Table of Contents
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INTRODUCTION ............................................... 2
Foreword ........................................................ 2
Contact Info ................................................... 2
G9901 Machine Data Sheet .......................... 3
G9902 Machine Data Sheet .......................... 5
G9903 Machine Data Sheet .......................... 7
Identification ................................................... 9
& Headstock Controls .................................. 11
& 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
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
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 G9903 ................... 57
Wiring Diagram ............................................ 58
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
Assembly Breakdown .................................. 67
Headstock Breakdown ................................. 70
System Breakdown ...................................... 73
System Breakdown ...................................... 75
One-Shot Oiler Breakdown .......................... 77
Accessories Breakdown & Parts List ........... 79
Label Placement .......................................... 80
WARRANTY AND RETURNS ........................ 85
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Table of Contents
