MODEL
G0596-99
INDUSTRIAL BENCH GRINDER
OWNER'S MANUAL
Copyright © JANUAry, 2006 By grizzly iNdUstriAl, iNC. rEVisEd oCtoBEr, 2009 (Bl)
WARNING: NO pORTION Of THIS MANUAL MAy BE REpRODUCED IN ANy SHApE
OR fORM WITHOUT THE WRITTEN AppROvAL Of GRIzzLy INDUSTRIAL, INC.
(For modEls mANUFACtUrEd siNCE 3/06) #pC7907 priNtEd iN tAiWAN
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Table of Contents
INTRODUCTION............................................................................................................................... 2
manual Accuracy........................................................................................................................ 2
Contact info................................................................................................................................ 2
identification ............................................................................................................................... 3
machine specfications ............................................................................................................... 3
SECTION 1: SAfETy....................................................................................................................... 4
safety instructions for machinery............................................................................................... 4
Additional safety for grinders .................................................................................................... 6
SECTION 2: CIRCUIT REQUIREMENTS ........................................................................................ 7
power Connection...................................................................................................................... 7
grounding................................................................................................................................... 8
Extension Cords......................................................................................................................... 8
phase Converter (g0599 only).................................................................................................. 8
SECTION 3: SET Up........................................................................................................................ 9
set Up safety............................................................................................................................. 9
items Needed for set Up ........................................................................................................... 9
Unpacking .................................................................................................................................. 9
inventory................................................................................................................................... 10
Eye shields .............................................................................................................................. 10
mounting................................................................................................................................... 10
dust Collection......................................................................................................................... 11
test run................................................................................................................................... 11
hardware recognition Chart.................................................................................................... 12
SECTION 4: OpERATIONS ........................................................................................................... 13
operation safety ...................................................................................................................... 13
grinding tips............................................................................................................................ 13
Wheel Care .............................................................................................................................. 14
Wheel selection ....................................................................................................................... 14
Wheel inspection...................................................................................................................... 15
Wheel dressing........................................................................................................................ 15
Wheel replacement................................................................................................................. 16
SECTION 5: ACCESSORIES......................................................................................................... 17
SECTION 6: SERvICE ................................................................................................................... 18
troubleshooting........................................................................................................................ 18
SECTION 7: WIRING...................................................................................................................... 19
Wiring safety instructions ........................................................................................................ 19
g0596 Wiring diagram............................................................................................................. 20
g0597/g0598 Wiring diagram................................................................................................. 21
g0599 Wiring diagram............................................................................................................. 22
SECTION 8: pARTS....................................................................................................................... 23
parts Breakdown main............................................................................................................. 23
parts Breakdown shield........................................................................................................... 24
parts list g0596-g0597 .......................................................................................................... 25
parts list g0598-g0599 .......................................................................................................... 26
WARRANTy AND RETURNS........................................................................................................ 29
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INTRODUCTION
Manual Accuracy
Contact Info
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-2-
model g0596-99 (mfg. since 3/06)
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Machine Specfications
Customer service #: (570) 546-9663 • to order Call: (800) 523-4777 • Fax #: (800) 438-5901
Model G0596-99
G0596
1
G0597
11⁄2
G0598
2
G0599
3
motor hp
Voltage/phase
Amps
110, 1-ph
14A
220V, 1-ph
8.5A
220V, 1-ph
12A
220V, 3-ph
10A
rpm
1800
1800
1200
1200
Wheel size
Wheel type
Arbor size
height
8 x 1 x 1"
type 1
1"
10 x 1 x 1"
type 1
1"
12 x 11⁄2 x 11⁄4
"
12 x 2 x 11⁄4
"
type 1
type 1
11⁄4
"
11⁄4
"
181⁄2
"
181⁄2
"
22"
30"
22"
30"
Width
24"
24"
depth
16"
171⁄2
"
19"
19"
dust port diameter
Net Weight
shipping Weight
shipping dimensions
21⁄2
"
21⁄2
"
3"
3"
118 lbs.
139 lbs.
132 lbs.
163 lbs.
220 lbs.
264 lbs.
226 lbs.
264 lbs.
34 x 24 x 20"
28 x 20 x 16"
28 x 22 x 18"
34 x 24 x 20"
Identification
d
A
B
C
g
E
F
D. oN/oFF switch
A. lighted Eye shield (to be used WITH safety
glasses and face shield)
B. grinding Wheel
E. Wheel safety guard
f. Coolant Cup
G. dust port
C. tool rest
-3-
model g0596-99 (mfg. since 3/06)
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SECTION 1: SAFETY
For Your Own Safety, Read Instruction
Manual Before Operating this Machine
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This
manual uses a series of symbols and signal words intended to convey the level of importance
of the safety messages. The progression of symbols is described below. Remember that safety
messages by themselves do not eliminate danger and are not a substitute for proper accident
prevention measures.
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.
This symbol is used to alert the user to useful information about
proper operation of the machine.
NOTICE
Safety Instructions for Machinery
Safety Instructions for Machinery
1. READ ENTIRE MANUAL BEFORE
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4. ALWAYS USE HEARING PROTECTION
WHEN OPERATING MACHINERY.ꢀ
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2. ALWAYS USE ANSI APPROVED
SAFETY GLASSES WHEN OPERATING
MACHINERY. :kZgnYVnꢀ ZnZ\aVhhZhꢀ dcanꢀ
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6. NEVER OPERATE MACHINERY WHEN
TIRED OR UNDER THE INFLUENCE OF
DRUGS OR ALCOHOL. 7ZꢀbZciVaanꢀVaZgiꢀ
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3. ALWAYS WEAR A NIOSH APPROVED
RESPIRATOR WHEN OPERATING
MACHINERY THAT PRODUCES DUST.ꢀ
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-4-
model g0596-99 (mfg. since 3/06)
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ꢀ
Safety Instructions for Machinery
7. ONLY ALLOW TRAINED AND PROP-
16. REMOVE CHUCK KEYS OR ADJUSTING
ERLY SUPERVISED PERSONNEL TO
OPERATE MACHINERY.ꢀ BV`Zꢀ hjgZꢀ
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17. DAMAGED MACHINERY.ꢀ8]ZX`ꢀ[dgꢀW^cY"
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8. KEEP CHILDREN/VISITORS AWAY.
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19. SECURE WORKPIECE.ꢀ JhZꢀ XaVbehꢀ dgꢀ
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10. DO NOT USE IN DANGEROUS
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21. MANY
MACHINES
CAN
EJECT
11. KEEP WORK AREA CLEAN AND WELL
LIGHTED. 8ajiiZgꢀVcYꢀYVg`ꢀh]VYdlhꢀbVnꢀ
XVjhZꢀVXX^YZcih#
WORKPIECES TOWARD OPERATOR.
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12. USE A GROUNDED POWER SUPPLY
RATEDFORTHEMACHINEAMPERAGE.
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22. STABLE MACHINE. BVX]^cZhꢀi]ViꢀbdkZꢀ
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WVhZhꢀꢃ^[ꢀjhZYꢄꢀVgZꢀadX`ZYꢀWZ[dgZꢀhiVgi^c\#
13. ALWAYS DISCONNECT FROM POWER
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i]ViꢀineZꢀd[ꢀYjhi#
SOURCE
BEFORE
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24. EXPERIENCING DIFFICULTIES. >[ꢀ Viꢀ
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15. MAKE SURE GUARDS ARE IN PLACE
AND WORK CORRECTLY BEFORE
USING MACHINERY.
-5-
model g0596-99 (mfg. since 3/06)
Download from Www.Somanuals.com. All Manuals Search And Download.
Additional Safety for Grinders
1. EyE pROTECTION. grinding ejects small
7. LUNG pROTECTION. grinding produces
hazardous dust, which may cause long-
term respiratory problems. Always wear a
Niosh–approved dust mask or respirator
when grinding.
particles at a high rate of speed. AlWAys
wear safety glasses when using this
machine.
2. MOUNTING TO BENCH/STAND. An unse-
cured grinder may become dangerously
out of control during operation. make sure
grinder is Firmly secured to a bench/
stand before use.
8. SIDE GRINDING. grinding on the side of
wheels can cause the them to break and
fly apart—unless the wheel is rated for side
grinding.
3. WHEEL SpEED RATING. Wheels oper-
ated at a faster speed than rated for
may break or fly apart. Before mount-
ing a new wheel, be sure the wheel
rpm rating is equal or higher than the
speed of the grinder.
9. TOp GRINDING. grinding on the top
of wheels greatly increases the risk of
workpiece kickback. Always grind on the
downward part of the wheel.
10. HAND/WHEEL CONTACT. grinding
wheels can remove a lot of skin fast. Keep
a firm grip on the workpiece and position
your hands a safe distance away when
grinding. do Not wear gloves as they
may get caught in the grinding wheel and
cause even more serious injuries.
4. WHEEL fLANGES. only use the flanges
included with the grinder when mounting
wheels. other flanges may not properly
secure the wheel and cause an accident.
5. RING TEST. perform a "ring test" on grind-
ing wheels before installation to ensure
that they are safe to use. A wheel that does
not pass the ring test may break or fly apart
during operation.
11. TOOL REST pOSITION. if the tool rest is
too far away from the wheel, the workpiece
may be pulled down, causing loss of con-
trol and pulling your hand into the grinding
wheel. Keep the tool rest within 1⁄8" from the
wheel when operating.
6. STARTING GRINDER. if a wheel is dam-
aged, it will usually fly apart shortly after
start-up. to protect yourself, always stand
to the side of the grinder when turning it
ON and allow it to run a full minute before
standing in front of it.
12. CRACKED WHEEL. Cracked wheels
may break and fly apart during operation.
replace cracked wheels immediately!
No list of safety guidelines can be complete.
Every shop environment is different. Always
consider safety first, as it applies to your
individual working conditions. Use this and
other machinery with caution and respect.
failure to do so could result in serious per-
sonal injury, damage to equipment, or poor
work results.
Like all machinery there is potential danger
when operating this machine. Accidents are
frequently caused by lack of familiarity or
failure to pay attention. Use this machine
with respect and caution to lessen the pos-
sibility of operator injury. If normal safety
precautions are overlooked or ignored, seri-
ous personal injury may occur.
-6-
model g0596-99 (mfg. since 3/06)
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SECTION 2: CIRCUIT REQUIREMENTS
plug Type
power Connection
With the exception of the g0596, the cord set
enclosed does not have a plug as the style of plug
you require will depend upon the type of service
you currently have or plan to install. We recom-
mend using the following plugs for your machine
Serious personal injury could occur if you
on a dedicated circuit only (see figures 1–?? for
connect the machine to the power source
examples):
before you have completed the set up pro-
cess. DO NOT connect the machine to the
g0597 at 220V ......................... NEmA 6-15 plug
power source until instructed to do so.
g0598 at 220V ......................... NEmA 6-15 plug
g0599 at 220V 3-phase.. NEmA 15-15r plug or
..220V locking shut-off switch (recommended)
Amperage Draw
the motor for your machine may draw the follow-
ing amps at maximum load.
g0596 at 110V single-phase ............... 14 Amps
g0597 at 220V single-phase.............. 8.5 Amps
g0598 at 220V single-phase............... 12 Amps
g0599 at 220V 3-phase....................... 10 Amps
power Supply Circuit Requirements
the power supply circuit for your machine mUst
be grounded and rated for the amperage given
below. Never replace a circuit breaker on an exist-
ing circuit with one of higher amperage without
consulting a qualified electrician to ensure compli-
ance with wiring codes. If you are unsure about
the wiring codes in your area or you plan to
connect your machine to a shared circuit, con-
figure 1. NEmA 6-15 plug and receptacle.
sult a qualified electrician.
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g0596 power source........... 110V single-phase
g0596 minimum Circuit size................ 20 Amps
g0597 power source ...........220V single-phase
g0597 minimum Circuit size................ 15 Amps
g0598 power source...........220V single-phase
g0598 minimum Circuit size................ 15 Amps
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g0599 power source...................220V 3-phase
g0599 minimum Circuit size................ 15 Amps
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figure 2. NEmA 15-15r plug and receptacle.
-7-
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Grounding
Extension Cords
We do not recommend the use of extension cords.
instead, arrange the placement of your equipment
and the installed wiring to eliminate the need for
extension cords.
in the event of an electrical short, grounding
reduces the risk of electric shock. the grounding
wire in the power cord must be properly connect-
ed to the grounding prong on the plug; likewise,
the outlet must be properly installed and ground-
ed. All electrical connections must be made in
accordance with local codes and ordinances.
if you find it absolutely necessary to use an exten-
sion cord with your machine, the extension cord
must also contain a ground wire and plug pin.
110v Operation
Use at least a 12 gauge cord that does not exceed
50 feet in length!
Electrocution or fire could
result if machine is not
grounded and installed in
compliance with electrical
codes. Compliance MUST
be verified by a qualified
electrician!
220v Operation
Use at least a 12 gauge cord that does not exceed
50 feet in length!
phase Converter
(G0599 Only)
the power from the manufactured leg may dam-
age electrical components on your machine if
connected to the wrong incoming power terminal.
only connect the manufactured leg to the "s"
terminal (see wiring diagram for identification).
DO NOT use a static phase converter, as they
notoriously damage electrical components.
This machine MUST have a ground prong in
the plug to help ensure that it is grounded.
DO NOT remove ground prong from plug
to fit into a two-pronged outlet! If the plug
will not fit the outlet, have the proper outlet
installed by a qualified electrician.
-8-
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SECTION 3: SET Up
Set Up Safety
Items Needed for
Set Up
This machine presents
the following items are needed to complete the
set up process, but are not included with your
machine:
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
•
•
•
•
•
Wrench or socket 12mm............................ 1
Wrench or socket 8mm.............................. 1
safety glasses (for each person) .............. 1
phillips screwdriver #2............................... 1
Assistant..................................................1-2
Wear safety glasses dur-
ing the entire set up pro-
cess!
Unpacking
the model g0596-99 was carefully packed when
it left our warehouse. if you discover the machine
is damaged after you have signed for delivery,
please immediately call Customer Service at
(570) 546-9663 for advice.
The Model G0596-99 is
a heavy machine. DO
NOT over-exert yourself
while unpacking or mov-
ing your machine—get
assistance.
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 con-
dition of your shipment, you should inventory the
contents.
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Inventory
Mounting
mount the grinder on the optional h7834 stand
(see page 17), or a workbench that is sturdy
enough to hold the weight of the machine and
any downward pressure that may be applied dur-
ing operation.
After all the parts have been removed from the
box you should have the following items:
Box 1:
Qty
A. grinder ....................................................... 1
B. Wrench 38mm (g0596/g0597).................. 1
C. Wrench 50mm (g0598/g0599).................. 1
the stand or workbench should be level, rigid,
and attached to the floor, so it will not move dur-
ing operation.
NOTICE
For proper safety, drill holes in your workbench
and secure the grinder with hex bolts, washers,
and hex nuts, or with lag screws and flat wash-
ers. (mounting hardware is not provided due to
the many possible set ups and workbench thick-
nesses.)
Some hardware/fasteners on the inventory
list may arrive pre-installed on the machine.
Check these locations before assuming that
any items from the inventory list are miss-
ing.
When locating your grinder, remember:
•
•
•
you will need room for potentially large
workpieces.
Eye Shields
the eye shields on the model g0596-99 may
come pre-mounted from the factory. if they do not,
attach them at this time with the two phillips head
screws provided.
maintain easy access to dust ports for attach-
ing dust collection system.
grinding without dust collection system
spreads dust in the immediate vicinity of the
grinder.
light switch
mounting screws
•
•
grinding creates flying sparks that mUst be
out of reach of any flammables.
you will need a lot of light around the
grinding wheel in addition to the lighted eye
shields.
figure 3. Eye shield.
DO NOT operate this grinder without the eye
shields or wheel guards in place. failure
to properly use these safety devices could
lead to serious injury!
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Dust Collection
Test Run
the test run ensures that the grinder and grinder
wheels were not damaged during shipping.
DO NOT operate the Model G0596-99 without
an adequate dust collection system. This
grinder creates substantial amounts of dust
while operating. failure to use a dust collec-
tion system can result in short and long-term
respiratory illness.
To test run the grinder:
1. review and understand all grinder safety
information.
2. remove the wheels and closely inspect the
overall conditions. Follow this by performing
a "ring test" (see Wheel Inspection on
page 15 and Wheel Replacement on page
16).
the model g0596-99 features a dust port at the
rear of the grinding wheel. if a dust collection sys-
tem is not attached, both ports have spark deflec-
tors that direct sparks downward.
3. plug the grinder into the power source.
4. put on safety glasses and face shield.
To connect a dust collection hose:
1. remove the spark deflector.
5. stand to the side of the line of the wheels
rotation, turn the grinder ON, and allow it to
run a least one minute, before standing in
front of it.
2. Fit the dust hose over the dust port, as shown
in figure 4, and secure in place with a hose
clamp.
3. tug the hose to make sure it does not come
off. Note: A tight fit is necessary for proper
performance.
—the grinder should run smoothly.
—grinding wheels should run true without
noticeable vibration.
—if there is an obvious problem with the way
the grinder is running, turn it OFF immedi-
ately and troubleshoot the problem, using
the troubleshooting table on page 18. do
Not operate the grinder until it is fixed.
spark deflector
dust port
figure 4. dust port.
fIRE AND EXpLOSION HAzARD! DO NOT
attach dust ports to a dust collection system
designed or used for wood dust collection.
-11-
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Hardware Recognition Chart
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SECTION 4: OpERATIONS
Operation Safety
Grinding Tips
the grinder is a safe tool when used properly. in
addition to the safety instructions in this manual,
the most important safety consideration is to use
common sense at all times. What may be okay in
one situation, may not be safe in another.
Damage to your eyes, lungs, and ears could
result from using this machine without prop-
er protective gear. Always wear safety glass-
es with face shield, a respirator, and hearing
protection when operating this machine.
Here are some tips to keep in mind while
grinding:
•
do Not grind on the side of the wheel. the
wheels provided with the model g0596-99
are not designed for side grinding. grinding
on the side greatly stresses the wheel and
may cause it to shatter.
•
Wear the proper protective clothing. particles
flying off of a grinding wheel will be travel-
ing very fast—prepare for this. Wear safety
glasses/face shield, a dust mask, earplugs,
a leather apron, and heavy leather boots.
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.
•
•
make sure all guards are in place.
remember that grinding often produces
sparks. do Not allow anyone to stand in
the path of the sparks. do Not grind near
flammable materials.
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.
•
•
maintain proper care of your wheels. read
the Wheel Care on page 14.
grasp the workpiece firmly and properly
support it on the tool rest during grinding.
maintain even pressure and control of the
workpiece when grinding.
•
•
Concentrate on the task at hand. stop
grinding if you are distracted.
do Not grind workpieces that are heavier
than the wheel itself. this stresses the
wheel. in these cases use a handheld grind-
er instead.
-13-
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Wheel Care
Wheel Selection
your safety when grinding depends, on a large
part, on the condition of the wheel during grind-
ing. A wheel in poor condition presents the possi-
bility of breaking apart during rotation and injuring
the operator and others in the area.
the model g0596/g0597 only accepts type 1
wheels with a 1" bore. the model g0598/g0599
only accepts type 1 wheels with a 11⁄4" bore.
Aluminum oxide and silicon carbide wheels are
marked in a somewhat uniform manner by all the
major manufacturers. Understanding these mark-
ings will help you understand the capabilities of
various wheels. Always refer to the manufactur-
er’s grinding recommendations when selecting a
wheel for your project.
Here are some tips to help you avoid breaking
the wheel:
•
Always transport, store and handle wheels
with care. Wheels may be damaged if they
are dropped or if heavy objects are stacked
on them.
The basic format for wheel numbering is:
Abrasive
type
Bond
type
•
•
select the right grinding wheel for the job.
do Not grind material inappropriate for the
wheel type.
prefix
grit size grade
60
1
A
l
V
select the right wheel for the machine. A
machine that rotates at a higher rpm than
the wheel is rated for may cause the wheel
to fly apart.
the prefix is the manufacturer’s designation for a
particular wheel type (eg, type 1 wheels).
the most common Abrasive Types used are A
for Aluminum oxide, C for silicon Carbide, and
occasionally sg for seeded gel.
•
•
mount the wheels properly. (see the Wheel
Replacement instructions on page 16 for
guidance.)
the Grit Size is a number that refers to the size
of the abrasive grain in the wheel. the lower the
number, the coarser the wheel. ten is a very
coarse wheel for roughing and 220 is usually the
upper range for fine finish work.
do not abuse the wheel by jamming the work
into the grinding wheel with excessive force
that causes the grinder to bog down, or apply
pressure to stop the wheel after turning the
grinder OFF.
Grade is an indication of the hardness of the
wheel—“A” being the softest and “z” being the
hardest.
•
•
dress the wheel when necessary. do not
allow it to become glazed.
Always spin water/coolant out of the wheel
before turning the grinder OFF. this may
take 5–10 minutes. (if moisture is left on the
wheel, the wheel may warp.)
Bond Type refers to the type of bonding material
used to hold the abrasive material. most general
purpose wheels will have a “V” indicating Vitrified
Clay is used. Vitrified Clay provides high strength
and good porosity. the other common bond type
is “B” for resin where synthetic resins are used.
these are used to grind cemented carbide and
ceramic materials.
•
•
•
do not store wheels in damp or wet loca-
tions.
do not grind on the side of the wheel unless
wheel is designed for side grinding.
Note: There may be other numbers inserted that
have meaning for a particular type of wheel. Refer
to the manufacturer’s technical data for a com-
plete explanation.
do not overtighten the nut when mounting
the wheel.
-14-
model g0596-99 (mfg. since 3/06)
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4. An undamaged wheel will emit a clear metal-
lic ring or “ping” sound in each of these spots.
A damaged wheel will respond with a dull
thud that has no clear tone.
Wheel Inspection
Before mounting a new grinding wheel, it must
be inspected. do not assume that a wheel is in
sound condition just because it is new—often
damage can occur in shipping, with age, or with
exposure to moisture.
5. if you determine from the ring test that the
wheel is damaged, do Not use it!
Wheel Dressing
First, do a visual Inspection. look for any
cracks, chips, nicks or dents in the surface of the
wheel. if you see any of these, do Not use the
wheel.
depending on the type of grinding you do, the
grinding wheel may require periodic dressing.
second, do a Ring Test. this test will give you an
indication of any internal damage that may not be
obvious during a visual inspection.
there are several different types of wheel dress-
ing devices available on the market (see page
17). dressing restores the abrasive quality of the
wheel surface and brings the wheel edge back to
a square form.
To perform a Ring Test:
1. make sure the wheel that you test is clean and
dry; otherwise, you may get false results.
refer to the instructions that accompany your
dressing accessory for complete details on how
to properly dress a wheel.
2. if size permits, balance the wheel with your
finger in the hole. if this is not possible, hang
the wheel in the air with a piece of cord or
string looped through the hole in the center.
3. At the spots shown in figure 5, gently tap
the wheel with a light non-metallic device
such as the handle of a screwdriver or a
wooden mallet.
Note: Finding the exact spot to tap will take
several attempts.
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ring test.
-15-
model g0596-99 (mfg. since 3/06)
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Wheel Replacement
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ALWAyS visually inspect and perform a
“ring test” on a wheel before assembly. DO
NOT use damaged wheels!
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the wheel guard must be removed in order to
mount or dismount a grinding wheel.
figure 6. Assembly order for wheel installation.
Arbor Nut
To replace a grinding wheel:
1. UNplUg thE griNdEr!
2. remove the wheel guard.
3. Use a wrench on the arbor nut. hold the
wheel from turning with your other hand.
Note that the wheel on the left-hand side of
the machine has left-handed threads, so the
arbor nut on that side must be turned clock-
wise to loosen.
4. remove the outer wheel flange and the
paper disc. pull the wheel free from the
arbor. there will also be a paper disc and a
wheel flange on the other side of the wheel.
figure 7. Nut removal/tightnening.
6. re-install the wheel guard.
5. mount the new wheel as shown in figure
6. Always make certain there is a paper or
fiber disc between the wheel flanges and
the wheel itself. tighten the nut snugly but
do Not over-tighten. over-tightening can
crack the wheel (see figure 7).
7. run a new wheel for at least one minute
while standing clear of the line of rotation. if
a wheel does have defects it will generally fail
within that time.
NEvER assemble a grinding wheel on the
arbor without paper or fiber discs between
the wheel and the flange. Not using the
discs can put stress on the wheel, causing
it to crack and possibly fall apart.
-16-
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ACCEssoriEs
SECTION 5: ACCESSORIES
Model H7834—341⁄2" Stand for Industrial
Bench Grinders.
G0596 Replacement Wheels
Model H8880—8 x 1 x 1" Al Oxide 24 Grit
Model H8881—8 x 1 x 1" Al Oxide 36 Grit
G0597 Replacement Wheels
Model H8882—10 x 1 x 1" Al Oxide 24 Grit
Model H8883—10 x 1 x 1" Al Oxide 36 Grit
G0598 Replacement Wheels
Model H8884—12 x 11⁄2 x 11⁄4" Al Oxide 24 Grit
Model H8885—12 x 11⁄2 x 11⁄4" Al Oxide 36 Grit
G0599 Replacement Wheels
Model H8886—12 x 2 x 11⁄4" Al Oxide 24 Grit
Model H8887—12 x 2 x 11⁄4" Al Oxide 36 Grit
Model H5944—#0 Wheel Dresser
Model H5945—#1 Wheel Dresser
Model H5946—#2 Wheel Dresser
Model H5891—1⁄4 Carat Diamond Dresser
Model H5892—3⁄4 Carat Diamond Dresser
Model G3446—Accu-Sharp Jigs
Model G4570—Accu-Sharp Stubby Chisel Jig
h5892
h5891
-17-
model g0596-99 (mfg. since 3/06)
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SECTION 6: SERvICE
review the troubleshooting and procedures in this section to fix your machine if a problem develops. 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
motor will not start. 1. low voltage.
1. Check power line for proper voltage.
2. inspect all lead connections on motor for loose or open
connections.
2. open circuit in motor or loose connections.
motor will not start; 1. short circuit in line cord or plug.
fuses or circuit
1. inspect cord or plug for damaged insulation and shorted
wires.
breakers blow.
2. short circuit in motor or loose connections.
2. inspect all connections on motor for loose or shorted termi-
nals or worn insulation.
3. incorrect fuses or circuit breakers in power line.
3. install correct fuses or circuit breakers.
motor overheats.
1. motor overloaded.
1. reduce load on motor.
motor stalls (result- 1. short circuit in motor or loose connections.
ing in blown fuses
1. inspect connections on motor for loose or shorted terminals
or worn insulation.
or tripped circuit).
2. low voltage.
2
Correct the low voltage conditions.
3. incorrect fuses or circuit breakers in power line.
4. motor overloaded.
3. install correct fuses or circuit breakers.
4. reduce load on motor.
machine
slows 1. operator is using too much pressure.
1. Use less pressure when grinding.
when operating.
Wavy
tion on surface of
workpiece.
condi- 1. machine vibrating.
1. make sure machine is securely mounted on a solid sur-
face.
2. Workpiece not being held firmly.
3. Wheel face uneven.
2. Use a holding device to firmly retain the workpiece.
3. dress the grinding wheel.
4. Wheel is too hard.
4. Use softer wheel, or reduce the feed rate.
1. dress the grinding wheel.
lines on surface of 1. impurity on wheel surface.
workpiece.
2. Workpiece not being held tightly.
2. Use a holding device to firmly retain the workpiece.
Burning
or cracks in the
workpiece.
spots 1. improper type of grinding wheel.
1. try a wheel which is softer style or a coarser grit.
2. slow down the rate of movement of the workpiece into
wheel.
2. improper feed rate.
3. Coolant required.
3. Add optional coolant system or introduce coolant by hand.
Wheel dulls quickly, 1. depth of cut too great.
grit falls off.
1. slow down the rate of movement of the workpiece into
wheel.
2. Wheel is too soft.
2. Wheel too soft for the material being ground, select harder
bond.
3. Wheel diameter too small.
4. Bad wheel dress.
3. replace the wheel.
4. dress the wheel.
5. defective wheel bonding.
5. Consult manufacturer of grinding wheel.
-18-
model g0596-99 (mfg. since 3/06)
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SECTION 7: WIRING
these pages are current at the time of printing. however, in the spirit of improvement, we may make chang-
es to the electrical systems of future machines. study this section carefully. if there are differences between
your machine and what is shown in this section, call technical support at (570) 546-9663 for assistance
BEForE making any changes to the wiring on your machine.
Wiring Safety Instructions
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-19-
model g0596-99 (mfg. since 3/06)
Download from Www.Somanuals.com. All Manuals Search And Download.
G0596 Wiring Diagram
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ON PAGE 19!
-20-
model g0596-99 (mfg. since 3/06)
Download from Www.Somanuals.com. All Manuals Search And Download.
G0597/G0598 Wiring Diagram
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L
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ON PAGE 19!
-21-
model g0596-99 (mfg. since 3/06)
Download from Www.Somanuals.com. All Manuals Search And Download.
G0599 Wiring Diagram
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7
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ON PAGE 19!
-22-
model g0596-99 (mfg. since 3/06)
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 8: pARTS
parts Breakdown Main
-23-
model g0596-99 (mfg. since 3/06)
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parts Breakdown Shield
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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
-24-
model g0596-99 (mfg. since 3/06)
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parts List G0596-G0597
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
1
H7834
STAND (OPTIONAL)
MOTOR 1HP,110,1PH (G0596)
CAPACITOR 30M 250V
MOTOR 1.5HP, 220V,1PH (G0597)
CAPACITOR 50M 250V
WHEEL GUARD, RIGHT (G0596)
WHEEL GUARD, RIGHT (G0597)
WHEEL GUARD, LEFT (G0596)
WHEEL GUARD, LEFT (G0597)
WHEEL FLANGE
12-17 P0596012-17
12-18 P0596012-18
12-19 PW08
LAMP COVER
2
P0596002
P0596002-1
P0597002
P0597002-1
P0596003
P0597003
P0596004
P0597004
P0596005
P0596006
P0597006
PN22
SPECIAL WASHER
2-1
2
FLAT WASHER #8
13
14
15
16
17
18
19
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
45
46
47
P0596013
P0596014
P0596015
P0596016
P0596017
P0596018
P0596019
P0597019
P0596020
PFB13
SWITCH BRACKET
2-1
3
SPARK HOOD
TOOL REST SUPPORT
WRENCH 38MM (G0596-G0597)
SPARK SHIELD (G0596-G0597)
SPARK SHIELD BRACKET
MAGNETIC SWITCH (G0596)
MAGNETIC SWITCH (G0597)
HANDLE 5/16-18 X 5/8
FLANGE BOLT 1/4-20 X 1
HEX BOLT 3/8-16 X 2
HEX BOLT 10-24 X 1-1/4
HEX BOLT 5/16-18 X 1/2
HEX BOLT M8-1.25 X 25
CAP SCREW 1/4-20 X 3/8
PHLP HD SCR 10-24 X 3/8
PHLP HD SCR 1/4-20 X 1/2
PHLP HD SCR 10-24 X 1/2
FLAT HD SCR 10-24 X 3/4
NYLON CLIP 8MM
3
4
4
5
6
WHEEL COVER (G0596)
WHEEL COVER (G0597)
HEX NUT 1-8 (G0596-G0597)
HEX NUT 1-8 LH (G0596-G0597)
WHEEL 8 X 1 X 1, 24 GRIT
WHEEL 8 X 1 X 1, 36 GRIT
WHEEL 10 X 1 X 1, 24 GRIT
WHEEL 10 X 1 X 1, 36 GRIT
WATER TRAY
6
7
8
PN18
PB58
9
H8880
PB155
9-1
9
H8881
PB09
H8882
PB07M
9-1
10
11
12
12
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-7
12-8
12-9
H8883
PSB17
P0596010
P0596011
P0596012
P0597012A
P0596012-1
P0596012-2
P0596012-3
P0596012-4
P0596012-5
P0596012-6
P0596012-7
P0597012-7
P0596012-8
P0596012-9
PS06
TOOL REST
PS04
EYE SHIELD ASSY (G0596)
EYE SHIELD ASSY (G0597-G0599)
FRAME
PS01
PFH21
P0596031
PN08
MOUNT
HEX NUT 3/8-16
PIVOT SUPPORT
PN05
HEX NUT 1/4-20
ARM
PWN02
P0596035
P0596036
P0596037
PW07
WING NUT 1/4-20
BAFFLE
STRAIN RELIEF
CLEAR SHIELD
MOTOR CORD
FLUORESCENT TUBE (G0596)
FLUORESCENT TUBE (G0597)
LAMP CONTACT
POWER CORD
FLAT WASHER 5/16
LOCK WASHER 3/8
PLW04
SWITCH
PW02
FLAT WASHER 3/8
12-10 P0596012-10
12-10 P0597012-10
12-11 P0596012-11
12-12 P0596012-12
12-13 P0596012-13
12-14 PHTEK33
BALLAST (G0596)
PLW03
LOCK WASHER 3/16
FLAT WASHER 1/4
BALLAST (G0597)
PW06
KNOB 1/4-20 X 1-3/4
KNOB 1/4-20 X 1/2
PLW04M
PLW03
LOCK WASHER 8MM
LOCK WASHER 3/16
MACHINE ID LABEL (G0596)
MACHINE ID LABEL (G0597)
FACE SHEILD LABEL
ELECTRICITY LABEL
KNOB 1/4-20 X 1
P0596045
P0597045
P0596046
PLABEL-14
TAP SCREW 8-32 X 1/4
HEX NUT 1/4-20
12-15 PN05
12-16 P0596012-16
POWER SUPPLY CORD
-25-
model g0596-99 (mfg. since 3/06)
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parts List G0598-G0599
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
1
H7834
STAND (OPTIONAL)
14
15
16
17
17
18
19
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
45
46
47
P0596014
P0598015
P0598016
P0598017
P0599017
P0596018
P0598019
P0599019
P0596020
PFB13
SPARK HOOD
2
P0598002
MOTOR 2HP, 1PH, 220V(G0598)
TOOL REST SUPPORT
WRENCH 50MM (G0598-G0599)
SPARK SHIELD(G0598)
SPARK SHIELD(G0599)
SPARK SHIELD BRACKET
MAGNETIC SWITCH 2HP(G0598)
MAGNETIC SWITCH 3HP(G0599)
HANDLE 5/16-18 X 5/8
FLANGE BOLT 1/4-20 X 1
HEX BOLT 3/8-16 X 2
HEX BOLT 10-24 X 1-1/2
HEX BOLT 5/16-18 X 1/2
HEX BOLT M8-1.25 X 25
CAP SCREW 1/4-20 X 3/8
PHLP HD SCR 10-24 X 3/8
PHLP HD SCR 1/4-20 X 1/2
PHLP HD SCR 10-24 X 1/2
FLAT HD SCR 10-24 X 3/4
NYLON CLIP 8MM
2-1
2
P0597002-1 CAPACITOR 50MFD-250VAC
P0599002
P0598003
P0598004
P0598005
P0598006
PN36
MOTOR 3HP, 3PH, 220V(G0599)
WHEEL GUARD, RIGHT
WHEEL GUARD, LEFT
3
4
5
WHEEL FLANGE
6
WHEEL COVER
7
HEX NUT 1-1/4-7 (G0598-G0599)
HEX NUT 1-1/4-7 LH (G0598-G0599)
WHEEL 12 X 1.5 X1-1/4, 24 GRIT
WHEEL 12 X 1.5 X1-1/4, 36 GRIT
WHEEL 12 X 2 X 1-1/4, 24 GRIT
WHEEL 12 X 2 X 1-1/4, 36 GRIT
WATER TRAY
8
PN37
9
H8884
PB58
9-1
9
H8885
PB93
H8885
PB09
9-1
10
11
11
12
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8
12-9
H8887
PB07M
P0596010
P0598011
P0599011
P0597012A
PSB17
TOOL REST (G0598)
PS06
TOOL REST (G0599)
PS04
EYE SHIELD W/ LIGHT ASSY
PS01
P0596012-1 FRAME
PFH21
P0596012-2 MOUNT
P0596031
PN08
P0596012-3 PIVOT SUPPORT
P0596012-4 ARM
HEX NUT 3/8-16
PN05
HEX NUT 1/4-20
P0596012-5 BAFFLE
PWN02
P0596035
P0598036
P0598037
PW07
WING NUT 1/4-20
P0596012-6 CLEAR SHIELD
P0597012-7 FLUORESCENT TUBE
P0596012-8 LAMP CONTACT
P0596012-9 SWITCH
STRAIN RELIEF
MOTOR CORD
POWER CORD
FLAT WASHER 5/16
12-10 P0597012-10 BALLAST
PLW04
LOCK WASHER 3/8
12-11 P0596012-11 KNOB 1/4-20 X 1-3/4
12-12 P0596012-12 KNOB 1/4-20 X 1/2
12-13 P0596012-13 KNOB 1/4-20 X 1
PW02
FLAT WASHER 3/8
PLW03
LOCK WASHER 3/16
FLAT WASHER 1/4
PW06
12-14 PHTEK33
12-15 PN05
TAP SCREW 8-32 X 1/4
HEX NUT 1/4-20
PLW04M
PLW03
LOCK WASHER 8MM
LOCK WASHER 3/16
MACHINE ID LABEL (G0598)
MACHINE ID LABEL (G0599)
FACE SHIELD LABEL
ELECTRICITY LABEL
12-16 P0596012-16 POWER SUPPLY CORD
12-17 P0596012-17 LAMP COVER
P0598045
P0599045
P0596046
PLABEL-14
12-18 P0596012-18 SPECIAL WASHER
12-19 PW08
FLAT WASHER #8
SWITCH BRACKET
13
P0596013
-26-
model g0596-99 (mfg. since 3/06)
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WARRANTY CARD
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WARRANTy AND RETURNS
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