure 46. Our most popular eye protection.

-35-

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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” Round Die

T20586—25/32” Round Die

T20587—29/32” Round Die

T20588—1-1/32” Round Die

T20589—8mm Round Punch

T20590—10mm Round Punch

T20591—12mm Round Punch

T20592—15mm Round Punch

T20593—19mm Round Punch

T20594—22mm Round Punch

T20595—26mm Round Punch

T20596—8.8mm Round Die

T20597—10.8mm Round Die

T20598—12.8mm Round Die

T20599—15.8mm Round Die

T20600—19.8mm Round Die

T20601—22.8mm Round Die

T20634—26.8mm Square Die

T20602—26.8mm Round Die

T20603—5/16” Square Punch

T20604—3/8” Square Punch

T20605—7/16” Square Punch

T20606—1/2” Square Punch

T20607—5/8” Square Punch

T20608—23/32” Square Punch

T20609—3/4” Square Punch

T20610—7/8” Square Punch

T20611—1” Square Punch

T20612—11/32” Square Die

T20613—13/32” Square Die

T20614—15/32” Square Die

T20615—17/32” Square Die

T20616—21/32” Square Die

T20617—3/4” Square Die

T20618—25/32” Square Die

T20619—29/32” Square Die

T20620—1-1/32” Square Die

T20621—8mm Square Punch

T20622—10mm Square Punch

T20623—12mm Square Punch

T20624—15mm Square Punch

T20625—19mm Square Punch

T20626—22mm Square Punch

T20627—26mm Square Punch

T20628—8.8mm Square Die

T20629—10.8mm Square Die

T20630—12.8mm Square Die

T20631—15.8mm Square Die

T20632—19.8mm Square Die

T20633—22.8mm Square Die

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SECTION 6: MAINTENANCE

Cleaning &

Protecting

Always disconnect power

to the machine before

performing maintenance.

Failure to do this may

result in serious person-

al injury.

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.

Schedule

When thoroughly clean and dry, protect the

unpainted metal surfaces with an application of

products like G96^®Gun Treatment, SLIPIT^®, or

Boeshield^®T-9 (see Section 5: Accessories on

Page 35 for more details).

For optimum performance from your machine,

follow this maintenance schedule and refer to any

specific instructions given in this section.

At least once a month, open the bottom access

panels and clean off debris and grime from the

motor, pump, ram assembly, reservoir, and limit

stop assemblies.

Daily Check:

•

Loose mounting bolts.

Damaged tooling.

Worn or damaged wires.

Operating temperature of hydraulic fluid.

Any other unsafe condition.

Daily Maintenance:

•

Check/fill hydraulic reservoir level.

Check/fill lubricant in beam one-shot oiler.

Clean and protect all unpainted surfaces and

tooling.

Monthly Maintenance:

•

Lubricate as necessary (refer to Lubrication

on Page 38).

•

Clean built-up grime and debris from inside

cabinet and off motor.

Quarterly Maintenance:

Check/adjust beam alignment.

•

Annual Maintenance:

Drain, clean, and re-fill hydraulic system.

•

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Shearing Hold-Down Adjustment

Rod

1. DISCONNECT MACHINE FROM POWER!

Lubrication

There are four points on the ironworker that

require at least monthly lubrication: 1) The beam

pivot shaft, 2) the shearing hold-down adjustment

rod, 3) the angle iron hold-down screws, and 4)

the shearing support frame leadscrew and bev-

eled gears.

2. Remove the two lock knobs and the shearing

hold-down from the machine.

3. Turn the hold-down over and unscrew the

adjustment rod from the hold-down, then

thoroughly clean the threads of the rod and

the nut (see Figure 50).

Before lubrication, wipe debris and built-up grime

from all threaded parts and gearing. 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.

Adjustment Rod

Beam Pivot Shaft

Use a grease gun to add 1–2 pumps of multi-pur-

pose automotive-grade grease to the beam pivot

shaft grease fitting on the rear of the machine

(see Figure 49).

Shearing Hold-Down

Figure 50. Back side of shearing hold-down and

adjustment rod.

4. Brush a light coat of multi-purpose automo-

tive-grade grease onto the threads and the

contact points with the shearing hold-down,

then re-install the adjustment rod and hold-

down.

Grease Fitting

Figure 49. Beam pivot shaft grease fitting on the

rear panel.

NOTICE

Failure to perform proper lubrication main-

tenance on this machine will lead to prema-

ture wear of the moving parts and will void

the warranty.

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5. Thoroughly clean the threads of the

leadscrew, beveled gears, and leadscrew nut

(see Figures 51–52).

Support Frame Lubrication

1. DISCONNECT MACHINE FROM POWER!

2. Remove the three lock knobs and shearing

Leadscrew Nut

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).

Hold-Down Screws

Figure 52. Shearing support frame leadscrew

nut.

Leadscrew and

Beveled Gears

6. Brush a light coat of multi-purpose auto-

motive-grade grease onto the threads and

gears, then re-install the support frame on

the machine.

Figure 51. Back side of shearing support frame.

4. Brush a light coat of multi-purpose automo-

tive-grade grease onto the threads, then re-

install the hold-down screws.

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hydraulic system

The operating temperature of the hydraulic fluid

should not exceed 160°F (70°C) with an optimum

operating temperature window of 50–95°F (10–

35°C). If the fluid temperature rises above 160°F,

stop the machine immediately and allow the fluid

to cool down.

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 this condition continues during operation, stop

using the machine immediately, then review

Troubleshooting on Page 43. If you still cannot

remedy the problem, contact a qualified hyraulic

service technician or our Tech Support at (570)

546-9663 for assistance.

If you have never maintained a hydraulic system

before, WE STRONGLY RECOMMEND that you

read books, get formal training, or seek the help of

a qualified hydraulic service technician.

Filling Hydraulic Reservoir

Tools Needed

Qty

Wrench 10mm................................................... 1

1. DISCONNECT MACHINE FROM POWER!

2. Remove the rear access panel.

NOTICE

Failure to perform regular and proper

hydraulic system maintenance and to keep

the hydraulic system in good operating

condition will lead to premature wear of the

moving parts, hoses, and valves, and will

void the warranty.

3. Remove the filler cap and add one of the rec-

ommended hydraulic fluids from Figure 54

or an equivalent to bring the fluid level in the

sight glass above the red line.

Use the sight glass mounted on the rear of the

hydraulic reservoir (see Figure 53) to check the

fluid level and temperature. Maintain the fluid level

above the red line on the sight glass.

Brand

B.P.

Type

Energol HLP 32

Hyspin AWS 82-6018

Nuto H32

Castrol

Esso

Mobil

Shell

Total

DTE 24

Tellus 32

Azolla ZS 32

Figure 54. Recommended hydraulic fluids.

BIOLOGICAL AND

POISON HAZARD!

Use proper personal pro-

tection equipment when

handling hydraulic fluid,

and follow federal, state,

and fluid manufacturer

requirements to proper-

ly dispose of hydraulic

fluid.

Figure 53. Hydraulic fluid reservoir sight glass

(rear access panel removed for photo clarity).

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4. Remove the drip pan and reservoir access

plate from the top of the reservoir (see Figure

56).

Draining & Re-Filling Hydraulic

Reservoir

Tools Needed

Qty

Wrench 10mm................................................... 1

Large Adjustable Wrench.................................. 1

Oil Catch Pan .................................................... 1

Drip Pan

To drain and re-fill the hydraulic reservoir:

1. DISCONNECT MACHINE FROM POWER!

2. Remove the rear access panel.

3. Unscrew the filler cap, and take out the filter

from the filler neck (see Figure 55).

Access Plate

Filler

Neck Filter

Figure 56. Top of hydraulic reservoir.

5. Position an oil catch pan under the outlet con-

nection (see Figure 57) of the reservoir, and

carefully remove the outlet hose to drain the

contents of the reservoir.

Outlet Hose Connection

Filler

Cap

Figure 55. Hydraulic reservoir filler components.

HYDRAULIC INJECTION

HAZARD.

Hydraulic oil leaks can

be under sufficient pres-

sure to penetrate your

skin and enter your

bloodstream. If oil is

injected into any part of

your body, it is a medical

emergency and may, if

not treated immediately,

result in severe infection,

permanent disability, or

even death.

Figure 57. Hydraulic reservoir outlet hose

connection.

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beam alignment

6. Reach through the opening in the top of the

reservoir left by the access plate and remove

the outlet filter from the reservoir.

The tooling randomly being in and out of align-

ment is a strong indicator that the beam may need

alignment.

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 parts, inside the reser-

voir, and the surrounding area.

Tools Needed

Qty

Hex Wrench 8mm.............................................. 1

Hex Wrench 12mm............................................ 1

Adjustable Wrench ............................................ 1

To align the beam:

1. DISCONNECT MACHINE FROM POWER!

NOTICE

If fluid contamination is severe or there has

been a component failure, have a qualified

hydraulic technician thoroughly flush the

system. Failure to follow this instruction

could lead to premature wear of the hydrau-

lic system and will void the warranty.

2. Remove the shearing hold-down, shearing

support frame, and shearing table from the

machine.

3. Identify the four beam adjustment lock nuts

and set screws on the front of the machine,

as shown in Figure 58.

8. When all parts are clean and dry, re-assem-

ble them and fill the reservoir with one of the

recommended hydraulic fluids from Figure

54 or an equivalent.

Lock Nuts & Set Screws

9. With the front and rear access panels removed

from the machine, re-connect the machine to

power and turn it ON.

10. Carefully check all hoses and connections

for leaks, then stand clear of the machine

and move the beam back and forth to verify

proper operation of the hydraulic system.

Note: Use a clean piece of cardboard to

check for leaks—NOT your hands.

Figure 58. Beam adjustment lock nuts and set

screws.

11. Turn the machine OFF, then re-install the

front and rear access panels.

4. Back off the lock nut, then loosen the set

screw (see the inset of Figure 58).

5. With very light pressure, re-tighten the set

Beam Alignment

screw until you feel a slight drag.

6. While holding the set screw in place, re-

As the beam slides back and forth between the

front and rear panels, four bronze pressure pads

keep the beam and the attached tooling prop-

erly aligned for safe and smooth operation. These

pressure pads wear under normal conditions and

require adjustment.

tighten the lock nut.

7. Repeat Steps 5–6 for the rest of the beam

adjustment lock nuts and set screws.

8. Re-install the shearing table, shearing sup-

port frame, and shearing hold-down.

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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.

Troubleshooting

Motor & Electrical

Symptom

Possible Cause

Possible Solution

Machine does not 1. Main Power switch turned off.

1. Rotate Main Power switch to ON or 1.

start or a breaker

trips.

2. Emergency Stop push-button is engaged/ 2. Rotate clockwise slightly until it pops out/replace it.

faulty.

3. Plug/receptacle is at fault or wired incor- 3. Test for good contacts; correct the wiring.

rectly.

4. Motor connection wired incorrectly.

4. Correct motor wiring connections (Page 56).

5. Ensure circuit size is suitable for this machine;

replace weak breaker.

5. Wall fuse/circuit breaker is blown/tripped.

6. Thermal overload relay has tripped.

6. Turn cut-out dial to increase working amps and push

the reset pin. Replace if tripped multiple times (weak

relay).

7. Contactor not getting energized/has burnt 7. Test for power on all legs and contactor operation.

contacts.

Replace unit if faulty.

8. Power supply switched OFF or is at fault.

8. Ensure power supply is switched on; ensure power

supply has the correct voltage.

9. Wiring is open/has high resistance.

9. Check for broken wires or disconnected/corroded

connections, and repair/replace as necessary.

10. Motor Start button or Main Power switch is 10. Replace faulty Start button or Main Power switch.

at fault.

11. Motor is at fault.

11. Test/repair/replace.

Machine stalls or is 1. Wrong workpiece material.

overloaded.

1. Use only metal with a hardness of 45 kg/mm²or less

and is within capacities of machine.

2. Motor connection is wired incorrectly.

2. Correct motor wiring connections (Page 56).

3. Test for good contacts; correct the wiring.

4. Test by rotating shaft; rotational grinding/loose shaft

requires bearing replacement.

3. Plug/receptacle is at fault.

4. Motor bearings are at fault.

5. Machine is undersized for the task.

6. Motor has overheated.

5. Use sharp tooling; keep workpiece within the capaci-

ties of machine; use cutting lubricant.

6. Clean off motor, let cool, and reduce workload.

7. Contactor not getting energized or has poor 7. Test for power on all legs and contactor operation.

contacts.

Replace if faulty.

8. Motor is at fault.

8. Test/repair/replace.

9. Hydraulic fluid low in reservoir.

9. Fill hydraulic reservoir (Page 40).

10. Hydraulic fluid pressure too low; hydraulic 10. Test/adjust for correct hydraulic fluid pressure (Page

pump at fault. 50), replace pump if necessary.

11. Hydraulic system has leaks or valves at 11. Check/repair/replace hydraulic hoses, connections,

fault.

and valves.

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Motor & Electrical

Symptom

Possible Cause

Possible Solution

Machine has vibra- 1. Motor wired out of phase.

tion or noisy opera-

1. Swap any to incoming power wires at the motor

(Page 56).

tion.

2. Motor or component is loose.

2. Inspect/replace stripped or damaged bolts/nuts, and

re-tighten with thread locking fluid.

3. Tighten/replace.

3. Motor mount loose/broken.

4. Machine is incorrectly mounted or sits 4. Tighten/replace anchor studs in floor; relocate/shim

unevenly.

machine.

5. Motor fan is rubbing on fan cover.

5. Replace dented fan cover; replace loose/damaged

fan.

6. Motor bearings are at fault.

6. Test by rotating shaft; rotational grinding/loose shaft

requires bearing replacement.

Operations

Symptom

Possible Cause

Possible Solution

Cuts are excessively 1. Tooling damaged or dull.

1. Check/sharpen/replace tooling.

2. Use the appropriate ironworker station for your

operation

ragged or not accu-

rate.

2. Not using proper station.

3. Tooling not installed properly.

3. Check/repair tooling installation and clearances.

4. Cutting stroke not continuous through the 4. Keep the Normal/Inch switch in Normal position and

workpiece.

pressure on pedal actuator until workpiece is cut

completely through.

5. Workpiece moves away from tooling during 5. Use hold-downs, table guides, and other devices to

operation. ensure workpiece is secure before cutting.

Tooling not cutting 1. Workpiece dimensions not within capacity 1. Make sure workpiece dimensions are within machine/

completely through

workpiece.

of machine.

station capacity; use cutting lubricant.

2. Check/sharpen/replace tooling.

2. Tooling is damaged or dull.

3. Hydraulic pump at fault.

3. Test/adjust correct hydraulic fluid pressure (Page

50); replace pump if necessary.

4. Hydraulic system has leaks or valves at 4. Check/repair/replace hydraulic hoses, connections,

fault.

and valves.

Loud unusual noise 1. Limit stops not properly set.

when beam revers-

es direction.

1. Set limit rings and stops to factory settings (Page

50).

Hydraulic fluid tem- 1. Machine cutting at/beyond capacity.

1. Turn machine OFF and allow hydraulic fluid to cool;

make cuts only with the capacity of your machine.

2. Reduce hyrdaulic fluid relief pressure to 3000 PSI

(Page 50).

perature

at/over

160°F (70°C).

2. Hydraulic fluid pressure set to high.

3. Incorrect hydraulic fluid type.

4. Hydraulic system at fault.

3. Use only one of recommended hydraulic fluids from

Figure 54 on Page 40.

4. Have a qualified hydraulic service technician ser-

vice/repair the hydraulic system.

-44-

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shearing blades

installing flat blades

4. Use the foot actuator to pivot the beam to

the right so that the flat head cap screws of

the top die are accessible, then release the

pedal actuator to hold it in that position (see

Figures 59–60).

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.

Top Die Cap Screws

Note: The cutting edges of the dies must remain

flat and parallel in relation to one another. DO

NOT grind the top or bottom of either die.

Tools Needed

Qty

Hex Wrench 5mm.............................................. 1

Hex Wrench 8mm.............................................. 1

Wrench 19mm................................................... 1

Feeler Gauge 0.004" (0.1mm)........................... 1

Adjustment Set Screw

Figure 59. Flat stock shearing dies (front view).

To remove and replace the flat stock shearing

dies:

1. Turn the motor OFF, and press the emergen-

cy stop button to avoid unexpected tooling

movement.

2. Remove the shearing hold-down, shearing

support frame, and shearing table.

3. Set the controls to Notch and Inch, reset

the emergency stop button, then turn the

machine ON.

Bottom Die Cap Screws

Figure 60. Flat stock shearing dies (rear view).

5. DISCONNECT MACHINE FROM POWER!

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.

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6. Have an assistant hold the dies as you remove

the flat head cap screws, then remove both

dies from the machine.

18. When you are satisfied with the clearance

adjustment, fully tighten the bottom die cap

screws, and re-check the clearances.

Note: To aid in re-installation, record the ori-

entation of each die as your remove it.

19. Re-install the shearing table and check its

alignment with the bottom die (Page 49).

7. Thoroughly clean the dies and mounting area

with a solvent or mineral spirits to remove

debris, mill flash, and built-up grime.

20. Re-install the shearing support frame and

shearing hold-down.

Note: If you will be storing the dies, protect

them with a light coat of an anti-rust prod-

uct like G96® Gun Treatment, SLIPIT®, or

Boeshield® T-9 (see Section 5: Accessories

on Page 35 for more details).

Angle Iron Shearing

Dies

Each of the dies at the angle iron shearing station

have four different mounting positions to use a

different set of cutting edges.

8. Make sure the beam is in proper alignment

with the panels (Page 42).

9. Back the bottom die adjustment screws (see

Figure 59) out until they no longer protrude

from the inside face of the front panel.

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.

10. Wipe a light coat of lubricant on all surfaces

of the dies (refer to Figure 18 on Page 22).

To re-install the angle iron shearing dies, use the

same tools, clearance specification, and proce-

dures used in re-installing the flat stock shearing

dies (refer to Page 45).

11. Install the bottom die and fully tighten the flat

head cap screws to secure the die tight to the

front panel.

12. Install the top die and fully tighten the cap

Tools Needed

Hex Wrench 8mm.............................................. 1

Qty

screws to secure it in place.

Hex Wrench 10mm............................................ 1

13. Reconnect the machine to power, and turn it

ON.

To remove the angle iron shearing dies:

14. Set the controls to Notch and Inch, bring the

1. Turn the motor OFF, and press the emergen-

cy stop button to avoid unexpected tooling

movement.

top die down and behind the bottom die.

15. Turn the motor OFF, and press the emer-

gency stop button to avoid unexpected move-

ment of the tooling.

2. Remove the shearing hold-down, shearing

support frame, and shearing table.

16. Loosen the bottom die cap screws 2–3

3. Set the controls to Notch and Inch, reset

the emergency stop button, then turn the

machine ON.

turns.

17. Use the feeler gauge and adjust the bottom

die set screws until the clearance between

the top and bottom dies is 0.004" (0.1mm)

along their full length.

-46-

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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.

Bar Stock Shearing

Dies

The orientation, position, and tolerances of the

bar stock shearing dies do not allow for flipping

them to use another cutting edge—neither can

they be ground or sharpened. When they become

damaged or dull, call Grizzly Tech Support at

(570) 546-9663 to order new ones.

Top Dies

Tools Needed

Qty

Hex Wrench 8mm.............................................. 1

Hex Wrench 10mm............................................ 1

Wrench 19mm................................................... 1

Adjustment Set Screws

To remove and replace the bar stock shearing

dies:

Figure 61. Angle iron shearing station dies (front

view)

1. Turn the motor OFF, and press the emergen-

cy stop button to avoid unexpected tooling

movement.

5. DISCONNECT MACHINE FROM POWER!

6. Have an assistant hold the dies as you

remove the cap screws, then remove all of

the dies from the machine.

2. Remove the shearing hold-down, shearing

support frame, and shearing table.

3. Set the controls to Notch and Inch, reset

the emergency stop button, then turn the

machine ON.

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, mill flash, and built-up grime.

4. Use the foot actuator to pivot the beam so

that the cutting holes of the dies line up, then

release the pedal actuator to hold it in that

position (see Figure 62).

Note: If you will be storing the dies, protect

them with a light coat of an anti-rust prod-

uct like G96® Gun Treatment, SLIPIT®, or

Boeshield® T-9 (see Section 5: Accessories

on Page 35 for more details).

Outer

Die

Bracket

Adjustment Lock Nut and Set Screw

Figure 62. Angle iron shearing station die

assembly.

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5. DISCONNECT MACHINE FROM POWER!

8. Wipe a light coat of lubricant on all surfaces

of the dies (refer to Figure 18 on Page 22).

6. Remove the two outer die brackets, then both

dies.

9. Insert the inner die so that the cutout on the

edge fits over the cap screw in the beam (see

Figure 63).

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 dies as your

remove them.

10. Insert the outer die, taking care to properly

orient the cutting holes with the inner die.

11. Loosen the adjustment lock nuts on the outer

die brackets (see Figure 62), then back out

the set screws 2–3 turns.

12. Secure the outer die brackets to the machine

so that the dies are held in place.

13. Thread all set screws in until they are snug

against the outer die, then back each one out

Cutout and

⁄4

of a turn.

Inner Die

Cap Screw

14. Re-tighten the adjustment lock nuts, making

sure the set screws stay in position.

15. Re-install the shearing support frame and

shearing hold-down.

Figure 63. Bar stock inner shearing die

orientation.

7. Thoroughly clean the dies and mounting area

with a solvent or mineral spirits to remove

debris, mill flash, and built-up grime.

The force of this ironwork-

er can quickly smash or

remove fingers or hands.

Always keep clear of all

cutting stations before

using the foot pedal actu-

ator to begin the opera-

tion.

Note: If you will be storing the dies, protect

them with a light coat of an anti-rust prod-

uct like G96® Gun Treatment, SLIPIT®, or

Boeshield® T-9 (see Section 5: Accessories

on Page 35 for more details).

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shearing table alignment

3. Loosen the shearing table mounting cap

Shearing Table

screws 1–2 turns.

Alignment

4. Reach under the table and loosen the adjust-

ment lock nuts (see Figure 65).

The shearing table must be level along the entire

length with the bottom flat stock shearing die for

accurate cuts.

Tools Needed

Qty

Straightedge ...................................................... 1

Hex Wrench 8mm.............................................. 1

Adjustable Wrench ............................................ 1

Adjustment

Hex Bolt

To adjust the shearing table to the bottom flat

stock shearing die:

Lock

Nut

1. DISCONNECT MACHINE FROM POWER!

2. Place a straightedge across the shearing

table and the top of the bottom die in multiple

locations (see Figure 64).

Figure 65. Shearing table adjustment lock nuts

and hex bolts.

5. Rotate the adjustment hex bolts to make

the table level with the top of the bottom die

along its entire length.

6. When you are satisfied with the adjustments,

re-tighten the lock nuts and the table mount-

ing cap screws.

Figure 64. Straightedge on shearing table and

die.

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limit rings

hydraulic fluid pressure

6. After successful tests in each direction, move

the limit stops just slightly further apart, and

repeat Step 5 until the tests are no longer

successful.

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.

7. Move the limit stops to the last successful

positions—this is the safe outside setting for

the limit stops.

8. Fully secure the limit stops, move the limit

rings up to the stops, then secure the limit

rings in place.

However, if the machine makes a noticeable unex-

pected noise just before the beam reverses direc-

tion, the limit rings and stops may be positioned

beyond the maximum safe position and will need

to be reset. This process is one of trial-and-error

and will require time and patience to successfully

complete.

9. Re-install the limit stop access panel before

beginning operations.

Hydraulic Fluid

Pressure

Tools Needed

Hex Wrench 4mm.............................................. 1

Wrench 10mm................................................... 1

Qty

To reset the position of the limit rings:

If the hydraulic fluid reaches beyond 3000 PSI, the

pressure relief valve protects the hydraulic system

by redirecting the fluid from the cylinder back into

the reservoir. Generally the only time this should

occur is when attempting a cutting operation that

is beyond the capacity of your machine.

1. Press the emergency stop button in to pre-

vent unexpected movement of the beam.

2. Remove the limit stop assembly access panel

from the front of the machine.

The pressure relief valve is calibrated at the fac-

tory and should not require change. However, if

necessary, contact a qualified hydraulic service

technician to load test the hydraulic system and

re-calibrate the pressure relief valve (see Figure

66).

3. Loosen the set screws on the limit rings, then

move and secure them all the way to the

outer edges of the limit bar.

4. Center the limit stops on the limit bar and

separate them approximately 2", then secure

them in place.

5. Set the controls to Normal, stand clear of the

machine, reset the emergency stop button,

then use the pedal actuator to test the limit

stop settings in both directions (Punch and

Notch).

Needle

Valve

—If there are no unexpected noises or prob-

lems as the beam moves through the

stroke and stops, then the setting is opera-

tional. Continue to Step 6.

Pressure

Relief

Valve

—If there is an unexpected noise as the

beam reverses direction, the position of the

limit stop is not correct. Move the limit stop

slightly toward the center, then repeat this

step.

Figure 66. Hydraulic pressure relief and needle

valves.

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Electrical Panel Wiring

Voltage

Transformer

Main

Power

Switch

Fuses

Contactor

Overload

Relay

Figure 67. Electrical panel wiring (see Wiring Diagram on Page 53)

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Control Panel Wiring

Emergency

Stop

Button

Power

Lamp

Motor

Stop

Button

Motor

Start

Button

Normal/Inch

Switch

Punch/Notch

Switch

Figure 68. Control panel wiring (see Wiring Diagram on Page 54)

G0646/G0647 50/65 Ton Ironworker

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electrical wiring diagram

Electrical Panel Wiring Diagram

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(See Wiring Diagrams &

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control panel wiring diagram

Control Panel Wiring Diagram

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on Page 53)

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components wiring diagram

Electrical Components Wiring Diagram

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Figure 69. Limit switch wiring.

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Figure 70. Hydraulic valve

solenoid wiring.

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Figure 71. Side emergency

stop button.

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To Electrical Panel

(see Wiring Diagram

on Page 53)

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Figure 72. Foot pedal wiring.

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motor wiring diagram

Motor Wiring Diagram

��

To Electrical Panel

(see Wiring Diagram

on Page 53)

Figure 73. 220V motor wiring.

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Hydraulic System Overview

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SECTION 8: PARTS

Upper Front-Half

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G0646 Upper Front-Half Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

P0646011

P0646012

PSB61M

P0646014

P0646015

P0646018

PN44M

PIVOT SHAFT

PW06M

FLAT WASHER 12MM

HEX NUT M12-1.75

LOCK PLATE

PN09M

CAP SCREW M10-1.5 X 20

PIVOT SHAFT BUSHING

HEX BOLT M20-2.5 X 140

SET SCREW M24-3 X 50

HEX NUT M24-3

P0646070

PFH61M

P0646072

PFH62M

P0646074

PFH63M

P0646079

P0646081

PW01

PUNCH TABLE

FLAT HD CAP SCR M12-1.75 X 35

PUNCH TABLE EXTENSION

FLAT HD CAP SCR M12-1.75 X 20

SHEAR TABLE

P0646021

PN44M

HEX BOLT M24-3 X 65

HEX NUT M24-3

FLAT HD CAP SCR M12-1.75 X 25

TABLE GUIDE

P0646023

PW03M

LEAD SCREW NUT

LOCK HANDLE 1/2-13

FLAT WASHER 1/2

FLAT WASHER 6MM

PSB07M

P0646026

P0646027

P0646028

P0646029

P0646030

PW08M

CAP SCREW M6-1 X 30

HOLD-DOWN UPPER

SECTION FRAME

PCB32M

P0646090

PSB54M

PLW10M

P0646093

PB04M

CARRIAGE BOLT 1/2-13 X 1-3/4

MOUNTING BLOCK

CAP SCREW M16-2 X 40

LOCK WASHER 16MM

PUNCH SIDE GUARD

HEX BOLT M6-1 X 10

FLAT WASHER 6MM

PUNCH GUARD PLEXIGLASS

FLAT WASHER 6MM

HEX BOLT M6-1 X 10

PUNCH TABLE CONNECTING PLATE

FLAT WASHER 12MM

HEX NUT M12-1.75

HOLD-DOWN LOWER

HANDWHEEL

STAR KNOB M16-2 X 30

FLAT WASHER 16MM

CAP SCREW M12-1.75 X 25

FLAT WASHER 12MM

SUPPORT PLATE

PW03M

PSB36M

PW06M

P0646096

PW03M

P0646034

PSB61M

PW04M

PB04M

CAP SCREW M10-1.5 X 20

FLAT WASHER 10MM

ANGLE HOLD-DOWN BOLT LONG

ANGLE HOLD-DOWN BOLT SHORT

KNURLED LOCK RING

UPPER HOLD-DOWN LEAD SCREW

BEVEL GEAR LARGE

BEVEL GEAR SMALL

SPECIAL HEX NUT

P0646099

PW06M

100

101

131

132

133

150

151

152

154

155

157

158

159

160

161

162

163

164

165

166

167

P0646037

P0646038

P0646039

P0646040

P0646041

PN09M

P0646131

PLW10M

PSB166M

P0646150

PSB167M

PW03M

NOTCH STRIPPER PLATE

LOCK WASHER 16MM

CAP SCREW M16-2 X 30

MOUNTING PLATE

41-1 P0646041-1

CAP SCREW M6-1 X 70

FLAT WASHER 6MM

FLAT WASHER 4MM

PHLP HD SCR M4-.7 X 30

HEX NUT M4-.7

P0646042

PSS01M

PB47M

SET SCREW M6-1 X 10

HEX BOLT M6-1 X 40

BUSHING

PW05M

PS51M

P0646045

P0646046

P0646047

PLW05M

PSB77M

PN09M

PN04M

LOWER HOLD-DOWN ADJUST ROD

SECTION BLADE CLAMP

LOCK WASHER 12MM

CAP SCREW M12-1.75 X 30

HEX NUT M12-1.75

P0646158

P0646159

P0646160

PSB60M

P0646162

PSS16M

P0646164

PW06M

SPACER 6MM

SPACER 8MM

LIMIT STOP BRACKET

CAP SCREW M8-1.25 X 55

LIMIT STOP ASSEMBLY

SET SCREW M8-1.25 X 10

HEX BOLT M12-1.75 X 150

FLAT WASHER 12MM

LOCK COLLAR

PSS104M

PSB111M

PSS10M

PLW05M

SET SCREW M12-1.75 X 45

CAP SCREW M12-1.75 X 35

SET SCREW M10-1.5 X 20

LOCK WASHER 12MM

P0646166

PN09M

HEX NUT M12-1.75

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G0647 Upper Front-Half Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

P0647011

P0647012

PSB61M

P0647014

P0646015

P0646018

PN44M

PIVOT SHAFT

PW06M

FLAT WASHER 12MM

HEX NUT M12-1.75

LOCK PLATE

PN09M

CAP SCREW M10-1.5 X 20

PIVOT SHAFT BUSHING

HEX BOLT M20-2.5 X 140

SET SCREW M24-3 X 50

HEX NUT M24-3

P0647070

PFH61M

P0647072

PFH62M

P0647074

PFH63M

P0647079

P0647081

PW01

PUNCH TABLE

FLAT HD CAP SCR M12-1.75 X 35

PUNCH TABLE EXTENSION

FLAT HD CAP SCR M12-1.75 X 20

SHEAR TABLE

P0646021

PN44M

HEX BOLT M24-3 X 65

HEX NUT M24-3

FLAT HD CAP SCR M12-1.75 X 25

TABLE GUIDE

P0647023

PW03M

LEAD SCREW NUT

LOCK HANDLE 1/2-13

FLAT WASHER 1/2

FLAT WASHER 6MM

PSB07M

P0647026

P0647027

P0647028

P0647029

P0646030

PW08M

CAP SCREW M6-1 X 30

HOLD-DOWN UPPER

SECTION FRAME

PCB32M

P0647090

PSB54M

PLW10M

P0647093

PB04M

CARRIAGE BOLT 1/2-13 X 1-3/4

MOUNTING BLOCK

CAP SCREW M16-2 X 40

LOCK WASHER 16MM

PUNCH SIDE GUARD

HEX BOLT M6-1 X 10

FLAT WASHER 6MM

PUNCH GUARD PLEXIGLASS

FLAT WASHER 6MM

HEX BOLT M6-1 X 10

PUNCH TABLE CONNECTING PLATE

FLAT WASHER 12MM

HEX NUT M12-1.75

HOLD-DOWN LOWER

HANDWHEEL

STAR KNOB M16-2 X 30

FLAT WASHER 16MM

CAP SCREW M12-1.75 X 25

FLAT WASHER 12MM

SUPPORT PLATE

PW03M

PSB36M

PW06M

P0647096

PW03M

P0647034

PSB61M

PW04M

PB04M

CAP SCREW M10-1.5 X 20

FLAT WASHER 10MM

ANGLE HOLD-DOWN BOLT LONG

ANGLE HOLD-DOWN BOLT SHORT

KNURLED LOCK RING

UPPER HOLD-DOWN LEAD SCREW

BEVEL GEAR LARGE

BEVEL GEAR SMALL

SPECIAL HEX NUT

P0647099

PW06M

100

101

131

132

133

150

151

152

154

155

157

158

159

160

161

162

163

164

165

166

167

P0647037

P0647038

P0647039

P0647040

P0647041

PN09M

P0647131

PLW10M

PSB166M

P0647150

PSB167M

PW03M

NOTCH STRIPPER PLATE

LOCK WASHER 16MM

CAP SCREW M16-2 X 30

MOUNTING PLATE

41-1 P0647041-1

CAP SCREW M6-1 X 70

FLAT WASHER 6MM

FLAT WASHER 4MM

PHLP HD SCR M4-.7 X 30

HEX NUT M4-.7

P0647042

PSS01M

PB47M

SET SCREW M6-1 X 10

HEX BOLT M6-1 X 40

BUSHING

PW05M

PS51M

P0647045

P0647046

P0647047

PLW05M

PSB77M

PN09M

PN04M

LOWER HOLD-DOWN ADJUST ROD

SECTION BLADE CLAMP

LOCK WASHER 12MM

CAP SCREW M12-1.75 X 30

HEX NUT M12-1.75

P0647158

P0647159

P0647160

PSB60M

P0647162

PSS16M

P0646164

PW06M

SPACER 6MM

SPACER 8MM

LIMIT STOP BRACKET

CAP SCREW M8-1.25 X 55

LIMIT STOP ASSEMBLY

SET SCREW M8-1.25 X 10

HEX BOLT M12-1.75 X 150

FLAT WASHER 12MM

LOCK COLLAR

PSS104M

PSB111M

PSS10M

PLW05M

SET SCREW M12-1.75 X 45

CAP SCREW M12-1.75 X 35

SET SCREW M10-1.5 X 20

LOCK WASHER 12MM

P0647166

PN09M

HEX NUT M12-1.75

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Upper Rear-Half

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G0646 Upper Rear-Half Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

P0646001

P0646002

P0646003

P0646004

P0646009

P0646010

PN28M

TOP PANEL FRONT

P0646081

PW01

LOCK HANDLE 1/2-13

FLAT WASHER 1/2

TOP PANEL REAR

HANGER FRAME

PCB32M

P0646084

P0646085

P0646086

P0646087

PB04M

CARRIAGE BOLT 1/2-13 X 1-3/4

SECTION REAR COVER

ANGLE REAR COVER

SHEAR REAR COVER

SHEAR BOTTOM COVER

HEX BOLT M6-1 X 10

FLAT WASHER 6MM

TOP COVER

LIFTING EYE BOLT MOUNT

LIFTING EYE BOLT

HEX NUT M20-2.5

P0646017

P0646020

P0646052

P0646053

PSB92M

PLW05M

P0646058

P0646059

P0646060

P0646061

PFH64M

PFH65M

PLW05M

PN09M

HEX BOLT M20-2.5 X 125

PRESSURE PAD

PW03M

SECTION BLADE ARM

SECTION BLADE BODY

CAP SCREW M12-1.75 X 40

LOCK WASHER 12MM

ANGLE BLADE BODY UPPER

ANGLE BLADE BODY LOWER

ANGLE BLADE ARM LOWER

ANGLE BLADE ARM UPPER

FLAT HD CAP SCR M10-1.5 X 60

FLAT HD CAP SCR M10-1.5 X 55

LOCK WASHER 12MM

HEX NUT M12-1.75

P0646090

PSB54M

PLW10M

P0646131

PLW10M

PSB166M

P0646134

PB04M

MOUNTING BLOCK

CAP SCREW M16-2 X 40

LOCK WASHER 16MM

NOTCH SIDE PLATE

131

132

133

134

135

136

170

171

172

186

187

188

189

LOCK WASHER 16MM

CAP SCREW M16-2 X 30

NOTCH END GUARD

HEX BOLT M6-1 X 10

FLAT WASHER 6MM

PW03M

P0646170

P0646171

P0646172

PSB50M

P0646187

P0646188

P0646189

BUSHING

CYLINDER AXLE

SPECIAL EXT RETAINING RING

CAP SCREW M5-.8 X 10

OIL LINE ELBOW CONNECTOR 4MM

OIL LINE 4-WAY CONNECTOR 4MM

OIL LINE 4MM

P0646068

P0646069

P0646076

PFH66M

PFH67M

P0646079

SHEAR BLADE ARM

SHEAR BLADE BODY

NOTCH TABLE

FLAT HD CAP SCR M10-1.5 X 30

FLAT HD CAP SCR M8-1.25 X 25

TABLE GUIDE

189-1 P0646189-1

ONE-SHOT OILER

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G0647 Upper Rear-Half Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

P0647001

P0647002

P0647003

P0647004

P0647009

P0646010

PN28M

TOP PANEL FRONT

P0647081

PW01

LOCK HANDLE 1/2-13

FLAT WASHER 1/2

TOP PANEL REAR

HANGER FRAME

PCB32M

P0647084

P0647085

P0647086

P0647087

PB04M

CARRIAGE BOLT 1/2-13 X 1-3/4

SECTION REAR COVER

ANGLE REAR COVER

SHEAR REAR COVER

SHEAR BOTTOM COVER

HEX BOLT M6-1 X 10

FLAT WASHER 6MM

TOP COVER

LIFTING EYE BOLT MOUNT

LIFTING EYE BOLT

HEX NUT M20-2.5

P0646017

P0647020

P0647052

P0647053

PSB92M

PLW05M

P0647058

P0647059

P0647060

P0647061

PFH64M

PFH65M

PLW05M

PN09M

HEX BOLT M20-2.5 X 125

PRESSURE PAD

PW03M

SECTION BLADE ARM

SECTION BLADE BODY

CAP SCREW M12-1.75 X 40

LOCK WASHER 12MM

ANGLE BLADE BODY UPPER

ANGLE BLADE BODY LOWER

ANGLE BLADE ARM LOWER

ANGLE BLADE ARM UPPER

FLAT HD CAP SCR M10-1.5 X 60

FLAT HD CAP SCR M10-1.5 X 55

LOCK WASHER 12MM

HEX NUT M12-1.75

P0647090

PSB54M

PLW10M

P0647131

PLW10M

PSB166M

P0647134

PB04M

MOUNTING BLOCK

CAP SCREW M16-2 X 40

LOCK WASHER 16MM

NOTCH SIDE PLATE

131

132

133

134

135

136

170

171

172

186

187

188

189

LOCK WASHER 16MM

CAP SCREW M16-2 X 30

NOTCH END GUARD

HEX BOLT M6-1 X 10

FLAT WASHER 6MM

PW03M

P0647170

P0647171

P0647172

PSB50M

P0646187

P0646188

P0646189

BUSHING

CYLINDER AXLE

SPECIAL EXT RETAINING RING

CAP SCREW M5-.8 X 10

OIL LINE ELBOW CONNECTOR 4MM

OIL LINE 4-WAY CONNECTOR 4MM

OIL LINE 4MM

P0647068

P0647069

P0647076

PFH66M

PFH67M

P0647079

SHEAR BLADE ARM

SHEAR BLADE BODY

NOTCH TABLE

FLAT HD CAP SCR M10-1.5 X 30

FLAT HD CAP SCR M8-1.25 X 25

TABLE GUIDE

189-1 P0646189-1

ONE-SHOT OILER

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G0646/G0647 50/65 Ton Ironworker

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Cabinet

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G0646/G0647 50/65 Ton Ironworker

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G0646 Cabinet

REF PART #

DESCRIPTION

REF PART #

190 P0646190

DESCRIPTION

FOOT PEDAL

P0646005

P0646006

P0646007

P0646008

PB04M

FRONT ACCESS PANEL

SUB-PANEL

190-1 P0646190-1

190-2 P0646190-2

FOOT PEDAL FLEXIBLE CONDUIT

FOOT PEDAL ELECTRICAL CABLE

EMERGENCY STOP BUTTON

EMERGENCY STOP BUTTON BOX

ELECTRICAL CABINET

CABINET DOOR

REAR ACCESS PANEL

LIMIT SWITCH ACCESS PANEL

HEX BOLT M6-1 X 10

191

191-1 P0646191-1

194 P0646194

194-1 P0646194-1

P0646191

PW03M

FLAT WASHER 6MM

153

168

169

173

174

175

176

177

178

179

180

181

P0646153

P0646168

P0646169

P0646173

P0646174

P0646175

P0646176

P0646177

P0646178

P0646179

P0646180

P0646181

RAM LIMIT SWITCH

HYDRAULIC CYLINDER

RAM

195

196

197

198

199

200

201

202

203

204

205

207

208

P0646195

P0646196

P0646197

P0646198

P0646199

P0646200

P0646201

P0646202

P0646203

P0646204

PN01M

ROTARY SWITCH

DOOR LOCK

HYD. LINE MANIFOLD-CYLINDER

HYD. LINE PUMP-MANIFOLD

HYD. LINE TANK-PUMP

HYDRAULIC MANIFOLD

OIL CATCH PAN

DOOR LOCK KEY PLASTIC

POWER LAMP

EMERGENCY STOP BUTTON

MOTOR START BUTTON

NORMAL/INCH SWITCH

MOTOR STOP BUTTON

PUNCH/NOTCH SWITCH

BASE

HYDRAULIC CONTROL VALVE ASSY

HYDRAULIC VALVE SOLENOID

HYDRAULIC RESERVOIR

RESERVOIR ACCESS PANEL

HEX BOLT M6-1 X 10

HEX NUT M6-1

181-1 P0646181-1

181-2 PB04M

P0646207

P0646208

MAIN POWER SWITCH

CONTACTOR TECO 16-N 220/440V

CONTACTOR TECO CNA-2 220/440V

OL RELAY TECO RHN-10K 12.5-18

OL RELAY TECO RHN10K 7-11

FUSE ASSEMBLY 5A

181-3 P0646181-3

RES. ACCESS PANEL GASKET

OIL SIGHT GLASS & THERMOMETER

MOTOR 5HP 220/440V 3-PH

MOTOR FAN COVER

208-1 P0646208-1

209 P0646209

209-1 P0646209-1

182

183

P0646182

P0646183

183-1 P0646183-1

183-2 P0646183-2

183-3 P0646183-3

210

211

212

213

P0646210

P0646211

P0646212

P0646213

MOTOR FAN

ELECTRICAL COMMUTATOR

TRANSFORMER

MOTOR JUNCTION BOX

HYDRAULIC PUMP

184

185

P0646184

P0646185

TERMINAL BLOCK

FILLER CAP

213-1 P0646213-1

213-2 P0646213-2

213-3 P0646213-3

ELECTRICAL PANEL

185-1 P0646185-1

185-2 P0646185-2

FILLER SCREEN

STRAIN RELIEF LARGE

STRAIN RELIEF SMALL

FILLER CAP GASKET

-65-

G0646/G0647 50/65 Ton Ironworker

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G0647 Cabinet

REF PART #

DESCRIPTION

REF PART #

190 P0646190

DESCRIPTION

FOOT PEDAL

P0647005

P0647006

P0647007

P0647008

PB04M

FRONT ACCESS PANEL

SUB-PANEL

190-1 P0646190-1

190-2 P0646190-2

FOOT PEDAL FLEXIBLE CONDUIT

FOOT PEDAL ELECTRICAL CABLE

SIDE EMERGENCY STOP BUTTON

EMERGENCY STOP BUTTON BOX

ELECTRICAL CABINET

CABINET DOOR

REAR ACCESS PANEL

LIMIT SWITCH ACCESS PANEL

HEX BOLT M6-1 X 10

191

191-1 P0646191-1

194 P0646194

194-1 P0646194-1

P0646191

PW03M

FLAT WASHER 6MM

153

168

169

173

174

175

176

177

178

179

180

181

P0646153

P0647168

P0647169

P0646173

P0646174

P0646175

P0646176

P0646177

P0646178

P0646179

P0646180

P0646181

RAM LIMIT SWITCH

HYDRAULIC CYLINDER

RAM

195

196

197

198

199

200

201

202

203

204

205

207

208

P0646195

P0646196

P0646197

P0646198

P0646199

P0646200

P0646201

P0646202

P0646203

P0647204

PN01M

ROTARY SWITCH

DOOR LOCK

HYD. LINE MANIFOLD-CYLINDER

HYD. LINE PUMP-MANIFOLD

HYD. LINE TANK-PUMP

HYDRAULIC MANIFOLD

OIL CATCH PAN

DOOR LOCK KEY PLASTIC

POWER LAMP

EMERGENCY STOP BUTTON

MOTOR START BUTTON

NORMAL/INCH SWITCH

MOTOR STOP BUTTON

PUNCH/NOTCH SWITCH

BASE

HYDRAULIC CONTROL VALVE ASSY

HYDRAULIC VALVE SOLENOID

HYDRAULIC RESERVOIR

RESERVOIR ACCESS PANEL

HEX BOLT M6-1 X 10

HEX NUT M6-1

181-1 P0646181-1

181-2 PB04M

P0646207

P0646208

MAIN POWER SWITCH

CONTACTOR TECO 16-N 220/440V

CONTACTOR TECO CNA-2 220/440V

OL RELAY TECO RHN-10K 12.5-18

OL RELAY TECO RHN10K 7-11

FUSE ASSEMBLY 5A

181-3 P0646181-3

RES. ACCESS PANEL GASKET

OIL SIGHT GLASS & THERMOMETER

MOTOR 5HP 220/440V 3-PH

MOTOR FAN COVER

208-1 P0646208-1

209 P0646209

209-1 P0646209-1

182

183

P0646182

P0647183

183-1 P0647183-1

183-2 P0647183-2

183-3 P0647183-3

210

211

212

213

P0646210

P0646211

P0646212

P0646213

MOTOR FAN

ELECTRICAL COMMUTATOR

TRANSFORMER

MOTOR JUNCTION BOX

HYDRAULIC PUMP

184

185

P0647184

P0646185

TERMINAL BLOCK

FILLER CAP

213-1 P0646213-1

213-2 P0646213-2

213-3 P0646213-3

ELECTRICAL PANEL

185-1 P0646185-1

185-2 P0646185-2

FILLER SCREEN

STRAIN RELIEF LARGE

STRAIN RELIEF SMALL

FILLER CAP GASKET

-66-

G0646/G0647 50/65 Ton Ironworker

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Notching Station

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REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

137

138

139

140

141

142

143

P0646137

P0646138

P0646139

P0646140

P0646141

PSB64M

NOTCH PUNCH

144

145

146

147

148

149

P0646144

PLW05M

PW06M

NOTCH BOLSTER CLAMP

LOCK WASHER 12MM

FLAT WASHER 12MM

HEX BOLT M12-1.75 X 55

CAP SCREW M10-1.5 X 25

TEE NUT M12-1.75

CAP SCREW M20-2.5 X 90

NOTCH SIDE DIE

NOTCH END DIE

PB12M

NOTCH BOLSTER

PSB64M

P0646149

CAP SCREW M10-1.5 X 25

SET SCREW M8-1.25 X 25

PSS21M

-67-

G0646/G0647 50/65 Ton Ironworker

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Punching Station

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REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

102

103

104

105

106

107

108

109

110

111

113

114

115

117

P0646102

SPECIAL SET SCREW

118

119

120

121

122

124

125

126

127

P0646118

P0646119

PTLW12M

P0646121

P0646122

P0646124

P0646125

PSS106M

PB12M

STRIPPER ADJUSTMENT SHAFT

COMPRESSION SPRING

EXT TOOTH WASHER 12MM

PUNCH RETAINING RING

PUNCH STRIPPER BASE

ROUND DIE SHOE

P0646103

P0646104

P0646105

PSB31M

PUNCH STRIPPER TOP PLATE

PUNCH PRESSURE PLATE

KNURLED KNOB

CAP SCREW M8-1.25 X 25

COMPRESSION SPRING

BUSHING

P0646107

P0646108

PW04M

ROUND DIE 5-29MM

FLAT WASHER 10MM

SET SCREW M12-1.75 X 55

HEX BOLT M12-1.75 X 55

LOCK WASHER 12MM

PUNCH BOLSTER CLAMP

PUNCH BOLSTER

PSB47M

CAP SCREW M10-1.5 X 40

PUNCH LOCATION KEY

PUNCH ADAPTER 81031 3-19MM

ROUND PUNCH 22MM

P0646111

P0646113

P0646114

P0646115

P0646117

127-1 PLW05M

128

129

130

P0646128

P0646129

P0646130

ROUND PUNCH ADAPTER 5-29MM

PUNCH ADAPTER 9036 13-38MM

TEE NUT M12-1.75

-68-

G0646/G0647 50/65 Ton Ironworker

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extension bar

Extension Bar & Tools

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REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

215

216

217

218

219

220

221

222

223

224

225

226

227

228

P0646215

GUIDE BAR

SCALE 1M

229

230

231

232

233

241

244

245

246

247

248

249

250

P0646229

PSB169M

PW06M

CLAMP

P0646216

P0646217

PSB70M

PLW06M

P0646220

PSB17M

P0646222

P0646223

P0646224

P0646225

PSB83M

PW03M

CAP SCREW M12-1.75 X 75

FLAT WASHER 12MM

SUPPORT SHAFT

MOUNTING BRACKET

CAP SCREW M10-1.5 X 45

LOCK WASHER 10MM

END CAP

P0646232

P0646233

P0646241

P0646244

PAW12M

PAW14M

PAW17M

P0646248

P0646249

P0646250

SENSOR MOUNT END CAP

SPANNER WRENCH

HEX WRENCH KIT 2.5-10MM

HEX WRENCH 12MM

HEX WRENCH 14MM

HEX WRENCH 17MM

ADJUSTABLE WRENCH

GREASE GUN

CAP SCREW M4-.7 X 10

PIVOT CLAMP

LOCK LEVER M12-1.75 X 40

LOCK LEVER M16-2 X 45

EXTENSION BAR

CAP SCREW M6-1 X 55

FLAT WASHER 6MM

HEX NUT M6-1

TOOL BOX

PN01M

-69-

G0646/G0647 50/65 Ton Ironworker

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Label Placement

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REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

301

302

303

304

305

306

307

308

309

P0646301

P0646302

P0647302

PLABEL-12B

P0646304

P0646305

P0646306

P0646307

P0646308

PLABEL-14

CLAMP WARNING LABEL VERT.

MACHINE ID LABEL (G0646)

MACHINE ID LABEL (G0647)

READ MANUAL LABEL HORZ.

SAFE OPERATION NOTICE LABEL

CLAMP WARNING LABEL HORZ.

EYE/FACE HAZARD LABEL HORZ.

DISCONNECT POWER LABEL HORZ.

SHOCK HAZARD LABEL HORZ.

ELECTRICITY LABEL

310

311

312

313

314

315

316

P0646310

P0647310

P0646311

P0647311

PLABEL-34

P0646313

PPAINT-11

PPAINT-1

G8588

TONNAGE LABEL (G0646)

TONNAGE LABEL (G0647)

MODEL NUMBER LABEL (G0646)

MODEL NUMBER LABEL (G0647)

PREWIRED 220V LABEL

ORANGE TOUCH UP PAINT

GRIZZLY PUTTY TOUCH UP PAINT

GRIZZLY GREEN TOUCH UP PAINT

GRIZZLY OVAL NAMEPLATE

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.

-70-

G0646/G0647 50/65 Ton Ironworker

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WARRANTY AND RETURNS

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