Grizzly G0559 Owner's Manual
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Grizzly G0559 Owner's Manual

Grizzly G0559 Owner's Manual

12" x 54" milling machine w/power feeds & digital readout
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MODEL G0559
12" x 54" MILLING MACHINE
w/POWER FEEDS & DIGITAL READOUT
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.

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  • Page 1 MODEL G0559 12" x 54" MILLING MACHINE w/POWER FEEDS & DIGITAL READOUT 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.

  • Page 3: Table Of Contents

    INTRODUCTION ... 2 SECTION 1: SAFETY ... 9 SECTION 2: CIRCUIT REQUIREMENTS ... 12 SECTION 3: SETUP ... 13 SECTION 4: OPERATIONS ... 23 Table of Contents SECTION 5: ACCESSORIES ... 36 SECTION 6: MAINTENANCE ... 39 SECTION 7: SERVICE ... 44 SECTION 8: WIRING ...

  • Page 4: Introduction

    INTRODUCTION Functional Overview Foreword www.grizzly.com Contact Info...
  • Page 5 Identification Figure 1. Page 31 Page 23...
  • Page 6 Figure 2.
  • Page 7 Figure 3.
  • Page 8 Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901 MODEL G0559 LARGE MILLING MACHINE 12 X 54 Product Dimensions: Weight... 3300 lbs. Length/Width/Height... 73 x 70 x 88 in. Foot Print (Length/Width)... 41-1/4 x 25 in.
  • Page 9 Main Specifications: Operation Info Spindle Travel... 5 in. Swing...31 in. Longitudinal Table Travel... 28 in. Cross Table Travel...15-1/4 in. Vert. Table Travel...13-1/4 in. Knee Travel...15-7/8 in. Ram Travel...18 in. Head Swivel...Left and Right 90 deg. Head Tilt... Left and Right 45 deg. Turret Or Column Swivel...360 deg.
  • Page 10 Other Specifications: Country Of Origin ... China Warranty ... 1 Year Serial Number Location ... Label on Electric Box Assembly Time ... 3-1/2 hours Features: One Shot Pump Lubrication Y, Z Covers Auto Down Feed Auto Stop with Micro Adjustable Stop Longitudinal Power Feed Cross Slide Power Feed Knee Power Feed...
  • Page 11 Safety Instructions for Machinery...

  • Page 13: Section 1: Safety

    Additional Safety Instructions For Mills UNDERSTANDING CONTROLS. SAFETY ACCESSORIES. WORK HOLDING. CHUCK KEY SAFETY SPINDLE SPEEDS. POWER DISRUPTION. STOPPING SPINDLE. CLEAN-UP. BE ATTENTIVE. Like all machinery there is potential danger when operating this mill. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this mill with respect and caution to reduce the risk of operator injury.

  • Page 14: Section 2: Circuit Requirements

    SECTION 2: CIRCUIT REQUIREMENTS 220V 3-Phase Operation Serious personal injury could occur if you connect the machine to the power source before you have completed the setup pro- cess. DO NOT connect the machine to the power source until instructed after setup. Electrocution or fire could result if this machine is not installed to code.

  • Page 15: Section 3: Setup

    Wear safety glasses dur- ing the entire setup pro- cess! The Model G0559 is a heavy machine. Serious personal injury occur if safe moving methods are not used. To be safe, get assis-...
  • Page 16 Inventory 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: (Figures 5–6) Figure 5. Figure 6. Immediately discard all plas- tic bags and packing materi- als to eliminate choking/suf- focation hazards for children...
  • Page 17 Clean Up For optimum performance, clean all moving parts or sliding contact surfaces. Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. NOT use these products to clean the machinery. Many cleaning solvents toxic Minimize your risk by only...
  • Page 18 Moving & Placing Base Unit The Model G0559 is a heavy machine. Serious personal occur if safe moving methods are not used. To be safe, get assis- tance and use power equipment rated for at least 4000 lbs. to move...
  • Page 19 Moving Machine with Straps Page 27 Ram Movement Figure 10. Note: Have your assistants steady the load as you move it to keep it from swinging. Mounting to Shop Figure 10 Head Movement Page 29 Bolting to Concrete Floors Figure 11 We strongly recommend securing your machine to the floor if it is hardwired to the power source.
  • Page 20 Assembly To assemble your milling machine: Page 27 Figure 12 Note: The keyway on the ball handle must align with the key on the leadscrew. Figure 12. Figure 13 Head Movement Figure 13. Figure 13 Figure 14 Figure 14.
  • Page 21 Figure 15. Figure 16. Figure 16. Figure 15 "X Figure 17. Figure 17 "Y...
  • Page 22 Test Run Troubleshooting Page 44 Before starting the mill, make sure you have performed the preceding assembly and adjustment instructions, and 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! To test run the machine:...
  • Page 23 NOTICE Continuous operation of this mill without properly and successfully completing all procedures of the Test Run could lead to machine damage, and could void the war- ranty. Figure 20 Figure 20. Cabinet Wiring Diagram Feeds Page 27 Test Run Spindle Break-In Electrical Page 51...
  • Page 24 Spindle Break-In NOTICE Successfully complete the spindle break-in procedure to avoid rapid wear of spindle components when placed into operation. To perform the spindle break-in procedure: Selecting Spindle Speed Range Page 30 Steps 4–5 Recommended Adjustments Page 44 Test Run Factory adjustments that should be verified: SERVICE Page 46...

  • Page 25: Section 4: Operations

    We STRONGLY RECOMMEND that you read books, trade magazines, or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training. Basic Controls Figures 21–23...
  • Page 26 C. Coolant Pump Switch: NOTICE Running the coolant pump without adequate coolant in the reservoir may permanently damage the coolant pump motor. This is considered abuse and is not covered by the warranty. D. Elevation Up & Down Buttons: E. ON Button: Emergency Stop Button: G.
  • Page 27 Vertical (Knee) Graduated Dial Increments Figure 26. Locks Resolution Figure 27 Figure Figure 27. Always keep the table locked in place unless controlled movement is required for your operation. Unexpected table movement dur- ing operations could cause the cutter to bind with the workpiece, which could result in personal injury or damage to the cutter and workpiece.
  • Page 28 Longitudinal & Cross Power Feeds Graduated Dial Increments Figures 28–29 Figure 28. Figure 29. A. Graduated Dial: Resolution B. Dial Lock Collar: C. Ball Handle: D. Feed/Jog Switch: E. Direction Switch: Lexan Gear Cover: G. Power Switch: H. Speed Dial: Leadscrew: Table Limit Stop: K.
  • Page 29 Stay clear of the spinning ball handles when using the power feeds to avoid entangle- ment and personal injury. Tools Needed To operate the longitudinal or cross power feed: Note: Power feed rates are difficult to pre- cisely adjust. We recommend that you exper- iment with different dial settings to find the feed rate that best works for your operation.
  • Page 30 Tools Needed Tilting the Head Figure 32 Figure 32. Note: Turn the tilting bolt clockwise to tilt the head back, and counterclockwise to tilt it for- ward. Always lock the head firmly in place after adjusting the tilt or rotation. Unexpected movement of the head during operations could cause the cutter to bind with the workpiece, which could result in personal...
  • Page 31 Ram Movement Tools Needed Moving Ram Back-and-Forth Figure 34. Note: Turn the adjustment bolt clockwise to move the ram back, and counterclockwise to move the ram forward. Rotating the Ram Figure 35 Figure Figure 35. Note: Take care not to entangle or stretch the electrical cabling as you move the ram and head.
  • Page 32 Setting Spindle Speed Calculating Spindle Speed Figure 36 Cutting Speeds for High Speed Steel (HSS) Cutting Tools Note: For carbide cutting tools, double the cutting speed. These values are a guideline only. Refer to the MACHINERY'S HANDBOOK for more detailed information.
  • Page 33 Note: The window on the left is for the low range, and the window on the right is for the high range. Figure 39. NOTICE Always have the spindle rotating BEFORE using the variable speed handwheel to avoid damage to the variable speed sys- tem.
  • Page 34 Figure 41 Note: If necessary, use the set screw on the side of the handle hub to adjust the detent ball tension so the handle can be installed and removed easily. Figure 41. Fine & Auto-Downfeed Components Figure 42 Figure 42. A.
  • Page 35 Downfeed Direction Pin: Using the Fine Downfeed Handwheel Using Auto-Downfeed Note: The downfeed stop is marked in incre- ments of 0.001", with one full revolution equal to 0.050" of quill movement. Note: The downfeed direction pin has three positions: 1) In for one direction, 2) center for stop, and 3) out for the other direction.
  • Page 36 Spindle Brake Figure 44 Figure 44. Loading/Unloading Tooling Tools Needed Loading Tooling Figure 45 Figure 45. Cutting tools are sharp and can quickly injure your hands. Always protect your hands when handling cutting tools.
  • Page 37 Figure 46 Figure 46. Note: Over-tightening the drawbar could make removing the tool holder from the spindle difficult. Unloading Tooling...

  • Page 38: Section 5: Accessories

    SECTION 5: ACCESSORIES G1076—52-PC. Clamping Kit Figure 47. H8257—Primrose Armor Plate with Moly-D Machine and Way Oil 1 Quart S. Balolia – President Figure 48. ⁄ " H8368—Electric Power Drawbar Figure 49. T10063—Milling Vise 12 T10064—Milling Vise 17 Figure 50. ⁄...
  • Page 39 G9299—10" Yuasa-Type Rotary Table Figure 51. 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 T20448 T20501 T20456 Figure 52. G5562—SLIPIT G5563—SLIPIT G2871—Boeshield G2870—Boeshield H3788—G96 H3789—G96...
  • Page 40 H5791—ER40 Quick Change Collet Set Figure 55. H5802—NT40 to MT#2 Sleeve H5803—NT40 to MT#3 Sleeve H8139—NT40 to R8 Adapter Figure 56. G5758—5" x 7" Tilt Table G5759—7" x 10" Tilt Table Figure 57. G5641—1-2-3 Blocks G5642—2-4-6 Blocks Figure 58.

  • Page 41: Section 6: Maintenance

    SECTION 6: MAINTENANCE Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious person- al injury. Schedule Daily Check: Every 8 Hours of Operation: Page 40 Every 40 Hours of Operation: Page 41 Page 41 Page 41 Every 120 Hours of Operation:...
  • Page 42 Lubrication NOTICE Follow reasonable lubrication practices as outlined in this manual for your mill. Failure to do so could lead to premature failure of your mill and will void the warranty. One-Shot Oiler Lubricant Frequency Figure 59. Quill Gearing Lubricant Figure 60.
  • Page 43 Bull Gear Lubricant Frequency Figure 61 Figure 61. Ram Way Lubricant Frequency Figure 62 Figure 62. Vertical Leadscrew Bevel Gears Lubricant Figure 63. Longitudinal & Cross Power Feed Gearing Lubricant Figure 64 Frequency Frequency Figure 64. Figure...
  • Page 44 Coolant Coolant is a potent and extremely solution to humans and animals. Use personal protective when handling coolant to prevent infections or poisoning. Tools Needed Checking/Adding Coolant Figure 65 Figure 65. poisonous Always use non-flammable water-based equipment coolant to avoid explosions when the fluid comes in contact with hot metal chips from the milling operation.
  • Page 45 The coolant reservoir on this mill is designed to store only coolant. During storage some fluids grow dangerous microbes, or, due to the collection of toxic metal chips in the fluid, the fluid can become a potent and extremely poisonous solution to humans and animals.

  • Page 46: Section 7: Service

    SECTION 7: SERVICE Troubleshooting Motor & Electrical Page 53...
  • Page 47 Operation Page 30 Page 30 Page 46 Page 40 Page 46 Page 30 Page 46...
  • Page 48 Adjusting Gibs NOTICE Excessively loose gibs may cause poor Figure 67. workpiece finishes, and may cause undue wear of sliding surfaces and ways. Over- tightening the gibs may cause premature wear of these sliding devices. Figure 68. Figures 67–69 Figure 69.
  • Page 49 Adjusting Backlash Tools Needed To adjust leadscrew backlash: Note: Take care to secure the small parts as you take them off and note the order of assembly. Figure 70 Figure 70. Figure 71. Figure 72. Figure 71 Figure 72...

  • Page 50: Section 8: Wiring

    GROUNDED CIRCUIT. WARNING! SHOCK HAZARD! Disconnect power before working on wiring. MOTOR WIRING. 5. EXPERIENCING DIFFICULTIES. NOTICE The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.grizzly.com.
  • Page 51 Wiring Overview Wiring Diagrams: Page 54 Page 53 Pages 51–52 Page 55 Page 55 Page 54 Page 53 Page 55 Page 53 READ ELECTRICAL SAFETY ON PAGE 48!
  • Page 52 Electrical Cabinet Wiring Figure 73. Pages 51–52 READ ELECTRICAL SAFETY ON PAGE 48!
  • Page 53 Electrical Cabinet Wiring Diagram (A) KM-1 NOTICE See Page 52 for additional wir- ing in this electrical cabinet. KM-2 KM-3 KM-4 READ ELECTRICAL SAFETY ON PAGE 48! Page 55 Page 54 Page 54 220 VAC 15-20 PLUG (as recommended)
  • Page 54 Electrical Cabinet Wiring Diagram (B) KM-1 KM-2 KM-3 KM-4 NOTICE See Page 51 for additional wir- ing in this electrical cabinet. READ ELECTRICAL SAFETY ON PAGE 48!
  • Page 55 Motor Wiring Diagrams Page 54 Figure 74. Page 51 Figure 75. Page 51 Figure 76. READ ELECTRICAL SAFETY ON PAGE 48!
  • Page 56 Electrical Components Wiring Diagrams (A) Control Panel Figure 77. Page 51 Direction Switch Page 53 Page 51 Figure 78. READ ELECTRICAL SAFETY ON PAGE 48!
  • Page 57 Electrical Components Wiring Diagrams (B) Vertical Limit Switches Upper Page 51 Lower Vertical Crank Figure 79. Safety Switch Page 51 Figure 80. Work Light Page 51 Figure 81. READ ELECTRICAL SAFETY ON PAGE 48!

  • Page 58: Section 9: Parts

    SECTION 9: PARTS Base Machine Breakdown...
  • Page 59 Base Machine Parts List REF PART # DESCRIPTION P0559001 QUILL HOUSING ADJUST GEAR P0559002 RAM ADAPTER P0559006 VERT. ADJUSTING WORM GEAR P0559007 WORM THRUST WASHER P0559008 VERTICAL WORM SHAFT P0559009 WORM KEY P0559010 P0559013 CAP SCREW P0559014 ROLL PIN P0559015 SCALE P0559016 RIVET...
  • Page 60 Base Machine Parts List REF PART # DESCRIPTION P0559131 RAM GIB P0559132 KNEE CRANK SAFETY SWITCH P0559133 LONGITUDINAL LIMIT SWITCH P0559134 ELECTRICAL CABINET P0559135 COOLANT PUMP ACCESS COVER PS09M PHLP HD SCR M5-.8 X 10 P0559137 COOLANT PUMP PSB28M CAP SCREW M6-1 X 15 P0559139 COOLANT HOSE 3/8 ID P0559140...
  • Page 61 Longitudinal & Cross Leadscrews Breakdown & Parts List REF PART # DESCRIPTION PN01 HEX NUT 1/2-20 P0559202 BALL CRANK HANDLE P0559203 DIAL LOCK NUT P0559204 GRADUATED DIAL P0559205 DIAL HOLDER PSB04M CAP SCREW M6-1 X 10 P0559207 BEARING RETAINER RING P204-20 BALL BEARING 204-20 P0559209...
  • Page 62 Head Breakdown...
  • Page 63 REF PART # DESCRIPTION P0559301 DOWNFEED SHAFT ASSEMBLY P0559320 GEARSHAFT PLUNGER P0559321 COMPRESSION SPRING PRP42M ROLL PIN 3 X 20 P0559323 SHIFT CRANK P0559324 KNOB PSB15M CAP SCREW M5-.8 X 20 P0559327 CLUSTER GEAR SHAFT BEARING P0559328 CLUSTER GEAR P0559329 CLUSTER GEAR KEY P0559331 CLUSTER GEAR SHAFT...
  • Page 64 REF PART # DESCRIPTION P0559435 ANG. CONTACT BEARING 7010ZZ P0559436 BEARING SPACER P0559437 BUSHING P0559438 BEARING P0559440 SPECIAL SOCKET SET SCREW P0559441 COLLET ALIGNMENT SCREW P0559442 QUILL PSS50M SET SCREW M4-.7 X 20 P0559445 FEED TRIP LEVER P0559446 TRIP LEVER PIN P0559448 QUILL LOCK SLEEVE P0559449...
  • Page 65 Upper Drive System Breakdown...
  • Page 66 Upper Drive System Parts List REF PART # DESCRIPTION PN02 HEX NUT 5/16-18 P0559502 SPEED READOUT DIAL P0559503 BRONZE BEARING PSS11M SET SCREW M6-1 X 16 P0559505 SPEED CHANGER HOUSING P0559506 SPEED CHANGER CHIP SHIELD PS05M PHLP HD SCR M5-.8 X 8 P0559509 ROLL PIN 3 X 24 509-1 PRP19M...
  • Page 67 Lower Drive System Breakdown...
  • Page 68 Lower Drive System Parts List REF PART # DESCRIPTION PSB15M CAP SCREW M5-.8 X 20 P0559603 WAVY WASHER 14MM P0559604 BALL BEARING 35 X 62 X 14MM PR56M EXT RETAINING RING 45MM P0559606 CAP SCREW PN08 HEX NUT 3/8-16 P0559608 SPINDLE MOTOR 5HP 220V 3-PH 608-1 P0559608-1 MOTOR FAN COVER...
  • Page 69 One-Shot Oiler Breakdown & Parts List REF PART # DESCRIPTION P0559701 ONE-SHOT OILER P0559702 ALUMINUM PIPE P0559703 OIL DISTRIBUTOR CPS4 P0559704 HEX BOLT P0559705 OIL DISTRIBUTOR A4 REF PART # DESCRIPTION P0559706 OIL DISTRIBUTOR CPS3 P0559707 STEEL FLEXIBLE TUBE P0559708 OIL DISTRIBUTOR A8 P0559709 OIL DISTRIBUTOR CPS5...
  • Page 70 Accessories Breakdown & Parts List REF PART # DESCRIPTION P0559500 RUBBER WAY COVER 500A P0559500A RUBBER CHIP DEFLECTOR P0559800 SPLASH PAN P0559801 DIGITAL DISPLAY UNIT P0559803 X-AXIS SCALE P0559804 Y-AXIS SCALE P0559806 OIL BOTTLE PWR1719 WRENCH 17/19 P0559808 WRENCH 18/21 PSDP2 SCREWDRIVER PHILLIPS #2 PSDF2...
  • Page 71 Electrical Cabinet Breakdown & Parts List REF PART # DESCRIPTION P0559805 TRANSFORMER JBK JB/T5555 220V P0559850 WIRE MANAGEMENT ASSY P0559851 OL RELAY DELIXI DZ108-20 220V P0559852 FUSE HOLDER DELIXI RT-18-32N P0559853 FUSE 6A REF PART # DESCRIPTION P0559854 CONTACTOR SHIHLIN S-P06 220V P0559855 ELECTRICAL OUTLET 110V P0559856...
  • Page 72 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. Label Placement...

  • Page 75: Warranty And Returns

    WARRANTY AND RETURNS...

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