MODEL G9901/G9902/G9903 VERTICAL MILLING MACHINE w/power FEED OWNER'S MANUAL

Transcript

1 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.

2 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 comprehension, 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.

3 Table of Contents INTRODUCTION... 2 SECTION 1: SAFETY SECTION 2: POWER SUPPLY SECTION 3: SETUP SECTION 4: OPERATIONS SECTION 5: ACCESSORIES SECTION 6: MAINTENANCE SECTION 7: SERVICE SECTION 8: WIRING SECTION 9: PARTS WARRANTY AND RETURNS... 89

4 INTRODUCTION Manual Accuracy Contact Info your machine may not exactly match the manual Machine Description

5 G9901 Machine Data Sheet Customer Service #: (570) To Order Call: (800) Fax #: (800) Product Dimensions: Weight lbs. Width (side-to-side) x Depth (front-to-back) x Height x 59 x 85 in. Footprint (Length x Width) x 24 in. Shipping Dimensions: Type... Wood Crate Content... Machine Weight lbs. Length x Width x Height x 50 x 78 in. Electrical: Power Requirement V/220V, Single-Phase, 60 Hz Prewired Voltage V Full-Load Current Rating... 19A at 110V, 9.5A at 220V Minimum Circuit Size... 30A at 110V, 15A at 220V Switch... Forward/Reverse Switch Voltage V Cord Length... 6 ft. Cord Gauge gauge Plug Included... No Recommended Plug/Outlet Type... NEMA L5-30 for 110V, NEMA 6-15 for 220V Motors: Main Type... TEFC Capacitor Start Induction Horsepower... 2 HP Voltage /220V Prewired V Phase... Single Amps... 19/9.5A Speed RPM Cycle Hz Number of Speeds... 1 Power Transfer... Belt Drive Bearings... Shielded, Permanently Lubricated

6 Main Specifications: Operation Info Spindle Travel... 5 in. Swing in. Longitudinal Table Travel /8 in. Cross Table Travel /2 in. Knee Travel in. Ram Travel in. Ram Swivel Angle deg. Head Travel... 5 in. Head Swivel (Left-to-Right)... Left and Right 90 deg. Head Swivel (Front-to-Back)... Left and Right 45 deg. Turret or Column Swivel (Left and Right) deg. Maximum Distance Spindle to Column in. Maximum Distance Spindle to Table in. Drilling Capacity for Cast Iron /2 in. Drilling Capacity for Steel /4 in. Number of Vertical Spindle Speeds... 8 Range of Vertical Spindle Speeds... 78, 98, 197, 278, 670, 850, 1700, 2400 RPM Number of Longitudinal Feeds... Variable Feed Rate RPM Quill Diameter /8 in. Quill Feed Rates , , in. Table Info Table Length in. Table Width... 9 in. Table Thickness /4 in. Number of T-Slots... 3 T-Slots Width... 5/8 in. T-Slots Height... 7/8 in. T-Slots Centers /2 in. Stud Size... 1/2 in. Spindle Info Spindle Taper... R-8 Spindle Size... 5/8 in. End Milling Capacity... 7/8 in. Face Milling Capacity... 3 in. Drawbar Diameter... 7/16 in. Drawbar TPI Drawbar Length in. Spindle Bearings... Angular Contact Lead Screw Info Leadscrew Diameter /4 in. Leadscrew TPI... 5 Leadscrew Length in. Construction Spindle Housing/Quill... Cast Iron Table... Ground Cast Iron Head... Cast Iron Column... Cast Iron Base... Cast Iron Paint... Epoxy Other Collar Graduations in.

7 G9902 Machine Data Sheet Customer Service #: (570) To Order Call: (800) Fax #: (800) Product Dimensions: Weight lbs. Width (side-to-side) x Depth (front-to-back) x Height x 67 x 85 in. Footprint (Length x Width) x 24 in. Shipping Dimensions: Type... Wood Crate Content... Machine Weight lbs. Length x Width x Height x 50 x 78 in. Electrical: Power Requirement V/220V, Single-Phase, 60 Hz Prewired Voltage V Full-Load Current Rating... 26A at 110V, 13A at 220V Minimum Circuit Size... 30A at 110V, 15A at 220V Switch... Forward/Reverse Switch Voltage V Cord Length... 6 ft. Cord Gauge gauge Plug Included... No Recommended Plug/Outlet Type... NEMA L5-30 for 110V, NEMA 6-15 for 220V Motors: Main Type... TEFC Capacitor Start Induction Horsepower... 2 HP Voltage /220V Prewired V Phase... Single Amps... 26/13A Speed RPM Cycle Hz Number of Speeds... 1 Power Transfer... Belt Drive Bearings... Shielded, Permanently Lubricated

8 Main Specifications: Operation Info Spindle Travel... 5 in. Swing in. Longitudinal Table Travel /4 in. Cross Table Travel /2 in. Knee Travel in. Ram Travel in. Head Travel... 5 in. Head Swivel (Left-to-Right) deg. Head Swivel (Front-to-Back) deg. Turret or Column Swivel (Left and Right) deg. Maximum Distance Spindle to Column in. Maximum Distance Spindle to Table in. Drilling Capacity for Cast Iron /4 in. Drilling Capacity for Steel... 1 in. Number of Vertical Spindle Speeds... 8 Range of Vertical Spindle Speeds... 78, 98, 197, 278, 670, 850, 1700, 2400 RPM Number of Longitudinal Feeds... Variable Feed Rate FPM Quill Diameter /8 in. Quill Feed Rates , , in./rev. Table Info Table Length in. Table Width... 9 in. Table Thickness /4 in. Number of T-Slots... 3 T-Slots Width... 5/8 in. T-Slots Height... 7/8 in. T-Slots Centers /2 in. Stud Size... 1/2 in. Spindle Info Spindle Taper... R-8 Spindle Size... 5/8 in. End Milling Capacity... 1 in. Face Milling Capacity... 3 in. Drawbar Diameter... 7/16 in. Drawbar TPI Drawbar Length in. Spindle Bearings... Radial Ball Lead Screw Info Leadscrew Diameter /4 in. Leadscrew TPI... 5 Leadscrew Length in. Construction Spindle Housing/Quill... Cast Iron Table... Ground Cast Iron Head... Cast Iron Column... Cast Iron Base... Cast Iron Paint... Epoxy Other Collar Graduations in.

9 G9903 Machine Data Sheet Customer Service #: (570) To Order Call: (800) Fax #: (800) Product Dimensions: Weight lbs. Width (side-to-side) x Depth (front-to-back) x Height x 67 x 85 in. Footprint (Length x Width) x 24 in. Shipping Dimensions: Type... Wood Crate Content... Machine Weight lbs. Length x Width x Height x 50 x 78 in. Electrical: Power Requirement V/440V, 3-Phase, 60 Hz Prewired Voltage V Full-Load Current Rating A at 220V, 3.1A at 440V Minimum Circuit Size... 15A Switch... Forward/Reverse Switch Voltage V Cord Length... 6 ft. Cord Gauge gauge Plug Included... No Recommended Plug/Outlet Type... NEMA for 220V, Hardwire for 440V Phase Converter... G5841 Motors: Main Type... TEFC Induction Horsepower... 2 HP Voltage V/440V Prewired V Phase... Three Amps A at 220V, 3.1A at 440V Speed RPM Cycle Hz Number of Speeds... 1 Power Transfer... Variable Speed Belt Drive Bearings... Shielded, Permanently Lubricated

10 Main Specifications: Operation Info Spindle Travel... 5 in. Swing in. Longitudinal Table Travel in. Cross Table Travel /2 in. Knee Travel in. Ram Travel in. Ram Swivel Angle deg. Head Travel... 5 in. Head Swivel (Left-to-Right)... Left and Right 90 deg. Head Swivel (Front-to-Back)... Left and Right 45 deg. Turret or Column Swivel (Left and Right) deg. Maximum Distance Spindle to Column in. Maximum Distance Spindle to Table in. Drilling Capacity for Cast Iron /4 in. Drilling Capacity for Steel... 1 in. Number of Vertical Spindle Speeds... Variable Range of Vertical Spindle Speeds RPM Number of Longitudinal Feeds... Variable Feed Rate RPM Quill Diameter /8 in. Quill Feed Rates , , in. Table Info Table Length in. Table Width... 9 in. Table Thickness /4 in. Number of T-Slots... 3 T-Slots Width... 5/8 in. T-Slots Height... 7/8 in. T-Slots Centers /2 in. Stud Size... 1/2 in. Spindle Info Spindle Taper... R-8 Spindle Size... 5/8 in. End Milling Capacity... 1 in. Face Milling Capacity... 3 in. Drawbar Diameter... 7/16 in. Drawbar TPI Drawbar Length in. Spindle Bearings... Radial Ball Lead Screw Info Leadscrew Diameter /4 in. Leadscrew TPI... 5 Leadscrew Length in. Construction Spindle Housing/Quill... Cast Iron Table... Ground Cast Iron Head... Cast Iron Column... Cast Iron Base... Cast Iron Paint... Epoxy Other Collar Graduations in.

11 Identification Figure 1. A. B. C. D. E. F. G. H. I. J. K.

12 Figure 2. L. M. N. O. P. Q. R. S. T.

13 G9901/G9902 Drive System & Headstock Controls Figure 3. A. B. C. D. E. F. G. H. I. J. K. L.

14 G9903 Drive System & Headstock Controls Figure 4. A. B. C. D. E. F. G. H. I. J. K. L. M. N. O.

15 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. NOTICE 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. Safety Instructions for Machinery OWNER S MANUAL. EYE PROTECTION. HAZARDOUS DUST. WEARING PROPER APPAREL. HEARING PROTECTION. MENTAL ALERTNESS.

16 DISCONNECTING POWER SUPPLY. APPROVED OPERATION. DANGEROUS ENVIRONMENTS. ONLY USE AS INTENDED. USE RECOMMENDED ACCESSORIES. CHILDREN & BYSTANDERS. REMOVE ADJUSTING TOOLS. SECURING WORKPIECE. FEED DIRECTION. FORCING MACHINERY. GUARDS & COVERS. NEVER STAND ON MACHINE. STABLE MACHINE. AWKWARD POSITIONS. UNATTENDED OPERATION. OFF MAINTAIN WITH CARE. CHECK DAMAGED PARTS. EXPERIENCING DIFFICULTIES.

17 Additional Safety Instructions For Mills UNDERSTANDING CONTROLS. SAFETY ACCESSORIES. WORK HOLDING. MACHINE CARE AND MAINTENANCE. DISCONNECT POWER. CHUCK KEY SAFETY. SPINDLE SPEEDS. POWER DISRUPTION. SPINDLE DIRECTION CHANGES. STOPPING SPINDLE. CLEAN-UP. AVOIDING ENTANGLEMENT. TOOL HOLDING. CUTTING TOOL INSPECTION. BE ATTENTIVE. EXPERIENCING DIFFICULTIES. 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.

18 Glossary of Terms VERY Arbor: Collet: Cutting Speed: Dial Indicator: Dividing Head: Down or Climb Milling: End Milling: Face Milling: Feed Rate: Fixture: Form Milling: Gang Milling: Gib: Headstock: Knee: Lead Screw: Peripheral Milling: Ram: Saddle: Side Milling: Slitting and Cutting Off: Spindle: Turret: Ways: X, Y, and Z-Axis:

19 SECTION 2: POWER SUPPLY G9901/G9902 Availability Electrocution, fire, or equipment damage may occur if machine is not correctly grounded and connected to the power supply. Full-Load Current Rating Circuit Information For your own safety and protection of property, consult a qualified electrician if you are unsure about wiring practices or electrical codes in your area. G9901: Full-Load Current Rating at 220V Amps Full-Load Current Rating at 110V Amps G9902: Full-Load Current Rating at 220V Amps Full-Load Current Rating at 110V Amps

20 Note: The circuit requirements listed in this manual apply to a dedicated circuit where only one machine will be running at a time. If this machine will be connected to a shared circuit where multiple machines will be running at the same time, consult a qualified electrician to ensure that the circuit is properly sized for safe operation. G9901 Circuit Requirements for 220V Nominal Voltage V/240V Cycle...60 Hz Phase... Single-Phase Circuit Rating Amps Plug/Receptacle... NEMA 6-15 G9901 Circuit Requirements for 110V Voltage Conversion G9902 Circuit Requirements for 220V Nominal Voltage V/240V Cycle...60 Hz Phase... Single-Phase Circuit Rating Amps Plug/Receptacle... NEMA 6-15 G9902 Circuit Requirements for 110V Voltage Conversion Nominal Voltage...110V/120V Cycle...60 Hz Phase... Single-Phase Circuit Rating Amps Plug/Receptacle...NEMA L5-30 Nominal Voltage...110V/120V Cycle...60 Hz Phase... Single-Phase Circuit Rating Amps Plug/Receptacle...NEMA L5-30

21 Grounding Requirements For 220V operation: GROUNDED 6-15 RECEPTACLE 6-15 PLUG Figure 1. No adapter should be used with the provided plug. If the plug does not fit the available receptacle, or the machine must be reconnected for use on a different type of circuit, the reconnection must be made by a qualified electrician and comply with all local codes and ordinances. For 110V operation: L5-30 GROUNDED LOCKING RECEPTACLE L5-30 LOCKING PLUG Figure 2.

22 Extension Cords Minimum Gauge Size at 220V...12 AWG Minimum Gauge Size at 110V...10 AWG Maximum Length (Shorter is Better)...50 ft. Voltage Conversion If the diagram included on the motor conflicts with the one in this manual, the motor may have changed since the manual was printed. Use the diagram provided on the motor. G9903 Availability Electrocution, fire, or equipment damage may occur if machine is not correctly grounded and connected to the power supply. Full-Load Current Rating Full-Load Current Rating at 220V Amps Full-Load Current Rating at 440V Amps

23 Circuit Requirements for 220V Nominal Voltage V/240V Cycle...60 Hz Phase... 3-Phase Circuit Rating Amps Plug/Receptacle...NEMA Cord...4-Wire, 14 AWG, 300VAC, S -Type Circuit Requirements for 440V Voltage Conversion Nominal Voltage V/480V Cycle...60 Hz Phase... 3-Phase Circuit Rating Amps Grounding Requirements For 220V operation: GROUNDED RECEPTACLE PLUG Figure 3. For your own safety and protection of property, consult a qualified electrician if you are unsure about wiring practices or electrical codes in your area. Note: The circuit requirements listed in this manual apply to a dedicated circuit where only one machine will be running at a time. If this machine will be connected to a shared circuit where multiple machines will be running at the same time, consult a qualified electrician to ensure that the circuit is properly sized for safe operation. No adapter should be used with the provided plug. If the plug does not fit the available receptacle, or the machine must be reconnected for use on a different type of circuit, the reconnection must be made by a qualified electrician and comply with all local codes and ordinances.

24 For 440V Operation: Voltage Conversion If the diagram included on the motor conflicts with the one in this manual, the motor may have changed since the manual was printed. Use the diagram provided on the motor. Figure 4.

25 SECTION 3: SETUP This machine presents serious injury hazards to untrained users. Read through this entire manual to become familiar with the controls and operations before starting the machine! Wear safety glasses during the entire setup process! Your milling machine is very heavy. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use a forklift to move the shipping crate and remove the machine from the crate. Needed for Setup Description Qty Unpacking please call us immediately at (570) for advice. Otherwise, filing a freight claim can be difficult. SUFFOCATION HAZARD! Keep children and pets away from plastic bags or packing materials unpacked with this machine. Discard immediately.

26 Inventory Clean Up Inventory: (Figure 5) Qty A. B. C. D. E. F. G. H. I. For optimum performance from your machine, 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. DO NOT use these products to clean the machinery. Many cleaning solvents are toxic if inhaled. Minimize your risk by only using these products in a well ventilated area. Figure 5. NOTICE If you cannot find an item on this list, check the mounting location on the machine or the packaging materials. Sometimes parts are pre-installed for shipping, or they become hidden by packaging materials. G7895 Grizzly Citrus Degreaser Figure 6.

27 Site Considerations Floor Load Machine Data Sheet Placement Location Figure 7 To reverse the table ball handles: Table Ball Handles Note: Use a 24mm wrench for the left Y-axis (longitudinal) ball handle acorn nut and a 19mm wrench for the other two. Figure 8 Note: Take care to align the keyway of the ball handle to the lead screw key. Figure 7. Item Dimension A. B. C. D Figure 8. Children and visitors may be seriously injured if unsupervised around this machine. Lock entrances to the shop or disable power connection to prevent unsupervised use.

28 Lifting & Moving Mill 3. Your milling machine is very heavy. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use a forklift to move the shipping crate and remove the machine from the crate. To lift and move your mill using lifting straps: To lift and move your mill using the eye bolt: 1. Figure 10 Ram Movement Page Figure 9 Figure Figure 9. Ram Movement Page 34 To reduce the risk of serious personal injury and property damage if the mill should fall during moving, only lift the mill enough to clear the shipping pallet and floor Figure 10

29 Mounting to Shop Floor Bolting to Concrete Floors Figure 11 Using Machine Mounts Figure 12 Figure12 NOTICE We strongly recommend securing your machine to the floor if it is hardwired to the power source. Consult with your electrician to ensure compliance with local codes. Figure11. NOTICE When using mounting bolts, use shims between the mill base and the floor to fill the gaps. Otherwise, the cast iron base could become warped and crack when tightening the mounting fasteners.

30 Test Run TroubleshootingPage ON To test run the machine: LubricationPage 45 Figures 28 & 29Page 36 Downfeed Operations Page OFF To test the power feed unit and table limit switch: Table Movement Page 31

31 Note: Alternatively, you can push in the limit switch plunger with a tool not your finger to make sure table movement will stop when the limit switch is activated. Spindle Break-In NOTICE Complete the spindle break-in procedure to avoid rapid deterioration of spindle components when placed into operation. To perform the spindle break-in procedure: Test Run Page 28 OFF Figures 28 & 29Page 36 ON OFF ON OFF

32 SECTION 4: OPERATIONS Operation Safety Operation Tips Follow these tips for safe and productive operations: Damage to your eyes could result from using this machine without proper protective gear. Always wear safety glasses or face shield when operating this machine. Loose hair and clothing could get caught in machinery and cause serious personal injury. Keep loose clothing and long hair away from moving machinery. NOTICE If you have never used this type of machine or equipment before, WE STRONGLY REC- OMMEND 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. Lubrication beginning Page 45 OFF

33 Table Movement Figure 13 Figure 14. Figure 13. Figure 15. Figures Always keep the table locked in place unless table movement is required for your operation. Unexpected table and workpiece movement could cause the cutter to bind and break apart, resulting in personal injury to the operator. Figure 16.

34 Figure 17 Stay clear of manual ball handles when using power feeds to avoid entanglement and personal injury. To operate the X-axis power feed: 1. Figure 18 Figure 17. A. Limit Switch. B. Limit Stop. C. Rapid Traverse Button. D. Directional Lever. E. Speed Dial. F. ON/OFF Switch. G. Ball Handle. H. Travel Graduated Dial. 2. Before running your power feed, be sure there is enough running clearance between the table, spindle, vise/clamps or jigs. Be aware that all of these objects represent potential pinch points Figure 18. ON

35 6. To tilt the headstock backward or forward: Figure 21 Note: Power feed rates are difficult to precisely adjust. We recommend that you experiment with different dial settings to find the feed rates that best work for your operation. 8. OFF Headstock Movement Figures Figure Figure Note: Turn the tilt bolt clockwise to tilt the headstock forward and counterclockwise to tilt the headstock back. Figure 19. Always lock the headstock firmly in place after adjusting the tilt or rotation. If the headstock slips during milling operation, the spinning cutter could bind and break apart, causing serious personal injury or property damage. Figure 20.

36 To rotate the headstock right or left: Figure 22 To move the ram forward or backward horizontally: Figure Figure 22. Figure Figure 23. Figure 23 Note: Turn the rotation bolt clockwise to rotate the headstock to the right and counterclockwise to rotate the headstock to the left. To rotate the ram around the column: Figure 24 Ram Movement Always lock the ram firmly in place after adjusting its position. If the headstock slips during milling operation, the spinning cutter could bind and break apart, causing serious personal injury or property damage. 3. Figure 24.

37 Setting RPM Calculating RPM 1. Figure 25 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. Figure 25. Selecting Spindle Speed Range OFF Model G9901/G9902 Spindle Speed Ranges (RPM) Figure 26. Model G9903 Spindle Speed Ranges (RPM) Figure 27.

38 When changing the spindle speed range, the spindle direction will reverse. Always know which way the spindle is spinning before engaging the cutting tool with your workpiece. 3. Figures Note: For the Model G9903, you must press the speed range lever in toward the headstock to retract the locking pin and move it. It may be necessary to rotate the spindle by hand to ensure the speed range gears have properly engaged. Figure 29. NOTICE Your milling machine is not designed to run in the neutral position of the speed range lever. Doing so may cause damage to the drive gears. Configuring Spindle Speed Controls (G9901 & G9902) Figure 30 Figure 28. NOTICE To avoid damage to the drive gears, make sure the mill is turned OFF and the spindle is stopped before you change the spindle speed range. Figure 30.

39 3. Figure Figure Figure 31 Figure 32 To avoid an entanglement hazard, always operate the Model G9901/G9902 mill with the two side belt covers in place. Configuring Spindle Speed Controls (G9903) 1. Figure 33 NOTICE To avoid damage to the variable speed system on the Model G9903 mill, always have the spindle in motion when changing the spindle speed. Figure 33. Figure 32. Note: Each speed range has an indicator window that shows the spindle speed as selected.

40 Downfeed Controls Coarse Downfeed Handle 1. OFF Figure Figure 34 Note: It may be necessary to rotate the spindle by hand to ensure the downfeed selector gears have properly engaged. Figure Figure 36 When changing the spindle speed range, the spindle direction will reverse. Always know which way the spindle is spinning before moving the cutting tool into the workpiece. Figure 34.

41 Figure 36 Fine Downfeed Handwheel 1. OFF 2. Figure Figure Figure 36. A. Power Downfeed Rate Dial: Note: The downfeed clutch will stay engaged until either you push the lever to the right, or the quill dog engages the downfeed stop. B. Fine Downfeed Handwheel: C. Power Downfeed Direction Pin: D. Quill Dog: E. Downfeed Stop: F. Quill Locking Lever: G. Downfeed Stop Locking Thumb Wheel: Power Downfeed System OFF ON When changing the spindle speed range, the spindle direction will reverse. Always know which way the spindle is spinning before moving the cutting tool into the workpiece. H. Downfeed Clutch Lever:

42 7. Figure 38 Dial Position Feed Rate (inches/spindle revolution) Figure 37. Spindle Brake OFF, Figure 39 & Figure 38. Note: When the spindle speed range is changed, the spindle direction will reverse and so will the power downfeed direction. Note: When using the power downfeed, the spindle will automatically return to the top when the quill dog reaches the downfeed stop. The accuracy of the power feed to the downfeed stop is ±0.010". Figure 39. NOTICE To avoid premature wear of the brake pads, use the spindle brake ONLY after power to the spindle has been turned OFF. NOTICE To avoid damage to the downfeed gearing, DO NOT use the power downfeed system for spindle speeds over 2400 RPM. Figure 40.

43 Loading/Unloading Tools 5. Figure 42 Figure Figure 42. Figure 41. To load a tool into the spindle: Note: Only tighten the drawbar until it is snug. Overtightening the drawbar could make removing the tool difficult. To unload a tool: Note: If the tool does not immediately release from the spindle when the drawbar is loosened, you may need to strike the top of the drawbar with a dead blow hammer or rubber mallet.

44 SECTION 5: ACCESSORIES H2689 R-8 Quick Change Collet Set G PC. Clamping Kit Figure 45. Figure 43. G " Yuasa-Type Rotary Table H Axis Digital Read Out (12" x 30") H Axis Digital Read Out (12" x 30" x 5") H Axis Digital Read Out (12" x 30" x ") μ Figure 44. Figure 46.

45 G2861 Face Mill G4051 Carbide Insert for Face Mill G Blocks G9815 Parallel Set H5556 Edge Finder Set Figure 47. G PC. 2 & 4 Flute TiN End Mill Set. Figure 50. G5562 SLIPIT 1 Qt. Gel G5563 SLIPIT 12 oz Spray G2871 Boeshield T-9 12 oz Spray G2870 Boeshield T-9 4 oz Spray H3788 G96 Gun Treatment 12 oz Spray H3789 G96 Gun Treatment 4.5 oz Spray Figure 48. G PC. Ball End Mill Set Figure 51. Figure 49.

46 SECTION 6: MAINTENANCE Every 40 Hours of Operation: Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious personal injury. Every 8 Hours of Operation: Schedule Lubrication Page 45 Every 1000 Hours of Operation: Cleaning and Protecting Replacing Belts Page 55 & 56 Lubrication Page 45 ACCESSORIES Page 42

47 Lubrication Overview Lubrication Tasks Downfeed Gearing and Spindle Bearings 1. Figure 52 Note: This recommended lubrication schedule is based on light to medium mill usage. Keeping in mind that lubrication helps to protect the value and operation of your mill, you may need to perform lubrication tasks more frequently depending on usage. 2. Figures 53 & 54 Lubrication Task Hours of Use Figure 52. NOTICE Failure to follow reasonable lubrication practices as outlined in this manual for your mill could lead to premature failure of your mill and will void the warranty. Figure 53. Figure 54.

48 3. 4. Note: Do not attempt to fill the cavity leading to the oil cup. Keeping the cotton string soaked with oil will slowly lubricate the related devices. Table Ways and Lead Screws Figure Figure Ram Dovetail Way Figure 57 Figure Note: There should be a thin film of oil on the table ways when adequately lubricated. Elevation Lead Screw 1. Figure 56 Figure 57.

49 Spindle Spline Figures 58 & 59 Power Feed Gearing Figure 60 Figure 58. Figure 60. Figure 59.

50 3. 4. Note: Make sure to remove and retain the small alignment key from lead screw (see Figure 61). Figure 62. Figure Step 2 5. Figure 62 9.

51 Speed Range Gearing Figures 63 & 64 Coolant Figure 63. Coolant fluid is a potent and extremely poisonous solution to humans and animals. Use personal protective equipment when handling coolant fluid to prevent infections or poisoning. Figure

52 SECTION 7: SERVICE Troubleshooting Motor & Electrical OFF ON Page 35 Page 55 & 56

53 Operation and Work Results Page 55 & 56 Page 35 SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Page 35 Page 35 Page 52 Page 35

54 Adjusting Gibs NOTICE Excessively loose gibs may cause poor finishes on the workpiece, and may cause undue wear of sliding surfaces and ways. Over-tightening the gibs may cause premature wear of these sliding devices. Figure 65. Note: To access the cross and elevation gib adjusting screws, you must remove the covering way wipers. The ram gib does not need adjustment. The horizontal locking bolts apply force when tight, and allow the gib to slide along the dovetail way when loose. Figure 66. Figures Figure 67.

55 Adjusting Backlash To adjust the Y-axis lead screw backlash: 1. To adjust the X-axis lead screw backlash: Figure Figure 68 Note: Align the device keyways with the lead screw key as you slide them off. Figure 69. Figure 68. Note: The bottom screw adjusts the amount of backlash, and the top screw, when tightened down, locks the bottom screw setting. 4. Figure Steps 3 4 Figure 70.

56 5. Figure 71 Adjusting Downfeed Clutch Lever To adjust the downfeed clutch lever: Figure 71. Note: The bottom screw adjusts the amount of backlash; and the top screw, when tightened down, locks the bottom screw setting Figure Steps 6 7 Note: Take care not to damage the mating surfaces of the mounting plate assembly bearings and the lead screw Figure 72. Page

57 Replacing Belts G9901 & G9902 Part Description Part Number To replace the belts: Figure Figure Note: Push down on the ribbed timing belt as you lift the spindle pulley assembly up to prevent it from binding. 8. Replacing Brake Shoes G9901 & G9902 Page Figure 73. Figure

58 Replacing Belts G9903 Part Description Part Number 4. Figure 76 Note: Tighten the bolts evenly, in small increments, to compress the spring. For example, turn one bolt two turns, then turn the other bolt two turns. To replace the belts: Figure Figure 76. Figure Figure 75.

59 7. Figure Figure Figure 77. Figure 78 Figure Figure 80 Figure 78. Note: Carefully pry up on the upper bearing housing, rotate it, and repeat this process until the housing comes free from the mill. Figure 80.

60 Note: If necessary, replace the brake shoes before replacing the belts. Refer to Replacing Brake Shoes G9903 on Page 60 for detailed instructions. 15. Figure Step Figure 81. Note: Be sure to remove the two M6-1 x 60 bolts after securing the retaining spring plate hex nut. 16. Figure 82 Figure 82.

61 Replacing Brake Shoes G9901 & G9902 To replace the brake shoes: 5. Figure Steps 2 7 Replacing Belts G9901 & G9902 Page 55 Note: There are four springs that may fall out when you flip the transmission case cover plate over. Do not lose these. 3. Figure Figure 85 Figure 85. Figure Figure Figure 85 Steps 9 11 Replacing Belts G9901 & G9902 Page 55

62 Replacing Brake Shoes G Figure 87 To replace the brake shoes: Steps 1 14 Replace Belts G9903 Page 56 Figure Figure 87. Step 3 5. Figure Step 2 7. Steps Replacing Belts G9903 Page 56 Figure 86.

63 SECTION 8: WIRING Note: Please gather the serial number and manufacture date of your machine before calling. This information can be found on the main machine label. Wiring Safety Instructions SHOCK HAZARD. MODIFICATIONS. WIRE CONNECTIONS. WIRE/COMPONENT DAMAGE. MOTOR WIRING. CAPACITORS/INVERTERS. CIRCUIT REQUIREMENTS. EXPERIENCING DIFFICULTIES. The photos and diagrams included in this section are best viewed in color. You can view these pages in color at

64 G9901/G V, Single-Phase Wiring Diagram Figure 89. G9902 Figure 88. G9901 READ ELECTRICAL SAFETY ON PAGE 61!

65 G9901/G V, Single-Phase Wiring Diagram READ ELECTRICAL SAFETY ON PAGE 61!

66 G V, 3-Phase Wiring Diagram Figure 90. READ ELECTRICAL SAFETY ON PAGE 61! Figure 91.

67 G V, 3-Phase Wiring Diagram READ ELECTRICAL SAFETY ON PAGE 61!

68 SECTION 9: PARTS Body Assembly Breakdown

69 Body Assembly Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P TAPERED PIN 8 X P WIPER 2 PSB84M CAP SCREW M X P VERTICAL GIB 3 P WORM GEAR 20T 55-1 P GIB SCREW M X 40 4 P RAM ADAPTER 56 PS14M PHLP HD SCR M6-1 X 12 5 P GRADUATED SCALE 58 P SMALL CHIP GUARD 6 P WORM GEAR 60 P MEDIUM CHIP GUARD 7 P FLANGE 61 P LARGE CHIP GUARD 8 PSB01M CAP SCREW M6-1 X P CLAMPING PLATE 9 P RETAINING RING 64 PN01M HEX NUT M P TAPERED SET SCREW M5-.8 X PSS25M SET SCREW M6-1 X P RAM 66 PSB155M CAP SCREW M X P TURRET 67 P KNEE 13 PSB14M CAP SCREW M X P LOCK PIN 14 P TAPER PIN 8 X P PHLP HD SCR M X P GRADUATED SCALE 72 PSS03M SET SCREW M6-1 X 8 16 P RIVET 2 X 5 73 P LEVER HUB 17 P SHAFT 74 P LEVER BOLT M X P HEX BOLT M16-2 X PN09M HEX NUT M PK10M KEY 5 X 5 X PK34M KEY 5 X 5 X P CLAMPING SLEEVE 77 PLW05M LOCK WASHER 12MM 30 P TABLE (G9901) 77-1 PW06M FLAT WASHER 12MM 30 P TABLE (G9902/G9903) 78 P SPECIAL BEVEL GEAR 31 P T-SLOT BOLT M X P SPECIAL WASHER 32 P TABLE STOP 80 P VERTICAL LEAD SCREW 33 PN03M HEX NUT M P BUSHING 36 PSB129M CAP SCREW M X P6206-2RS BALL BEARING RS 37 P HANDLE KNOB 83 P BEARING RETAINER RING 37-1 P HANDLE BOLT M X PSB155M CAP SCREW M X PSS03M SET SCREW M6-1 X 8 85 PSS03M SET SCREW M6-1 X 8 39 PSB163M CAP SCREW M X P HANDLE KNOB 40 PSB11M CAP SCREW M X P HANDLE 41 P GIB SCREW M X P CLUTCH 42 P TABLE STOP BRACKET 90 P SPECIAL NUT M33 X P LONGITUDINAL GIB (G9901) 91 P GRADUATED DIAL 43 P LONGITUDINAL GIB (GG902/G9903) 92 P BUSHING 44 P WIPER 93 PR25M INT RETAINING RING 47MM 45 P SPECIAL PIN 94 P REGULATING RING 46 P LOCKING PIN 95 P62042RZ BALL BEARING 62042RZ 47 P LOCKING SCREW M X PSB01M CAP SCREW M6-1 X P LOCKING LEVER 97 P BEARING COVER 49 P CROSS GIB 98 PK08M KEY 5 X 5 X P WIPER HOLDER 99 P SHAFT 51 PS05M PHLP HD SCR M5-.8 X P62042RZ BALL BEARING 62042RZ 52 P SADDLE 101 P SPECIAL WASHER 53 P WIPER HOLDER 102 P SPIRAL BEVEL GEAR

70 REF PART # DESCRIPTION REF PART # DESCRIPTION 103 PSB64M CAP SCREW M X PW06M FLAT WASHER 12MM 104 P KNEE SUPPORT 124 P ROTARY DISC 105 P THREADED BUSHING 125 P KEY 6 X 10 X P OIL CUP 6MM 126 P CLAMPING BLOCK 107 PSB155M CAP SCREW M X P CLAMPING BLOCK 108 P COLUMN 128 PRP100M ROLL PIN 3 X P GRADUATED SCALE 129 P SPECIAL BOLT M X P SPIDER GEAR PN09M HEX NUT M P SPECIAL BOLT M X PSS06M SET SCREW M X P GEAR SHAFT 917 P FORWARD/REVERSE SWITCH 121 P LEVER 918 P SWITCH BOX 122 P LEVER KNOB

71 Table Assembly Breakdown

72 Table Assembly Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 30 P TABLE (G9901) 219 PK12M KEY 5 X 5 X P TABLE (G9902/G9903) 220 P THREADED CONICAL PIN 8 X PN45 ACORN NUT 1/ PSS14M SET SCREW M X PN46 ACORN NUT 5/ P CROSS LEAD BRACKET 202 P HANDLE 223 P CROSS LEAD SCREW 203 P HANDLE BODY 224 P WOODRUFF KEY 204 P SPECIAL NUT M33 X PSB18M CAP SCREW M4-.7 X P GRADUATED DIAL 226 P BEARING BRACKET 206 P BUSHING 227 PSB130M CAP SCREW M X PSB11M CAP SCREW M X P BUSHING 208 P FLANGE 229 P BUSHING 209 P62042RZ BALL BEARING 62042RZ 230 P BEARING RETAINER RING 210 P SPACER 231 PSB155M CAP SCREW M X P SPACER 232 P GRADUATED DIAL 212 PSB61M CAP SCREW M X P SPECIAL NUT M33 X P LEFT TABLE BRACKET 234 P HANDLE BODY 214 PK31M KEY 4 X 4 X P RIGHT TABLE BRACKET 215 P LONG. LEAD SCREW (G9901) 236 P62042RZ BALL BEARING 62042RZ 215 P LONG. LEAD SCREW (G9902) 237 P SPACER 215V2 P V2 LONG. LEAD SCREW (G9903) 238 P BUSHING 216 P ADJUSTING SCREW M X P GRADUATED DIAL 217 P THREADED BUSHING 1-1/ P NUT 1-1/4" 218 P THREADED BUSHING 1-1/ P NUT 1-1/4"

73 Model G9901/G9902 Drive Assembly Breakdown

74 Model G9901/G9902 Drive Assembly Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 301 P DRAWBAR 24-3/ PN01M HEX NUT M P DRAWBAR SPACER PSB24M CAP SCREW M5-.8 X P SPECIAL NUT M33 X PLW01M LOCK WASHER 5MM 304 P SPECIAL NUT M60 X PRP76M ROLL PIN 4 X P7007-OPEN-P5 BALL BEARING 7007-OPEN-P P HOLDER M6-1 X P SPACER 344 PW06M FLAT WASHER 12MM 307 P SPACER P THICK HEX NUT M12 X P60072RS BALL BEARING RS 345 P HANDLE 309 P SPRING P HANDLE KNOB 311 P BEARING BRACKET 346 PSS03M SET SCREW M6-1 X PSB58M CAP SCREW M X P MOTOR PULLY 315 P SPRING 348 P SPECIAL WASHER 316 PRP11M ROLL PIN 2.5 X PR88M INT RETAINING RING 8MM 317 P BRAKE LOCK STUD 350 PB07M HEX BOLT M X P BRAKE SHOE 351 P COTTON CORE TYPE OIL CAP 319 P SPINDLE PULLEY 352 P OIL CUP ADAPTER 320 P COUPLING SHAFT 353 P COPPER TUBE 321 PK149M KEY 8 X 8 X PS68M PHLP HD SCR M6-1 X PVA32 V-BELT A-32 4L P COVER 323 P RIBBED TIMING BELT 356 PK40M KEY 8 X 8 X P PULLEY FLANGE 357 P WORM COUPLING SHAFT 325 P TIMING BELT PULLEY 358 P BULL GEAR 326 P TABBED LOCK WASHER 16MM 359 PSB01M CAP SCREW M6-1 X PSS31M SET SCREW M5-.8 X P THREADED CONICAL PIN 8 X P FLANGE NUT M P BEARING BRACKET 329 P HANDLE KNOB 362 P6203 BALL BEARING 6203ZZ 330 PSS81M SET SCREW M3-.5 X PR23M INT RETAINING RING 40MM 331 P HANDLE HUB 364 P SPLINE SHAFT P HANDLE 365 P WOODRUFF KEY 5 X P PIN 366 P PINION 333 P BUSHING 367 P6203 BALL BEARING 6203ZZ 334 P SPECIAL WASHER 368 P PLUG 335 P TRANSMISSION COVER PLATE 371 P THRUST BEARING 40 X 68 X P TAPERED PIN 10 X P TABBED LOCK WASHER 39MM 337 PSB130M CAP SCREW M X P FLANGE NUT M P MOTOR RING 375 P COVER 339 P HANDLE 376 PSB26M CAP SCREW M6-1 X P HANDLE KNOB 377 P FLANGE RING SMALL 341 P STUD M X P FLANGE RING LARGE 342 P BELT HOUSING 379 P SHIFTER FORK 343 P RIGHT BELT COVER 380 PRP16M ROLL PIN 3 X P LEFT BELT COVER 381 P CONNECTING BAR P SPRING PLATE 385 P BRACKET P BRACKET 386 PSB03M CAP SCREW M5-.8 X PN06M HEX NUT M P SHIM

75 REF PART # DESCRIPTION REF PART # DESCRIPTION 388 P SHAFT BRACKET 398 P SPRING 389 P TAPERED PIN 8 X P HANDLE 390 PSB11M CAP SCREW M X P HANDLE KNOB 391 P LEVER BRACKET 500 RM MOTOR 2HP,110/220V,1-PH 392 PRP22M ROLL PIN 4 X P MOTOR FAN 393 P ECCENTRIC BLOCK P MOTOR FAN COVER 394 P CONICAL PIN P S. CAP CD60,150MFD,265VAC 395 P PIN P R. CAP CBB60,20MFD,450VAC 396 PRP56M ROLL PIN 4 X P WIRING/CAPACITOR JUNCTION BOX 397 P SPANNER SHAFT P TERMINAL BOARD

76 Headstock Breakdown

77 Headstock Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 501 PN01M HEX NUT M P BEVEL GEAR 502 PLW03M LOCK WASHER 6MM 552 P BUSHING 503 P BEVEL GEAR 553 PSS01M SET SCREW M6-1 X P BUSHING 554 PSS03M SET SCREW M6-1 X P BUSHING 555 P SLIDE ROD 506 PSS31M SET SCREW M5-.8 X PRP43M ROLL PIN 3 X P WORM GEAR SPACER 557 P HOLLOW SHAFT 508 P WORM GEAR 560 P SMALL SHAFT 509 P SHAFT 561 PSS26M SET SCREW M5-.8 X PK103M KEY 3 X 3 X P PIN 511 PK98M KEY 3 X 3 X P SLIDE 512 PN03M HEX NUT M P ECCENTRIC WHEEL 513 PW01M FLAT WASHER 8MM 565 P CLUSTER GEAR COVER 514 PK103M KEY 3 X 3 X PSS41M SET SCREW M X P BEVEL GEAR 567 P COMPRESSION SPRING 516 P FEED ENGAGE PIN 568 P STEEL BALL 3/16" 517 P WORM GEAR SUPPORT 569 PSB24M CAP SCREW M5-.8 X P SHAFT 570 P DIAL KNOB 519 P FLANGE 571 PSS26M SET SCREW M5-.8 X P PLUNGER 572 PSS26M SET SCREW M5-.8 X P SPRING 573 PSB78M CAP SCREW M5-.8 X PRP42M ROLL PIN 3 X P THREAD PIN 523 P SHIFTER CRANK 575 P SLEEVE 524 P HANDLE KNOB 576 PSS03M SET SCREW M6-1 X PSB33M CAP SCREW M5-.8 X P PLUG 4X2 526 PSS03M SET SCREW M6-1 X P SPECIAL NUT M22 X P BUSHING 579 P SPRING 528 P GEAR 580 P CLUTCH 529 P GEAR 581 P COUPLING SHAFT 530 P GEAR 582 P KEY 531 PK150M KEY 3 X 3 X PS56M PHLP HD SCR M4-.7 X PSS03M SET SCREW M6-1 X PLW02M LOCK WASHER 4MM 533 P BEVEL GEAR SHAFT 585 PSS04M SET SCREW M6-1 X PR02M EXT RETAINING RING 14MM 586 PSS04M SET SCREW M6-1 X P BUSHING 587 P ADJUSTING WASHER 536 P GEAR 588 P COMPRESSION SPRING 537 PK96M KEY 3 X 3 X P TOP PIN 538 P GEAR SHAFT 590 P SLEEVE 539 PK03M KEY 3 X 3 X P THRUST BEARING 15 X 28 X P GEAR 592 P FEED WORM GEAR 541 P BUSHING 593 P CLUTCH 542 P BUSHING 594 PRP24M ROLL PIN 5 X P WORM GEAR 595 PRP39M ROLL PIN 4 X PSB28M CAP SCREW M6-1 X P CONNECTING ROD 545 PRP02M ROLL PIN 3 X P SPECIAL WASHER 10MM 546 P BUSHING 598 PR01M EXT RETAINING RING 10MM 547 P SPECIAL WASHER 599 P COVER 548 P SLEEVE 600 PSS91M SET SCREW M6-1 X P BEVEL GEAR 601 PN01M HEX NUT M P REVERSE CLUTCH 602 PRP03M ROLL PIN 5 X 20

78 REF PART # DESCRIPTION REF PART # DESCRIPTION 603 P LEVER 651 PR13M EXT RETAINING RING 65MM 604 P HANDLE 652 P QUILL LOCK BOLT M X P HANDLE KNOB 653 P LOCK SLEEVE 606 P BRACKET 654 P SPECIAL SCREW M6-1 X PSB27 CAP SCREW 5/8-11 X 2-1/2 655 P T-SLOT BOLT M X PSS03M SET SCREW M6-1 X P SLEEVE 609 PK29M KEY 4 X 4 X PN09M HEX NUT M P FEED REVERSE KNOB STUD 658 PS17M PHLP HD SCR M4-.7 X P REVERSE KNOB 659 P SCALE 612 P PIN 660 PR05M EXT RETAINING RING 15MM 613 P RETAINING RING 661 P ADJUSTING NUT 614 P STEEL BALL 3/16" 662 P DIAL 615 P SPRING 663 P STOP KNOB 616 PSS16M SET SCREW M X P QUILL LEAD SCREW 617 PRP76M ROLL PIN 4 X PSB130M CAP SCREW M X P T-ROD 666 P SHAFT 620 P SPRING 1.2 X 10 X PK34M KEY 5 X 5 X P SHAFT 668 PSS16M SET SCREW M X P BUSHING 669 P PIN 623 P BUSHING 670 PRP24M ROLL PIN 5 X P PLUNGER 671 PK34M KEY 5 X 5 X P HANDWHEEL 672 PB136M HEX BOLT M4-.7 X P HANDWHEEL HANDLE 673 P STOP PLATE 627 P SPINDLE 674 PSS60M SET SCREW M X PSB33M CAP SCREW M5-.8 X P SPRING 629 P LOCK NUT 676 P STEEL BALL 3/16" 630 P LOCK NUT 677 PSS35M SET SCREW M4-.7 X P6206-2RS BALL BEARING RS 678 P HANDLE HUB 632 P QUILL SKIRT 679 P BUSHING 633 P NOSE PIECE 680 P BUSHING 634 P SPINDLE DIRT SHIELD 681 P COILED SPRING 635 P THRUST BEARING 40 X 60 X P GEAR 636 P BEARING SLEEVE 683 P LEVER 637 P BEARING SLEEVE 684 P SHAFT 638 P THRUST BEARING 40 X 60 X PSS20M SET SCREW M X P ADJUSTING NUT M39 X P WORM GEAR 640 PSS26M SET SCREW M5-.8 X PK37M KEY 4 X 4 X P DOG POINT SET SCREW M5-.8 X PSS26M SET SCREW M5-.8 X P QUILL 689 P SHAFT 643 P OIL SEALER 690 P HANDLE 644 PN07M HEX NUT M P HANDLE KNOB 645 PSS100M SET SCREW M3-.5 X P HEADSTOCK 646 P FORKED ROD 693 P OIL CUP ADAPTER 647 P THREAD PIN 694 P OIL CUP 648 PSB18M CAP SCREW M4-.7 X P TUBING 649 P THREADED BUSHING P COTTON WIRE 650 P RETAINING PLATE

79 Model G9903 Upper Drive System Breakdown

80 Model G9903 Upper Drive System Breakdown REF PART # DESCRIPTION REF PART # DESCRIPTION 701 PSB01M CAP SCREW M6-1 X P UPPER PULLEY HALF 702 P BEARING CAP 741 PSS01M SET SCREW M6-1 X P6007ZZ BALL BEARING 6007ZZ 743 P LOWER PULLEY HALF 706 P CAP SCREW M X P COMPRESSION SPRING 707 PN02M HEX NUT M P SPRING COLLAR 708 P MOTOR 2HP, 220V,3-PH 746 PSB38M CAP SCREW M5-.8 X P MOTOR MOUNT PLATE 748 PSB14M CAP SCREW M X P MOTOR WIRING JUNCTION BOX 752 P TAPER PIN 8 X P MOTOR FAN COVER 753 P MIDDLE HOUSING P MOTOR FAN 754 P LOWER COVER 709 PB32M HEX BOLT M X P RIVET C2 X P UPPER HOUSING 758 P NAMEPLATE 711 P SHAFT 761 P NAMEPLATE 712 PRP56M ROLL PIN 4 X P LOWER HOUSING 713 P CLAMPING PLATE 764 PS19M PHLP HD SCR M5-.8 X P DRAWBAR 765 P COVER PLATE 715 PRP42M ROLL PIN 3 X P RETAINING RING 6MM 716 P SHAFT 767 P BRAKE OPERATING FINGER 717 PS52M PHLP HD SCR M4-.7 X P SHAFT 718 PW05M FLAT WASHER 4MM 769 P HANDLE KNOB 722 P BEARING SLIDING HOUSING 770 P HANDLE 723 P BALL BEARING RS 771 P PIN 725 P PULLEY 772 PSS26M SET SCREW M5-.8 X P RETAINING RING 38MM 773 P SHAFT 727 P VARIABLE SPEED BELT 775 P BRACKET 728 P PULLEY 777 PSS01M SET SCREW M6-1 X P BEARING CAP 778 PSB02M CAP SCREW M6-1 X P BALL BEARING RS 780 PS08M PHLP HD SCR M5-.8 X P BRAKE SPRING 783 P REGULATING RING 732 P BRAKE SHOE 785 P MOTOR SPLINE SLEEVE 734 P UPPER COUPLING SHAFT 786 P KEY 6 X 6 X PSS01M SET SCREW M6-1 X P SPLINE SLEEVE 738 PK149M KEY 8 X 8 X 25

81 Model G9903 Lower Drive System Breakdown

82 Model G9903 Lower Drive System Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 708 P MOTOR 2HP, 220V,3-PH 849 P FLANGE P MOTOR WIRING JUNCTION BOX 850 PSS02M SET SCREW M6-1 X P MOTOR FAN COVER 851 P GUIDE P MOTOR FAN 852 PSB18M CAP SCREW M4-.7 X P UPPER HOUSING 853 P DRIP PIPE 754 P LOWER COVER 854 P OIL CUP 763 P LOWER HOUSING P OIL PIPE ADAPTER 801 PN18M ACORN NUT M P SPRING 802 P DIAL 857 P GEAR SLEEVE 804 PSS04M SET SCREW M6-1 X P GEAR SHAFT 805 P HOUSING 860 P DETENT PLATE 806 P CHIP SHIELD 861 P SPECIAL NUT M PS17M PHLP HD SCR M4-.7 X PW06M FLAT WASHER 12MM 808 P BUSHING 863 P THREADED STUD M X PRP16M ROLL PIN 3 X PSS04M SET SCREW M6-1 X P SPEED CHANGER CHAIN 1/8" X 1/2" 865 P SET BLOCK 816 P BUSHING 866 P SET PIN 817 P HANDWHEEL 867 P COMPRESSION SPRING 819 P HANDWHEEL HANDLE 868 PSB33M CAP SCREW M5-.8 X P CAUTION PLATE 869 P HANDLE KNOB 821 PSS03M SET SCREW M6-1 X P HANDLE SHAFT 825 PSB48M CAP SCREW M6-1 X P HANDLE HUB 828 P SOLID PIN 3 X PRP02M ROLL PIN 3 X P SHAFT 873 PRP02M ROLL PIN 3 X P WORM GEAR 874 PSB14M CAP SCREW M X P BEVEL GEAR 875 PSB38M CAP SCREW M5-.8 X PK03M KEY 3 X 3 X PK07M KEY 6 X 6 X P SHAFT 878 P WOODRUFF KEY 5 X P RIBBED TIMING BELT 879 P BALL BEARING 837 P UPPER COUPLING SHAFT 880 P PINION SHAFT 839 P LOWER COUPLING SHAFT 881 P KEY 840 P BULL GEAR 883 P PINION GEAR 841 P6008ZZ BALL BEARING 6008ZZ 884 P BEARING CAP 842 PR70M INT RETAINING RING 68MM 885 PSB24M CAP SCREW M5-.8 X P SPACER 886 P TIMING PULLEY 846 PW04M FLAT WASHER 10MM 887 PN05M HEX NUT M P SPECIAL BOLT 888 P FRONT COVER 848 P SPRING SHIM 889 PSB39M CAP SCREW M4-.7 X 20