Grizzly G9901 Owner's manual

MODEL G9901/G9902/G9903

VERTICAL MILLING MACHINE

w/POWER FEED

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.

#TS9704 PRINTED IN CHINA

Model G9903

Model G9902

Model G9901

This manual provides critical safety instructions on the proper setup,

operation, maintenance, and service of this machine/tool. Save this

document, refer to it often, and use it to instruct other operators.

Failure to read, understand and follow the instructions in this manual

may result in fire or serious personal injury—including amputation,

electrocution, or death.

The owner of this machine/tool is solely responsible for its safe use.

This responsibility includes but is not limited to proper installation in

a safe environment, personnel training and usage authorization,

proper inspection and maintenance, manual availability and compre-

hension, application of safety devices, cutting/sanding/grinding tool

integrity, and the usage of personal protective equipment.

The manufacturer will not be held liable for injury or property damage

from negligence, improper training, machine modifications or misuse.

Some dust created by power sanding, sawing, grinding, drilling, and

other construction activities contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive

harm. Some examples of these chemicals are:

• Lead from lead-based paints.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you

do this type of work. To reduce your exposure to these chemicals:

Work in a well ventilated area, and work with approved safety equip-

ment, such as those dust masks that are specially designed to filter

out microscopic particles.

Table of Contents

SECTION 6: MAINTENANCE ......................... 44

Schedule ...................................................... 44

Cleaning and Protecting .............................. 44

Lubrication Overview ................................... 45

Lubrication Tasks ......................................... 45

Coolant ......................................................... 49

SECTION 7: SERVICE ................................... 50

Troubleshooting ........................................... 50

Adjusting Gibs .............................................. 52

Adjusting Backlash....................................... 53

Adjusting Downfeed Clutch Lever................ 54

Replacing Belts G9901 & G9902 ................. 55

Replacing Belts G9903 ................................ 56

Replacing Brake Shoes G9901 & G9902 .... 59

Replacing Brake Shoes G9903 ................... 60

SECTION 8: WIRING ...................................... 61

Wiring Safety Instructions ............................ 61

G9901/G9902 220V, Single-Phase ............. 62

Wiring Diagram ............................................ 62

G9901/G9902 110V, Single-Phase ............. 63

Wiring Diagram ............................................ 63

G9903 220V, 3-Phase Wiring Diagram ....... 64

G9903 440V, 3-Phase Wiring Diagram ....... 65

SECTION 9: PARTS ....................................... 66

Body Assembly ............................................ 66

Table Assembly ........................................... 69

Model G9901/G9902 Drive Assembly ......... 71

Headstock .................................................... 74

Model G9903 Upper Drive System .............. 77

Model G9903 Lower Drive System .............. 79

One-Shot Oiler ............................................. 81

Accessories .................................................. 83

Label Placement .......................................... 84

WARRANTY AND RETURNS ........................ 89

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

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

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

G9901 Machine Data Sheet .......................... 3

G9902 Machine Data Sheet .......................... 5

G9903 Machine Data Sheet .......................... 7

Identification ................................................... 9

G9901/G9902 Drive System

& Headstock Controls .................................. 11

G9903 Drive System

& Headstock Controls .................................. 12

SECTION 1: SAFETY ..................................... 13

Safety Instructions for Machinery ................ 13

Additional Safety Instructions For Mills ........ 15

Glossary of Terms ....................................... 16

SECTION 2: POWER SUPPLY ...................... 17

G9901/G9902 .............................................. 17

G9903 .......................................................... 20

SECTION 3: SETUP ....................................... 23

Needed for Setup ......................................... 23

Unpacking .................................................... 23

Inventory ...................................................... 24

Clean Up ...................................................... 24

Site Considerations ...................................... 25

Table Ball Handles ....................................... 25

Lifting & Moving Mill ..................................... 26

Mounting to Shop Floor ............................... 27

Test Run ...................................................... 28

Spindle Break-In .......................................... 29

SECTION 4: OPERATIONS ........................... 30

Operation Safety .......................................... 30

Operation Tips ............................................. 30

Table Movement .......................................... 31

Headstock Movement .................................. 33

Ram Movement............................................ 34

Setting RPM ................................................. 35

Downfeed Controls ...................................... 38

Spindle Brake............................................... 40

Loading/Unloading Tools ............................. 41

SECTION 5: ACCESSORIES ......................... 42

-2-

Model G9901/G9902/G9903 Milling Machine

INTRODUCTION

Machine Description

We stand behind our machines! If you have ques-

tions or need help, contact us with the information

below. Before contacting, make sure you get the

serial number

and manufacture date

from the

machine ID label. This will help us help you faster.

Grizzly Technical Support

1815 W. Battlefield

Springfield, MO 65807

Phone: (570) 546-9663

Email: [email protected]

We want your feedback on this manual. What did

you like about it? Where could it be improved?

Please take a few minutes to give us feedback.

Grizzly Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: [email protected]

Contact Info

We are proud to provide a high-quality owner’s

manual with your new machine!

We

made every effort to be exact with the

instruc-

tions, specifications, drawings, and photographs

in this manual. Sometimes we make mistakes, but

our policy of continuous improvement also means

that

sometimes the machine

you receive is

slightly different than shown in the manual

.

If you find this to be the case, and the difference

between the manual and machine leaves you

confused or unsure about something

,

check our

website for an updated version. W

e post

current

manuals and

manual updates for free

on our web-

site at

www.grizzly.com.

Alternatively, you can call our Technical Support

for help. Before calling, make sure you write down

the

Manufacture Date and Serial Number

from

the machine ID label (see below). This information

is required for us to provide proper tech support,

and it helps us determine if updated documenta-

tion is available for your machine.

Manufacture Date

Serial Number

Manual Accuracy

This vertical mill is used to remove material

from metal workpieces to form complex shapes.

Tooling is inserted into the spindle, which can

be positioned in nearly any orientation above the

table and workpiece.

During most operations, the workpiece is clamped

to the table, then it is moved into the rotating cut-

ter in any combination of three paths—longitudi-

nal (X-axis), cross (Y-axis), and vertical (Z-axis).

The range of movement for the table is greater

than that of the head and spindle. However some

operations, such as drilling or tapping, are better

accomplished with vertical quill (spindle) move-

ment, using the coarse or fine downfeed con-

trols.

Model G9901/G9902/G9903 Milling Machine

-3-

The information contained herein is deemed accurate as of 2/26/2018 and represents our most recent product specifications.

Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased.

PAGE 1 OF 3

Model G9901

MACHINE DATA

SHEET

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901

MODEL G9901 9" X 42" VERTICAL MILL W/ POWER FEED

Product Dimensions:

Weight............................................................................................................................................................ 2325 lbs.

Width (side-to-side) x Depth (front-to-back) x Height........................................................................... 66 x 59 x 85 in.

Footprint (Length x Width)............................................................................................................................ 36 x 24 in.

Space Required for Full Range of Movement (Width x Depth).............................................................. 60 x 66-1/2 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate

Content........................................................................................................................................................... Machine

Weight............................................................................................................................................................ 2380 lbs.

Length x Width x Height....................................................................................................................... 55 x 51 x 79 in.

Must Ship Upright................................................................................................................................................... Yes

Electrical:

Power Requirement............................................................................................. 110V or 220V, Single-Phase, 60 Hz

Prewired Voltage.................................................................................................................................................. 220V

Full-Load Current Rating.................................................................................................... 19A at 110V, 9.5A at 220V

Minimum Circuit Size.......................................................................................................... 30A at 110V, 15A at 220V

Connection Type....................................................................................................................................... Cord & Plug

Power Cord Included.............................................................................................................................................. Yes

Power Cord Length................................................................................................................................................. 6 ft.

Power Cord Gauge......................................................................................................................................... 14 AWG

Plug Included........................................................................................................................................................... No

Recommended Plug Type............................................................................................. L5-30 for 110V, 6-15 for 220V

Switch Type........................................................................................................................... Forward/Reverse Switch

Motors:

Main

Horsepower................................................................................................................................................ 2 HP

Phase............................................................................................................................................ Single-Phase

Amps.................................................................................................................................................... 19A/9.5A

Speed................................................................................................................................................ 1725 RPM

Type................................................................................................................. TEFC Capacitor-Start Induction

Power Transfer .................................................................................................................................. Belt Drive

Bearings..................................................................................................... Shielded & Permanently Lubricated

G9901 Machine Data Sheet

-4-

Model G9901/G9902/G9903 Milling Machine

The information contained herein is deemed accurate as of 2/26/2018 and represents our most recent product specifications.

Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased.

PAGE 2 OF 3

Model G9901

Main Specifications:

Operation Info

Spindle Travel.............................................................................................................................................. 5 in.

Max Distance Spindle to Column............................................................................................................... 20 in.

Max Distance Spindle to Table.................................................................................................................. 18 in.

Longitudinal Table Travel (X-Axis)...................................................................................................... 25-7/8 in.

Cross Table Travel (Y-Axis)................................................................................................................ 12-1/2 in.

Vertical Table Travel (Z-Axis).................................................................................................................... 16 in.

Vertical Head Travel (Z-Axis)....................................................................................................................... 5 in.

Ram Travel................................................................................................................................................ 12 in.

Turret or Column Swivel (Left /Right)................................................................................................... 360 deg.

Head Tilt (Left/Right).............................................................................................................................. 90 deg.

Head Tilt (Front/Back)............................................................................................................................ 45 deg.

Drilling Capacity for Cast Iron................................................................................................................ 1-1/2 in.

Drilling Capacity for Steel...................................................................................................................... 1-1/4 in.

End Milling Capacity................................................................................................................................. 7/8 in.

Face Milling Capacity................................................................................................................................... 3 in.

Table Info

Table Length.............................................................................................................................................. 42 in.

Table Width.................................................................................................................................................. 9 in.

Table Thickness.................................................................................................................................... 2-3/4 in.

Number of T-Slots............................................................................................................................................ 3

T-Slot Size................................................................................................................................................ 5/8 in.

T-Slots Centers...................................................................................................................................... 2-1/2 in.

Number of Longitudinal Feeds.............................................................................................................. Variable

X-Axis Table Power Feed Rate................................................................................................... 0 – 11.67 FPM

X/Y-Axis Travel per Handwheel Revolution.......................................................................................... 0.200 in.

Z-Axis Travel per Handwheel Revolution............................................................................................. 0.100 in.

Spindle Info

Spindle Taper............................................................................................................................................... R-8

Number of Vertical Spindle Speeds.................................................................................................................. 8

Range of Vertical Spindle Speeds............................................................................................. 78 – 2400 RPM

Quill Diameter........................................................................................................................................ 3-3/8 in.

Quill Feed Rates................................................................................................ 0.0019, 0.0035, 0.0058 in./rev.

Drawbar Thread Size............................................................................................................................. 7/16-20

Drawbar Length................................................................................................................................. 24-3/16 in.

Spindle Bearings....................................................................................................... Angular Contact Bearings

Construction

Spindle Housing/Quill................................................................................................. Chrome-Plated Cast Iron

Table....................................................................................................................................... Ground Cast Iron

Head.................................................................................................................................................... Cast Iron

Column/Base....................................................................................................................................... Cast Iron

Base..................................................................................................................................................... Cast Iron

Paint Type/Finish.................................................................................................................................... Enamel

Other Specifications:

Country of Origin ................................................................................................................................................ China

Warranty ........................................................................................................................................................... 1 Year

Approximate Assembly & Setup Time ...................................................................................................... 2-1/2 Hours

Serial Number Location ...................................................................................................... ID Label on Front of Knee

ISO 9001 Factory .................................................................................................................................................... No

Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................................................... No

Model G9901/G9902/G9903 Milling Machine

-5-

The information contained herein is deemed accurate as of 2/26/2018 and represents our most recent product specifications.

Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased.

PAGE 1 OF 3

Model G9902

MACHINE DATA

SHEET

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901

MODEL G9902 9" X 49" VERTICAL MILL W/ POWER FEED &

SINGLE‐PHASE

Product Dimensions:

Weight............................................................................................................................................................ 2340 lbs.

Width (side-to-side) x Depth (front-to-back) x Height........................................................................... 66 x 67 x 85 in.

Footprint (Length x Width)............................................................................................................................ 36 x 24 in.

Space Required for Full Range of Movement (Width x Depth).............................................................. 60 x 66-1/2 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate

Content........................................................................................................................................................... Machine

Weight............................................................................................................................................................ 2412 lbs.

Length x Width x Height....................................................................................................................... 55 x 50 x 77 in.

Must Ship Upright................................................................................................................................................... Yes

Electrical:

Power Requirement............................................................................................. 110V or 220V, Single-Phase, 60 Hz

Prewired Voltage.................................................................................................................................................. 220V

Full-Load Current Rating..................................................................................................... 26A at 110V, 13A at 220V