Grizzly G9901 User manual
MODEL G9901/G9902/G9903
VERTICAL MILLING MACHINE
w/POWER FEED
OWNER'S MANUAL
COPYRIGHT © OCTOBER, 2007 BY GRIZZLY INDUSTRIAL, INC., REVISED MARCH, 2008 (TS)
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
Table of Contents
SECTION 5: ACCESSORIES ......................... 39
SECTION 6: MAINTENANCE ......................... 41
Schedule ...................................................... 41
Cleaning and Protecting .............................. 41
Lubrication Overview ................................... 42
Lubrication Tasks ......................................... 42
Coolant ......................................................... 46
SECTION 7: SERVICE ................................... 47
Troubleshooting ........................................... 47
Adjusting Gibs .............................................. 49
Adjusting Backlash ...................................... 50
Adjusting Downfeed Clutch Lever ............... 51
Replacing Belts G9901 & G9902 ................. 52
Replacing Belts G9903 ................................ 53
Replacing Brake Shoes G9901 & G9902 .... 56
Replacing Brake Shoes G9903 ................... 57
G9901/G9902 220V, Single-Phase
Wiring Diagram ............................................ 58
G9901/G9902 110V, Single-Phase
Wiring Diagram ............................................ 59
G9903 220V, 3-Phase Wiring Diagram ....... 60
G9903 440V, 3-Phase Wiring Diagram ....... 61
SECTION 8: PARTS ....................................... 62
Body Assembly Breakdown ......................... 62
Table Assembly Breakdown ........................ 65
Model G9901/G9902 Drive
Assembly Breakdown .................................. 67
Headstock Breakdown ................................. 70
Model G9903 Upper Drive
System Breakdown ...................................... 73
Model G9903 Lower Drive
System Breakdown ...................................... 75
One-Shot Oiler Breakdown .......................... 77
Accessories Breakdown & Parts List ........... 79
Label Placement .......................................... 80
WARRANTY AND RETURNS ........................ 85
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: CIRCUIT REQUIREMENTS ...... 17
Model G9901 110/220V Operation .............. 17
Model G9902 110/220V Operation .............. 18
Model G9903 220/440V
3-Phase Operation ....................................... 19
SECTION 3: SETUP ....................................... 20
Setup Safety ................................................ 20
Items Needed for Setup ............................... 20
Unpacking .................................................... 20
Inventory ...................................................... 21
Clean Up ...................................................... 21
Site Considerations ...................................... 22
Table Ball Handles ....................................... 22
Lifting & Moving Mill ..................................... 23
Mounting to Shop Floor ............................... 24
Test Run ...................................................... 25
Spindle Break-In .......................................... 26
SECTION 4: OPERATIONS ........................... 27
Operation Safety .......................................... 27
Operation Safety .......................................... 27
Table Movement .......................................... 28
Headstock Movement .................................. 30
Ram Movement ........................................... 31
Setting RPM ................................................. 32
Downfeed Controls ...................................... 35
Spindle Brake .............................................. 37
Loading/Unloading Tools ............................. 38
-2- Model G9901/G9902/G9903 Milling Machine
INTRODUCTION
Foreword
We are proud to offer the Model G9901/G9902/
G9903 Vertical Milling Machine. This machine
is part of a growing Grizzly family of fine met-
alworking 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 commitment to customer
satisfaction.
The specifications, drawings, and photographs
illustrated in this manual represent the Model
G9901/G9902/G9903 when the manual was pre-
pared. However, owing to Grizzly’s policy of con-
tinuous improvement, changes may be made at
any time with no obligation on the part of Grizzly.
For your convenience, we always keep current
Grizzly manuals available on our website at
www.grizzly.com. Any updates to your machine
will be reflected in these manuals as soon as they
are complete. Visit our site often to check for the
latest updates to this manual!
If you have any comments regarding this manual,
please write to us at the address below:
Grizzly Industrial, Inc.
C/O Technical Documentation Manager
P.O. Box 2069
Bellingham, WA 98227-2069
Email: [email protected]
We stand behind our machines. If you have any
service questions or parts requests, please call or
write us at the location listed below.
Grizzly Industrial, Inc.
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: (570) 546-9663
Fax: (800) 438-5901
E-Mail: [email protected]
Web Site: http://www.grizzly.com
Contact Info
Model G9901/G9902/G9903 Milling Machine -3-
G9901 Machine Data Sheet
-4- Model G9901/G9902/G9903 Milling Machine
Model G9901/G9902/G9903 Milling Machine -5-
G9902 Machine Data Sheet
-6- Model G9901/G9902/G9903 Milling Machine
Model G9901/G9902/G9903 Milling Machine -7-
G9903 Machine Data Sheet
-8- Model G9901/G9902/G9903 Milling Machine
Model G9901/G9902/G9903 Milling Machine -9-
Figure 1. Identification, left side (Model G9902 shown).
A. Ram
B. Motor
C. Drive System
D. Headstock
E. Table
F. Z-Axis (Vertical Elevation) Crank
Identification
G. X-Axis (Longitudinal) Ball Handle
H. Knee
I. One-Shot Oiler
J. Z-Axis Lock Handle
K. Column
A
B
C
D
E
G
F
H
I
J
K
-10- Model G9901/G9902/G9903 Milling Machine
Figure 2. Identification, front (Model G9902 shown).
L. Forward/Reverse Power Switch
M. X-Axis (Longitudinal) Limit Switch
N. X-Axis Limit Stop
O. X-Axis Ball Handle
P. X-Axis Power Feed Unit
L
P
Q
R
S
T
Q
N
Q. X-Axis Table Lock Handle
R. Y-Axis (Cross) Ball Handle
S. Knee Support
T. Y-Axis Table Lock Handle
MN
O
Model G9901/G9902/G9903 Milling Machine -11-
G9901/G9902 Drive System & Headstock
Controls
A
B
C
D
E
G
H
J
K
L
F
Figure 3. Model G9901/G9902 drive system and headstock controls.
A. Spindle Brake
B. Manual/Power Downfeed Selector
C. Coarse Downfeed Handle
D. Quill Locking Lever
E. Dial Indicator Rod
F. Adjustable Downfeed Stop
G. Downfeed Clutch Lever
H. Fine Downfeed Handwheel
I. Power Downfeed Direction Pin
J. Power Downfeed Rate Dial
K. Forward/Reverse Power Switch
L. Spindle Speed Range Lever
I
-12- Model G9901/G9902/G9903 Milling Machine
G9903 Drive System & Headstock Controls
Figure 4. Model G9903 drive system and headstock controls.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
A. Low Range Variable Speed Indicator
B. High Range Variable Speed Indicator
C. Variable Speed Handwheel
D. Spindle Speed Range Lever
E. Manual/Power Downfeed Selector
F. Coarse Downfeed Handle
G. Quill Locking Lever
H. Dial Indicator Rod
I. Adjustable Downfeed Stop
J. Downfeed Clutch Lever
K. Fine Downfeed Handwheel
L. Power Downfeed Direction Pin
M. Power Downfeed Rate Dial
N. Forward/Reverse Power Switch
O. Spindle Brake
Model G9901/G9902/G9903 Milling Machine -13-
Safety Instructions for Machinery
SECTION 1: SAFETY
-14- Model G9901/G9902/G9903 Milling Machine
Model G9901/G9902/G9903 Milling Machine -15-
Additional Safety Instructions For Mills
1. UNDERSTANDING CONTROLS. Make
sure you understand the use and operation
of all controls.
2. SAFETY ACCESSORIES. Always use a
chip guard in addition to your safety glasses
or use a face shield when milling to reduce
the risk of injury from flying chips.
3. WORK HOLDING. Before starting the
machine, be certain the workpiece has been
properly clamped to the table. NEVER hold
the workpiece by hand during operation.
4. CHUCK KEY SAFETY. Always remove
chuck key, drawbar wrench, and any service
tools immediately after use.
5. SPINDLE SPEEDS. Select the spindle
speed that is appropriate for the type of
work and material. Allow the mill to gain full
speed before beginning a cut.
6. POWER DISRUPTION. In the event of a
local power outage during operation, turn
OFF all switches to avoid possible sudden
start up once power is restored.
7. SPINDLE DIRECTION CHANGES. Never
reverse spindle direction while the spindle is
in motion.
8. STOPPING SPINDLE. DO NOT stop the
spindle using your hand. Allow the spindle to
stop on its own, or use the spindle brake.
9. CLEAN-UP. DO NOT clear chips by hand
or compressed air. Use a brush or vacuum,
and never clear chips while the spindle is
turning.
10. MACHINE CARE AND MAINTENANCE.
Never operate the mill with damaged or
worn parts. Maintain your mill in proper
working condition. Perform routine inspec-
tions and maintenance promptly. Put away
adjustment tools after use.
11. DISCONNECT POWER. Make sure the mill
is turned OFF, disconnected from its power
source and all moving parts have come to a
complete stop before changing cutting tools,
starting any inspection, adjustment, or main-
tenance procedure.
12. AVOIDING ENTANGLEMENT. DO NOT
wear loose clothing, gloves, or jewelry when
operating mill. Tie back long hair and roll up
sleeves.
13. TOOL HOLDING. Always use the proper
tools for your operation. Make sure tools are
held firmly in place.
14. CUTTING TOOL INSPECTION. Inspect
drills and end mills for sharpness, chips,
or cracks before each use. Replace dull,
chipped, or cracked cutting tools immedi-
ately. Handle new cutting tools with care.
Leading edges are very sharp and can
cause lacerations.
15. BE ATTENTIVE. DO NOT leave mill run-
ning unattended for any reason.
16. EXPERIENCING DIFFICULTIES. If at any
time you are experiencing difficulties per-
forming the intended operation, stop using
the machine! Contact our Technical Support
at (570) 546-9663.
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
lessen the possibility of operator injury. If normal safety precautions are overlooked or ignored,
serious personal injury may occur.
-16- Model G9901/G9902/G9903 Milling Machine
Glossary of Terms
Arbor: A machine shaft that supports a cutting
tool.
Collet: A conical shaped split-sleeve bushing
that holds round tools by pressing against their
outside diameter.
Cutting Speed: The distance a point on a cut-
ter moves in one minute, expressed in surface
meters or feet per minute.
Dial Indicator: An instrument used in setup and
inspection work that shows the amount of error in
size or alignment of a part.
Dividing Head: A milling machine accessory
used to divide a circular object into a number of
equal parts.
Down or Climb Milling: Feeding the workpiece
in the same or opposite direction as the cutter
rotation.
End Milling: The operation of machining flat
surfaces either horizontal, vertical, or at an angle
using an end mill as a cutter.
Face Milling: The milled surface in this method
results from the combined action of cutting edges
located on the face or end of the cutting tools.
Feed Rate: Usually measured in inches per min-
ute.
Fixture: A device that securely holds the workpiece
in place during a cutting operation.
Form Milling: The machining of irregular con-
tours by using form cutters.
Gang Milling: When more than two cutters are
mounted on the arbor to machine surfaces of a
workpiece.
The following is a list of common definitions, terms and phrases used throughout this manual as they relate
to this mill and metalworking in general. Become familiar with these terms for assembling, adjusting and
operating this mill. Your safety is VERY important to us at Grizzly!
Gib: A tapered wedge located along a sliding
member to take up wear or to ensure a proper fit.
Headstock: The mill component that houses the
vertical spindle, motor, and drive system.
Knee: The mill device that the saddle and table
are mounted on, which can move along the Z-axis
path.
Lead Screw: The device that moves the table
along the X-axis, Y-axis, and Z-axis paths.
Peripheral Milling: The milled surface in this
method is produced by cutting teeth located on
the periphery (outer edge) of the cutter body.
Ram: The mill component that holds the head-
stock and moves in a linear path across the col-
umn.
Saddle: The sliding component that holds the
table and moves along the Y-axis path.
Side Milling: The operation of machining a verti-
cal surface on the side of a workpiece using a
side milling cutter.
Slitting and Cutting Off: Metal slitting saws are
used for milling narrow slots and for cutting off
stock.
Spindle: The revolving hollow shaft that holds
and drives the tool holder or arbor.
Turret: The top part of the column that the ram
rotates on.
Ways: The precision machined and flat tracks
on the mill on which the table, saddle, and knee
travel.
X, Y, and Z-Axis: The straight path the table
can travel longitudinally, crosswise, or vertically
respectively.
Model G9901/G9902/G9903 Milling Machine -17-
Amperage Draw
The Model G9901 features a 110/220V motor that
is prewired for 220V and draws the following amps
under maximum load:
Model G9901 Motor Draw at 110V ....... 19 Amps
Model G9901 Motor Draw at 220V ...... 9.5 Amps
Circuit Requirements
We recommend connecting your machine to a
dedicated and grounded circuit that is rated for
the amperage given below. Never replace a circuit
breaker on an existing circuit with one of higher
amperage without consulting a qualified electri-
cian to ensure compliance 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, consult a qualified electrician.
110V Circuit ........................................... 30 Amps
220V Circuit ........................................... 15 Amps
Serious personal injury could occur if you
connect the machine to the power source
before you have completed the set up pro-
cess. DO NOT connect the machine to the
power source until instructed to do so.
Model G9901
110/220V Operation
Electrocution or fire could
result if this machine is
not grounded correctly or
if your electrical configura-
tion does not comply with
local and state codes. You
MUST ensure compliance
by checking with a quali-
fied electrician!
SECTION 2: CIRCUIT REQUIREMENTS
Recommended Plug Types
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 recommend using the following plugs
(see Figure 5 for an example):
110V Plug & Receptacle .................NEMA L5-30
220V Plug & Receptacle .................. NEMA 6-15
Extension Cords
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:
• For 110V, use at least a 12 gauge cord that
does not exceed 50 feet in length.
• For 220V, use at least a 14 gauge cord that
does not exceed 50 feet in length.
• Ensure that the extension cord contains a
ground wire and ground prong.
Rewiring for 110V Operation
The Model G9901 comes prewired for 220V oper-
ation. To change to 110V operation, the forward/
reverse switch and the motor must be rewired.
Refer to the G9901/G9902 110V Wiring Diagram
on Page 59.
Figure 5. Model G9901 recommended plugs.
L5-30 Plug & Outlet
for 110V
6-15 Plug & Outlet
for 220V
circuit requirements
-18- Model G9901/G9902/G9903 Milling Machine
Amperage Draw
The Model G9902 features a 110/220V motor that
is prewired for 220V and draws the following amps
under maximum load:
Model G9902 Motor Draw at 110V ....... 26 Amps
Model G9902 Motor Draw at 220V ....... 13 Amps
Circuit Requirements
We recommend connecting your machine to a
dedicated and grounded circuit that is rated for
the amperage given below. Never replace a circuit
breaker on an existing circuit with one of higher
amperage without consulting a qualified electri-
cian to ensure compliance 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, consult a qualified electrician.
110V Circuit ........................................... 30 Amps
220V Circuit ........................................... 20 Amps
Serious personal injury could occur if you
connect the machine to the power source
before you have completed the set up pro-
cess. DO NOT connect the machine to the
power source until instructed to do so.
Model G9902
110/220V Operation
Recommended Plug Types
The cord set enclosed does not have a plug as
the style of plug and connection you require will
depend upon the type of service you currently
have or plan to install. We recommend using the
following power connections (see Figure 6 for an
example):
110V Plug & Receptacle .................NEMA L5-30
220V Plug & Receptacle ..................NEMA 6-20
Extension Cords
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:
• For 110V, use at least a 12 gauge cord that
does not exceed 50 feet in length.
• For 220V, use at least a 14 gauge cord that
does not exceed 50 feet in length.
• Ensure that the extension cord contains a
ground wire and plug pin.
Rewiring for 110V Operation
The Model G9902 comes prewired for 220V oper-
ation. To change to 110V operation, the forward/
reverse switch and the motor must be rewired.
Refer to the G9901/G9902 110V Wiring Diagram
on Page 59.
Figure 6. Model G9902 recommended power
connections.
L5-30 Plug & Outlet
for 110V
6-20 Plug & Outlet
for 220V
Electrocution or fire could
result if this machine is
not grounded correctly or
if your electrical configura-
tion does not comply with
local and state codes. You
MUST ensure compliance
by checking with a quali-
fied electrician!
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