Download Woodstock SHOP FOX M1106 Specifications
Transcript
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E]dcZ/ (+%,()"()-'Dc"A^cZIZX]c^XVaHjeedgi/iZX]"hjeedgi5h]de[dm#W^o 8DENG><=ICDK:B7:G'%%*7NLDD9HID8@>CI:GC6I>DC6A!>C8#G:K>H:99:8:B7:G!'%%.8G ,+''8G L6GC>C</CDEDGI>DCD;I=>HB6CJ6AB6N7:G:EGD9J8:9>C6CNH=6E:DG;DGBL>I=DJI I=:LG>II:C6EEGDK6AD;LDD9HID8@>CI:GC6I>DC6A!>C8# Eg^ciZY^c8]^cV K_`jdXelXcgifm`[\jZi`k`ZXcjX]\kp`ejkilZk`fejfek_\gifg\ij\klg# fg\iXk`fe#dX`ek\eXeZ\Xe[j\im`Z\f]k_`jdXZ_`e\&\hl`gd\ek% =X`cli\kfi\X[#le[\ijkXe[Xe[]fccfnk_\`ejkilZk`fej^`m\e`ek_`j dXelXcdXpi\jlck`ej\i`fljg\ijfeXc`ealip#`eZcl[`e^XdglkXk`fe# \c\ZkifZlk`fefi[\Xk_% K_\fne\if]k_`jdXZ_`e\&\hl`gd\ek`jjfc\cpi\jgfej`Yc\]fi`kjjX]\ lj\%K_`ji\jgfej`Y`c`kp`eZcl[\jYlk`jefkc`d`k\[kfgifg\i`ejkXccX$ k`fe`eXjX]\\em`ifed\ek#g\ijfee\ckiX`e`e^Xe[ljX^\Xlk_fi`qX$ k`fe#gifg\i`ejg\Zk`feXe[dX`ek\eXeZ\#dXelXcXmX`cXY`c`kpXe[ Zfdgi\_\ej`fe#Xggc`ZXk`fef]jX]\kp[\m`Z\j#YcX[\&Zlkk\i`ek\^i`kp# Xe[k_\ljX^\f]g\ijfeXcgifk\Zk`m\\hl`gd\ek% K_\dXel]XZkli\in`ccefkY\_\c[c`XYc\]fi`ealipfigifg\ikp [XdX^\]ifde\^c`^\eZ\#`dgifg\ikiX`e`e^#dXZ_`e\df[`]`ZXk`fejfi d`jlj\% Jfd\[ljkZi\Xk\[Ypgfn\ijXe[`e^#jXn`e^#^i`e[`e^#[i`cc`e^#Xe[ fk_\iZfejkilZk`feXZk`m`k`\jZfekX`ejZ_\d`ZXcjbefnekfk_\JkXk\f] :Xc`]fie`XkfZXlj\ZXeZ\i#Y`ik_[\]\Zkjfifk_\ii\gif[lZk`m\_Xid% Jfd\\oXdgc\jf]k_\j\Z_\d`ZXcjXi\1 C\X[]ifdc\X[$YXj\[gX`ekj% :ipjkXcc`e\j`c`ZX]ifdYi`Zbj#Z\d\ekXe[fk_\idXjfeipgif[lZkj% 8ij\e`ZXe[Z_ifd`ld]ifdZ_\d`ZXccp$ki\Xk\[cldY\i% Pflii`jb]ifdk_\j\\ogfjli\jmXi`\j#[\g\e[`e^fe_fnf]k\epfl [fk_`jkpg\f]nfib%Kfi\[lZ\pfli\ogfjli\kfk_\j\Z_\d`ZXcj1 Nfib`eXn\ccm\ek`cXk\[Xi\X#Xe[nfibn`k_Xggifm\[jX]\kp\hl`g$ d\ek#jlZ_Xjk_fj\[ljkdXjbjk_XkXi\jg\Z`Xccp[\j`^e\[kf]`ck\i flkd`ZifjZfg`ZgXik`Zc\j% <C<:KI@:8C J<KLG FG<I8K@FEJ D8@EK<E8E:< J<IM@:< G8IKJ LJ<K?<HL@:B>L@;<G8><C89<CJKFJ<8I:?FLK@E=FID8K@FE=8JK J8=<KP @EKIF;L:K@FE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%* Woodstock Technical Support ............................................................................ 3 About Your New 13 x 40 Gear Head Lathe ............................................................. 3 Specifications ............................................................................................... 4 J8=<KP%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%Standard Safety Instructions ............................................................................. 6 Additional Safety Instructions for Gear Head Lathes................................................. 8 Avoiding Potential Injuries ................................................................................ 9 220V 3-phase Operation................................................................................. 10 Extension Cords .......................................................................................... 10 Grounding ................................................................................................. 10 J<KLG%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% (( Unpacking ................................................................................................. 11 Items Needed for Set Up ................................................................................ 11 Inventory .................................................................................................. 12 Cleaning Machine......................................................................................... 13 Machine Placement ...................................................................................... 13 Mounting Lathe on Shop Floor ......................................................................... 14 Handwheel Handles ...................................................................................... 15 Test Run.................................................................................................... 15 FG<I8K@FEJ%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% (General .................................................................................................... 16 Turning On Power ........................................................................................ 16 Three-Jaw Direct Mount Scroll Chuck ................................................................ 17 Replacing Jaws ........................................................................................... 19 Four-Jaw Direct Mount Independent Chuck.......................................................... 22 Faceplate .................................................................................................. 24 Gap Piece Removal ...................................................................................... 25 Tailstock ................................................................................................... 26 Drilling with the Tailstock .............................................................................. 26 Cutting Shallow Tapers with the Tailstock ........................................................... 27 Tailstock Alignment ...................................................................................... 27 Centers..................................................................................................... 29 Steady Rest ................................................................................................ 30 Follow Rest ................................................................................................ 30 Setting Compound Slide ................................................................................. 31 Four-Way Tool Post ....................................................................................... 31 Foot Brake................................................................................................. 32 Manual Feed .............................................................................................. 32 Setting RPM ............................................................................................... 33 Spindle Break-In .......................................................................................... 34 Setting Power Feed Rate ................................................................................ 34 Thread Settings ........................................................................................... 36 Change Gears ............................................................................................. 37 Threading Operation..................................................................................... 38 @EKIF;L:K@FE :fek\ekj @EKIF;L:K@FE J8=<KP <C<:KI@:8C J<KLG FG<I8K@FEJ D8@EK<E8E:< J<IM@:< G8IKJ D8@EK<E8E:<%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% *0 General .................................................................................................... 39 Cleaning ................................................................................................... 39 Lubrication ................................................................................................ 39 Coolant System ........................................................................................... 40 J<IM@:<%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% +( General .................................................................................................... 41 Cross Feed Backlash ..................................................................................... 41 Gibs......................................................................................................... 41 Replacing V-Belt .......................................................................................... 43 Main Electrical Box ...................................................................................... 44 Wiring Diagram (M1098 220V 3-Phase) ................................................................ 45 Motor Connections (M1098 220V 3-Phase)............................................................ 46 Troubleshooting........................................................................................... 47 G8IKJ%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% +/ Base Assembly ............................................................................................ 48 Base Parts List ............................................................................................ 49 Headstock Assembly ..................................................................................... 50 Headstock Assembly ..................................................................................... 51 Headstock Assembly ..................................................................................... 52 Headstock Parts List ..................................................................................... 53 Headstock Parts List ..................................................................................... 54 Gearbox Assembly ........................................................................................ 55 Gearbox Assembly ........................................................................................ 56 Gearbox Assembly ........................................................................................ 57 Gearbox Parts List ....................................................................................... 58 Gearbox Parts List ....................................................................................... 59 Apron Assembly ........................................................................................... 60 Apron Assembly ........................................................................................... 61 Apron Parts List .......................................................................................... 62 Carriage Assembly ........................................................................................ 63 Carriage Parts List ....................................................................................... 64 Tool Post Assembly ....................................................................................... 65 Tool Post Parts List ....................................................................................... 66 Tailstock Assembly ....................................................................................... 67 Tailstock Parts List ....................................................................................... 68 Bed Assembly ............................................................................................. 69 Bed Parts List ............................................................................................. 70 End Gear Assembly ....................................................................................... 71 End Gear Parts List ...................................................................................... 72 Coolant, Work Light, & Thread Dial Assembly ....................................................... 73 Coolant, Work Light, & Thread Dial Parts List ...................................................... 74 Steady & Follow Rest Assemblies ...................................................................... 75 Steady & Follow Rest Parts List ........................................................................ 76 Warranty ................................................................................................... 77 LJ<K?<HL@:B>L@;<G8><C89<CJKFJ<8I:?FLK@E=FID8K@FE=8JK @EKIF;L:K@FE Nff[jkfZbK\Z_e`ZXcJlggfik We stand behind our machines! In the event that questions arise about your machine, parts are missing, or a defect is found, please contact Woodstock International Technical Support at (360) 734-3482 or send e-mail to: k\Z_$jlggfik7j_fg]fo%Y`q. Our knowledgeable staff will help you troubleshoot problems and send out parts for warranty. If you need the latest edition of this manual, you can download it from _kkg1&&nnn%j_fg]fo%Y`q. If you still have questions after reading the latest manual, or if you have comments please contact us at: Nff[jkfZb@ek\ieXk`feXc#@eZ% 8kke1K\Z_e`ZXcJlggfik;\gXikd\ek G%F%9fo)*'0 9\cc`e^_Xd#N80/)). 8YflkPfliE\n(*o+'>\Xi?\X[CXk_\ Your new E:AB8AJ® 13 x 40 Gear Head Lathe has been specially designed to provide many years of trouble-free service. Close attention to detail, ruggedly built parts and a rigid quality control program assure safe and reliable operation. The Model M1098 Gear Head Lathe has precision-ground induction-hardened ways, removable gap with 40" between centers, an oil-bath headstock, threading gearbox, and apron. The 2 HP, 220V, 3-phase motor drives the spindle at eight speeds. The four-way turret style tool post assures rigid tool holding and accurate positioning. The Model M1098 includes a coolant pump, steady and follow rests, three and four-jaw chucks, a 10" faceplate, and an MT#3 tailstock taper. The lathe is made of cast iron throughout and has flame-hardened headstock gears. Woodstock International, Inc. is committed to customer satisfaction in providing this manual. It is our intent to make sure all the information necessary for safety, ease of assembly, practical use and durability of this product be included. -3- @EKIF;L:K@FE D('0/(*o+'>\Xi?\X[CXk_\ @EKIF;L:K@FE D('0/(*o+'>\Xi?\X[CXk_\ Jg\Z`]`ZXk`fej Spindle Motor .............................2 HP, 6.5 A, 1.5 KW, 220V, Three-Phase, 1725 RPM Overall Length .................................................................................... 78" Overall Depth .................................................................................. 29.5" Footprint ................................................................................70.5" x 15.5" Height ............................................................................................52.5" Bed Width......................................................................................... 7.3" Swing Over Bed ................................................................................... 13" Swing Over Gap .................................................................................18.3" Swing Over Saddle ............................................................................... 7.8" Distance Between Centers ......................................................................40" Height of Center Line ........................................................................... 6.5" Compound Slide Travel..........................................................................3.2" Cross Slide Travel ................................................................................ 6.3" Tailstock Barrel Travel ..........................................................................3.9" Leadscrew Diameter......................................................................... 22 mm Feed Rod ...................................................................................... 19 mm Cutting Tool Maximum Size .......................................................... 16 X 16 mm Camlock System ................................................................................. D1-4 Spindle Bore ...................................................................................... 1.5" Spindle Taper ................................................................................... MT#5 Tailstock Diameter ........................................................................... 32 mm Tailstock Taper ................................................................................. MT#3 Spindle Speeds ........................................................................ 70-2000 RPM Feed Rate Range .................................................................. 0.14-0.376 mm/r Thread Range (Inch) .................................................................... 2.25–40 TPI Thread Range (Metric) ................................................................... 0.4-7 mm Bed Ways.....................................................................1660 x 186 x 308 mm Longitudal Feed ..................................................................0.052-1.392 mm/r Cross Feed ....................................................................... 0.014-0.376 mm/r Approximate Shipping Weight ............................................................ 1433 lbs. Approximate Net Weight.................................................................. 1279 lbs. -4- @EKIF;L:K@FE D('0/(*o+'>\Xi?\X[CXk_\ :fekifcjXe[=\Xkli\j D A B C F H E I J L K M N O P G AM Q R AF AK S AH T U AO AO W V Z AN AG AJ AI AD AE AC AB AA X Y The Model M1098 lathe. 8% 9% :% ;% <% =% >% ?% @% A% B% C% D% E% F% G. H% I% J% K% Headstock Spindle Speed Levers Spindle Chuck and Chuck Guard Four-Way Tool Post Work Light Compound Rest and Handwheel Steady Rest Cross Slide and Handwheel Coolant Hose Dead Center and Quill Follow Rest Quill Lock Tailstock Lock Splash Guard Tailstock Handwheel Tailstock Bed Ways Bed Lead Screw L% Feed Rod M% Rack N% Thread Dial O% Apron Oil Level Sight Glass P% Spindle Rotation ON/OFF Q% Half-Nut Lever 88% Power Feed Lever 89% Carriage Apron 8:% Longitudinal Feed Handwheel 8;% Headstock Oil Level Sight Glass 8<% Foot Brake 8=% Coolant Pump ON/OFF 8>% Thread Selection Dials 8?% Jog Button 8@% Emergency Stop 8A% Oil Level Sight Glass 8B% Power Lamp 8D% Lead Screw/Feed Rod Direction Lever 8E% Gap 8F% Lathe lifting location (4 locations) -5- D('0/(*o+'>\Xi?\X[CXk_\ J8=<KP J8=<KP I<8;D8EL8C9<=FI<FG<I8K@E>D8:?@E<% =8@CLI<KF=FCCFN@EJKIL:K@FEJ9<CFNN@CC I<JLCK@EG<IJFE8C@EALIP% 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. EFK@:< This symbol is used to alert the user to useful information about proper operation of the equipment, and/or a situation that may cause damage to the machinery. JkXe[Xi[JX]\kp@ejkilZk`fej (% K_fifl^_cpi\X[k_\@ejkilZk`feDXelXcY\]fi\fg\iXk`e^pflidXZ_`e\%Learn the applications, limitations and potential hazards of this machine. Keep the manual in a safe and convenient place for future reference. )% B\\gnfibXi\XZc\XeXe[n\ccc`^_k\[%Clutter and inadequate lighting invite potential hazards. *% >ifle[Xcckffcj%If a machine is equipped with a three-prong plug, it must be plugged into a threehole grounded electrical receptacle or grounded extension cord. If using an adapter to aid in accommodating a two-hole receptacle, ground using a screw to a known ground. +% N\Xi\p\gifk\Zk`feXkXcck`d\j%Use safety glasses with side shields or safety goggles that meet the appropriate standards of the American National Standards Institute (ANSI). ,% 8mf`[[Xe^\iflj\em`ifed\ekj%Do not operate this machine in wet or open flame environments. Airborne dust particles could cause an explosion and severe fire hazard. -% <ejli\Xcc^lXi[jXi\j\Zli\cp`egcXZ\and in working condition. .% DXb\jli\jn`kZ_`j`ek_\F==gfj`k`febefore connecting power to machine. /% B\\gnfibXi\XZc\Xe#free of clutter, grease, etc. 0% B\\gZ_`c[i\eXe[m`j`kfijXnXp%Visitors must be kept at a safe distance while operating unit. ('% :_`c[giff]pflinfibj_fgwith padlocks, master switches or by removing starter keys. ((% JkfgXe[[`jZfee\Zkk_\dXZ_`e\n_\eZc\Xe`e^#X[aljk`e^fij\im`Z`e^% -6- D('0/(*o+'>\Xi?\X[CXk_\ ()% ;f efk ]fiZ\ kffc% The machine will do a safer and better job at the rate for which it was designed. (*% Lj\Zfii\Zkkffc%Do not force machine or attachment to do a job for which it was not designed. (,% I\dfm\Z_lZbb\pj#iX^j#Xe[kffcj%Before turning the machine on, make it a habit to check that all chuck keys and wrenches have been removed. (-%8mf`[lj`e^Xe\ok\ej`feZfi[%But if you must use one, examine the extension cord to ensure it is in good condition. Immediately replace a damaged extension cord. Always use an extension cord that uses a ground pin and connected ground wire. Use an extension cord that meets the amp rating on the motor nameplate. If the motor is dual voltage, be sure to use the amp rating for the voltage you will be using. If you use an extension cord with an undersized gauge or one that is too long, excessive heat will be generated within the circuit, increasing the chance of a fire or damage to the circuit. (.% B\\ggifg\i]ffk`e^Xe[YXcXeZ\ at all times. (/% CfZbk_\dfY`c\YXj\]ifddfm`e^Y\]fi\]\\[`e^k_\nfibg`\Z\`ekfk_\dXZ_`e\. (0% ;f efk c\Xm\ dXZ_`e\ leXkk\e[\[% Wait until it comes to a complete stop before leaving the area. )'% G\i]fiddXZ_`e\dX`ek\eXeZ\Xe[ZXi\%Follow lubrication and accessory attachment instructions in the manual. )(% B\\gdXZ_`e\XnXp]ifdfg\e]cXd\%Operating machines near pilot lights or open flames creates a high risk if dust is dispersed in the area. Dust particles and an ignition source may cause an explosion. Do not operate the machine in high-risk areas, including but not limited to, those mentioned above. ))% @]XkXepk`d\pflXi\\og\i`\eZ`e^ difficulties performing the intended operation, stop using the machine! Then contact our technical support or ask a qualified expert how the operation should be performed. )*% 9\XnXi\k_XkZ\ikX`edXk\i`XcjdXpZXlj\XeXcc\i^`Zi\XZk`fe`eg\fgc\Xe[Xe`dXcj, especially when exposed to fine dust. Make sure you know what type of material dust you will be exposed to and the possibility of an allergic reaction. )+%?XY`kjÇ^ff[Xe[YX[ÇXi\_Xi[kfYi\Xb%Develop good habits in your shop and safety will become second-nature to you. -7- J8=<KP (+%N\Xigifg\iXggXi\c%Do not wear loose clothing, neck ties, gloves, jewelry, and secure long hair away from moving parts. D('0/(*o+'>\Xi?\X[CXk_\ J8=<KP 8[[`k`feXcJX]\kp@ejkilZk`fej ]fi>\Xi?\X[CXk_\j I<8;Xe[le[\ijkXe[k_`j \ek`i\ `ejkilZk`fe dXelXc Y\]fi\lj`e^k_`jdXZ_`e\% J\i`flj g\ijfeXc `ealip dXp fZZli `] jX]\kp Xe[ fg\iXk`feXc`e]fidXk`fe`j efk le[\ijkff[ Xe[ ]fc$ cfn\[% ;F EFK i`jb pfli jX]\kpYpefki\X[`e^ LJ<k_`jXe[fk_\idXZ_`e\ipn`k_ZXlk`fe Xe[ i\jg\Zk% 8cnXpj Zfej`[\i jX]\kp ]`ijk# Xj `k Xggc`\j kf pfli `e[`m`[lXc nfib`e^ Zfe[`k`fej%Efc`jkf]jX]\kp^l`[\c`e\jZXe Y\ Zfdgc\k\Ç\m\ip j_fg \em`ifed\ek `j [`]]\i\ek%=X`cli\kf]fccfn^l`[\c`e\jZflc[ i\jlck `e j\i`flj g\ijfeXc `ealip# [XdX^\ kf\hl`gd\ekfigffinfibi\jlckj% (% I\X[Xe[le[\ijkXe[k_`jdXelXcY\]fi\fg\iXk`e^k_`jdXZ_`e\% )% ;fefkZc\XiZ_`gjYp_Xe[% Use a brush, and never clear chips while the lathe is turning. *% 8cnXpjj\c\Zkk_\i`^_kZlkk\i]fik_\afY, Xe[dXb\jli\Zlkk\ijXi\j_Xig% The right tool decreases strain on the lathe components and provides a better finish. +% 8cnXpji\dfm\Z_lZbb\p% Never walk away from the lathe with the key in the chuck. ,% DXb\jli\nfibg`\Z\`jgifg\icp_\c[`eZ_lZbY\]fi\jkXik`e^cXk_\% A workpiece thrown from the chuck will severely injure you or a bystander. -% KliecXk_\F==Y\]fi\Z_Xe^`e^jg\\[j% The lathe must be turned F== and the spindle brought to a complete stop before changing gears. .% >\kXjj`jkXeZ\n_\e`ejkXcc`e^cXi^\Z_lZbj% Large lathe chucks are very heavy and awkward to hold, so protect your hands and the precision ground ways. Always use a chuck cradle or piece of plywood over the ways of the lathe. /% Jlggfik`e^cfe^nfibg`\Z\jif a workpiece extends out of the end of the headstock for a turning operation, make sure it is supported as not to wobble violently when the lathe is turned on. 0% DXb\jli\nfibg`\Z\_XjX[\hlXk\Zc\XiXeZ\Y\]fi\jkXik`e^dXZ_`e\%Check tool and tool post clearance, chuck clearance, and saddle clearance before starting the lathe. ('%8cnXpjlj\k_\Xggifgi`Xk\]\\[Xe[jg\\[iXk\j% ((%E\m\iXkk\dgkkfjcfnfijkfgk_\cXk_\Z_lZbYplj`e^pfli_Xe[% ()%DX`ekX`e`e^XjX]\nfibgcXZ\% Never leave lathe unattended while it is running. (*%8mf`[`e^Xj\m\i\\ekXe^c\d\ek`ealip% Long hair, ponytails, loose clothing and sleeves is an entanglement hazard. Make sure they are all tied out of the way and do not dangle. (+. Gi\m\ek`e^cXk_\ZiXj_\j% Release any automatic feeds after completing a job. -8- D('0/(*o+'>\Xi?\X[CXk_\ 8mf`[`e^Gfk\ek`Xc@eali`\j J8=<KP =`^li\(%Always protect the bed ways, and unplug the lathe when retooling the lathe. =`^li\*% Always wear face and eye protection when using lathes. =`^li\)%Never walk away from the lathe leaving the chuck key inserted in the chuck. =`^li\+% Never use hands to stop or slow the chuck when shutting down the lathe. =`^li\,%Never wear loose clothing or gloves when working with the lathe. -9- D('0/(*o+'>\Xi?\X[CXk_\ ))'M*$g_Xj\Fg\iXk`fe <C<:KI@:8C The E:AB8AJ Model M1098 power supply requirement is 220 volt, three-phase. If you do not have three-phase power available, you will have to install a phase converter. We recommend that you hard-wire this lathe to a dedicated circuit with a verified ground, using the circuit breaker size given below. Never replace a circuit breaker with one of higher amperage without consulting a qualified electrician to ensure compliance with wiring codes. @]pflXi\ lejli\XYflkk_\n`i`e^Zf[\j`epfliXi\XfipflgcXe kf Zfee\Zk pfli dXZ_`e\ kf X j_Xi\[ Z`iZl`k# pfl dXp Zi\Xk\ X ]`i\ _XqXi[ÇZfejlck X hlXc`]`\[ \c\Zki`Z`Xe kf i\[lZ\k_`ji`jb% If you must use a plug and receptacle, you will need a NEMA-style 15-15 plug and receptacle (j\\=`^li\-). ;FEFKXkk\dgkkfnfibfepflij_fg \c\Zki`ZXc jpjk\d `] pfl Xi\ lejli\ XYflk \c\Zki`ZXc Zf[\j Xe[ n`i`e^ J\\bXjj`jkXeZ\]ifdXhlXc`]`\[\c\Z$ ki`Z`Xe%@^efi`e^k_`jnXie`e^ZXeZXlj\ \c\ZkifZlk`fe :8LK@FE1 Using a circuit breaker rated higher than 10 amps will increase the risk of fire! <ok\ej`fe:fi[j DO NOT use an extension cord for 220V/440V high amperage industrial shop machines. You must follow all local electrical codes when connecting this machine to a power source. OFF >ifle[`e^ This machine must be grounded! If you have any questions about correct electrical installation, contact a qualified electrician for assistance to make sure all connections are safe and adhere to your local electrical codes. KLIEF==Xe[CF:Bpfli dXjk\igfn\ijn`kZ_jf ef gfn\i `j XmX`cXYc\ kf k_\ cXk_\ Y\]fi\ Zfee\Zk`e^ \c\Zki`ZXc n`i\j @] pfl `^efi\ k_`j nXie`e^ j\i`flj \c\Zki`ZXc j_fZb dXp fZZli# ZXlj`e^ `ealip fi [\Xk_ G G Z Z X X W W 15-15P 15-15R =`^li\-% Typical 220V 3-phase 15 Amp 4-prong plug and receptacle. -10- D('0/(*o+'>\Xi?\X[CXk_\ J<KLG LegXZb`e^ The E:AB8AJ Model M1098 has been carefully packaged for safe transporting. If you notice the machine has been damaged, please contact your authorized E:AB 8AJ dealer immediately. @k\djE\\[\[]fiJ\kLg The following items are needed, but not included, to setup your machine: Fork Lift or 1.5-Ton Hoist 1.5 Ton lifting straps and hooks Precision Level Safety Glasses (for each person) Solvent for cleaning Shop Rags for cleaning Floor Anchors J<KLG • • • • • • • I<8;Xe[le[\ijkXe[k_`j\ek`i\`ejkilZ$ k`fe dXelXc Y\]fi\ lj`e^ k_`j dXZ_`e\% J\i`flj g\ijfeXc `ealip dXp fZZli `] jX]\kpXe[fg\iXk`feXc`e]fidXk`fe`jefk le[\ijkff[ Xe[ ]fccfn\[% ;F EFK i`jb pflijX]\kpYpefki\X[`e^ K_\Df[\cD('0/n\`^_jXggifo`dXk\$ cp ()/' cYj% J\i`flj g\ijfeXc `ealip dXp fZZli `] jX]\ dfm`e^ d\k_f[j Xi\ efk ]fccfn\[% Pfl n`cc e\\[ gfn\i c`]k`e^ \hl`gd\ek Xe[ Xjj`jkXeZ\ kf i\dfm\ k_`j dXZ_`e\ ]ifd k_\ ZiXk\% Fk_\in`j\#j\i`fljg\ijfeXc`ealipdXp fZZli% JL==F:8K@FE ?8Q8I; @dd\[`Xk\cp [`jZXi[ Xcc gcXjk`Z YX^j Xe[ gXZb`e^ dXk\i`Xcj kf \c`d`eXk\ Z_fb`e^&jl]$ ]fZXk`fe _XqXi[j ]fi Z_`c[i\eXe[Xe`dXcj% -11- D('0/(*o+'>\Xi?\X[CXk_\ @em\ekfip The following is a description of the main components shipped with the E:AB8AJ® Model M1098. Lay the components out to inventory them. B D C DX`e:fek\ekj=`^li\. HKP 8% Model M1098 Gear Head Lathe ..........................1 9% Steady Rest .................................................1 :% Follow Rest .................................................1 ;% Three-Jaw Chuck ..........................................1 A J<KLG 8ZZ\jjfipDflek`e^j=`^li\/ <% 10" Faceplate...............................................1 I% 8" Four-Jaw Universal Chuck ............................1 >% Four-Jaw Chuck Key.......................................1 ?% Hardware Bag • Camlock Studs ...........................................3 • Camlock Stud Fasteners ................................3 =`^li\.% Main contents. Kffc9fo:fek\ek=`^li\0 @% Tool Box .....................................................1 A% Oil Gun ......................................................1 B% Open End Wrenches 10/12, 14/17, 17/19 .........1 EA C% Slotted Screwdriver .......................................1 D% Phillips Head Screwdriver ................................1 E% Three-Jaw Chuck Jaws ...................................3 F% Hex Wrenches 3, 4, 5, 6, 8, 10MM ..................1 EA G% MT#3 Dead Centers........................................2 H% MT#5-#3 Morse Taper Sleeve .............................1 I% Center Sleeve MT#5 to MT#3 ............................1 J% Three-Jaw Chuck Key .....................................1 K% Tool Post Wrench ..........................................1 L% Change Gear 40T) ........................................1 F E H G =`^li\/% Accessories. If any parts appear to be missing, examine the packaging carefully to be sure those parts are not among the packing materials. If any parts are missing, find the part number in the back of this manual and contact Woodstock International, Inc. at (360) 734-3482 or at [email protected] I J U Q K P L R EFK@:< O S T M N N_\efi[\i`e^i\gcXZ\d\ekgXikj#i\]\ikfk_\gXikj c`jkXe[[`X^iXd`ek_\YXZbf]k_\dXelXc% =`^li\0% Tool box contents. -12- D('0/(*o+'>\Xi?\X[CXk_\ :c\Xe`e^DXZ_`e\ The ways and other unpainted parts of your Gear Head Lathe are coated with a waxy grease that protects them from corrosion during shipment. Clean this grease off with a solvent cleaner or citrus-based degreaser. DO NOT use chlorine-based solvents such as brake parts cleaner or acetone—if you happen to splash some onto a painted surface, you will ruin the finish. *-NXcc:c\XiXeZ\ ,(%, (,%, DXZ_`e\GcXZ\d\ek =cffiCfX[1 Your Gear Head Lathe represents a large load (1279 Lbs.) distributed in a 70 1/2" x 15 1/2" footprint. We recommend placing this machine on concrete floors only. Nfib`e^:c\XiXeZ\j1 Consider existing and anticipated needs, size of material to be processed through the machine, and space for auxiliary stands, work tables or other machinery when establishing a location for your gear head lathe (see =`^li\('). C`^_k`e^1 Lighting should be bright enough to eliminate shadow and prevent eye strain. <c\Zki`ZXc1Electrical circuits must be dedicated or large enough to handle amperage requirements. Outlets must be located near each machine, so power or extension cords are clear of high-traffic areas. Follow local electrical codes for proper installation of new lighting, outlets, or circuits. -13- .'%, (+)%, =`^li\('% Minimum wall clearances. D8B< pfli j_fg ÈZ_`c[ jX]\%É <ejli\ k_Xk pfli nfibgcXZ\ `j `eXZZ\jj`Yc\ kf pfle^jk\ij Yp Zcfj`e^ Xe[ cfZb`e^ Xcc \ekiXeZ\j n_\e pfl Xi\ XnXp% E<M<I Xccfn lekiX`e\[ m`j`kfij `e pfli j_fg n_\e Xjj\dYc`e^# X[aljk`e^ fi fg\iXk$ `e^\hl`gd\ek% J<KLG 8CN8PJ nfib `e n\cc$m\ek`cXk\[ Xi\Xj ]Xi ]ifd gfjj`Yc\ `^e`k`fe jfliZ\j n_\e lj`e^ jfcm\ekj kf Zc\Xe dXZ_`e\ip% DXep jfcm\ekj Xi\ kfo`Z n_\e `e_Xc\[ fi `e^\jk\[%Lj\ZXi\n_\e[`jgfj`e^ f] nXjk\ iX^j Xe[ kfn\cj kf Y\ jli\k_\p;FEFKZi\Xk\]`i\fi \em`ifed\ekXc_XqXi[j% E<M<I lj\ ]cXddXYc\j jlZ_ Xj ^Xj fi fk_\ig\kifc\ld$YXj\[jfcm\ekjkfZc\Xe pflidXZ_`e\%K_\j\gif[lZkj_Xm\cfn ]cXj_ gf`ekj Xe[ gi\j\ek k_\ i`jb f] \ogcfj`feXe[j\m\i\g\ijfeXc`ealip D('0/(*o+'>\Xi?\X[CXk_\ Dflek`e^CXk_\feJ_fg =cffi Although not required, we recommend that you mount your new machine to the floor. Because this is an optional step and floor materials may vary, floor mounting hardware is not included. Generally, you can either bolt your machine to the floor or mount it on machine mounts. Both options are described below. Whichever option you choose, it will be necessary to use a precision level to level your machine. J<KLG 9fck`e^kf:feZi\k\=cffij Lag shield anchors with lag bolts (=`^li\(() and anchor studs (=`^li\()) are two popular methods for anchoring an object to a concrete floor. We suggest you research the many options and methods for mounting your machine and choose the best that fits your specific application. =`^li\((% Typical lag shield anchor and lag bolt. EFK@:< 8eZ_fijkl[jXi\jkife^\iXe[dfi\g\idXe\ekXck\i$ eXk`m\jkfcX^j_`\c[XeZ_fij2_fn\m\i#k_\pn`ccjk`Zb flkf]k_\]cffi#n_`Z_dXpZXlj\Xki`gg`e^_XqXi[`] pfl[\Z`[\kfdfm\pflidXZ_`e\XkXcXk\igf`ek% Lj`e^DXZ_`e\Dflekj Using machine mounts, shown in =`^li\(*, gives the advantage of fast leveling and vibration reduction. The large size of the foot pads distributes the weight of the machine to reduce strain on the floor. =`^li\()% Typical anchor stud. =`^li\(*% Machine mount example. -14- D('0/(*o+'>\Xi?\X[CXk_\ ?Xe[n_\\c?Xe[c\j KfXkkXZ_k_\_Xe[c\j#[fk_\j\jk\gj1 Cross feed Handwheel Using the screwdriver, attach the handles (=`^li\(+) to the threaded hole in the handwheels. Longitudinal Handwheel K\jkIle The purpose of the test run is to make sure the lathe operates correctly before proceeding with additional set up. Check to make sure that the auto feed is not engaged, the chuck is secure in the spindle, and there are no loose parts around the spindle. Set the lathe to the slowest RPM before the test run. =`^li\(+% Longitudinal and cross feed handle locations. KfY\^`ek_\k\jkilegifZ\[li\#[fk_\j\jk\gj1 (% Make sure there are no obstructions around or underneath the spindle. *% Set the lathe to (0'IGD. Refer to GX^\** to adjust RPM. +% Put on safety glasses, and make sure any bystanders are wearing safety glasses and are out of the way. ,% Plug the lathe in, or move the power supply lever at the power supply panel to FE. The power lamp on the lathe will then illuminate. • If it does not illuminate, disconnect power to the machine, and inside of the main electrical box, move the circuit breaker to the FE position. -% Move the Jg`e[c\IfkXk`feFE&F== lever so the chuck turns. The lathe should run smoothly, with little or no vibration or rubbing noises. • If you hear squealing or grinding noises,turn the machine F== immediately and unplug the machine. Correct any problem before further operation. • If the the problem is not readily apparent, refer to KiflYc\j_ffk`e^ on GX^\+/. .% Turn the lathe F== and complete the Jg`e[c\ 9i\Xb$@e on GX^\*+ before using the lathe. -15- J<KLG )% Make sure the lathe is lubricated and all gear box oil levels are full. Refer toClYi`ZXk`fe on GX^\*0. D('0/(*o+'>\Xi?\X[CXk_\ FG<I8K@FEJ >\e\iXc EFK@:< Complete the Jg`e[c\9i\Xb$@e procedure on GX^\*+ before using this lathe for any cutting or threading operations.Fk_\in`j\^\XiYfo[XdX^\n`ccfZZli% The Model M1098 will perform many types of operations that are beyond the scope of this manual. Many of these operations can be dangerous or deadly if performed incorrectly. FG<I8K@FEJ The instructions in this section are written with the understanding that the operator has the necessary knowledge and skills to operate this machine. @] Xk Xep k`d\ pfl Xi\\og\i`\eZ`e^[`]]`Zlck`\jg\i]fid`e^Xepfg\iXk`fe# jkfglj`e^k_\dXZ_`e\ 8cnXpjn\XijX]\kp^cXjj\jn_\efg\i$ Xk`e^k_\>\Xi?\X[CXk_\%=X`cli\kf ZfdgcpdXpi\jlck`ej\i`fljg\ijfeXc `ealipi\hl`i`e^Xe\p\gXkZ_% If you are an inexperienced operator, we strongly recommend that you read books, trade articles, or seek training from an experienced lathe operator before performing any unfamiliar operations. 8Yfm\Xcc#pflijX]\kpj_flc[ Zfd\]`ijk Klie`e^FeGfn\i See =`^li\(,, once plugged in, there is power to the lathe at all times unless it is unplugged or the main power panel lever is moved to the F== position. When illuminated, the power light on the lathe indicates that the power is being supplied to the lathe. If you press the emergency stop button, the power light will go out and cut power to potential machine operations only. Twisting the EMERGENCY STOP button and letting it pop out will restore power to machine operations. To completely, cut all power to the lathe, it must be unplugged, or the main shop power supply lever must be moved and locked in the F== position. ;FEFK`em\jk`^Xk\gifYc\djfiX[aljk k_\ >\Xi ?\X[ CXk_\ n_`c\ `k `j ile$ e`e^%NX`klek`ck_\dXZ_`e\`jklie\[ f]]#legcl^^\[Xe[Xccnfib`e^gXikj _Xm\Zfd\kfXZfdgc\k\jkfgY\]fi\ gifZ\\[`e^ Power Light Emergency Stop Efk\1 K_\Jg`e[c\IfkXk`feFE&F==C\m\ifek_\Xgife jkXikjk_\jg`e[c\dfkfi`eXgXik`ZlcXi[`i\Zk`fe% =`^li\(,% Power light and emergency stop locations. -16- D('0/(*o+'>\Xi?\X[CXk_\ K_i\\$AXn;`i\ZkDflek JZifcc:_lZb Three-jaw scroll chucks feature hardened steel jaws that self-center the workpiece within 0.002"-0.003". An extra set of jaws is included for machining larger workpieces. The three-jaw direct mount scroll chuck featured in these instructions has three cam-lock studs that mount directly to the chuck and hold the chuck tight to the spindle nose. Kfi\dfm\fidflekpflik_i\\$aXn[`i\ZkdflekjZifcc Z_lZbpfln`cce\\[k_\]fccfn`e^kffcj1 • • • • Chuck Key Dead Blow Hammer A Chuck Cradle or a piece of plywood large enough to span the bedways and support the weight of the chuck Breaker Bar (optional) G@E:? ?8Q8I; Gifk\Zk pfli _Xe[j Xe[ gi\Z`j`fe ^ifle[ Y\[nXpj n`k_ gcpnff[ n_\e i\dfm`e^ cXk_\ Z_lZb K_\ _\Xmp n\`^_k f] X ]Xcc$ `e^ Z_lZb ZXe ZXlj\ j\i`flj `ealip% Kfi\dfm\k_\\o`jk`e^Z_lZb#[fk_\j\jk\gj1 (% DISCONNECT POWER TO THE LATHE! *. Loosen the 3 cam-locks by turning the chuck key counterclockwise until the mark on the cam-lock aligns with the single mark on the spindle nose in =`^li\(.% This will be approximately one-third of a turn. If you look carefully, you will see the cam-lock rise up out of the spindle nose. If the cam-lock stud does not freely release from the cam-lock, wiggle the cam-lock until the cam-lock stud releases. FG<I8K@FEJ )% Lay a chuck cradle or protective layer of plywood over the bedways to protect the precision ground surfaces from damage and to prevent fingers from being pinched (see =`^li\(-). =`^li\(-%Simple chuck cradle made of scrap lumber. Efk\1 K_\j\ZXd$cfZbjdXpY\m\ipk`^_k%8Yi\Xb\i YXidXpY\lj\[kfX[[c\m\iX^\% =`^li\(.%Loosening the cam-locks. -17- D('0/(*o+'>\Xi?\X[CXk_\ +% Using a dead blow hammer or other soft mallet, lightly tap around the outer circumference of the chuck body to break the chuck free from the camlocks and from the spindle nose taper. CXi^\ Z_lZbj Xi\ m\ip _\Xmp% 8cnXpj ^\k Xjj`jkXeZ\ n_\e i\dfm`e^ fi `ejkXcc`e^ cXi^\ Z_lZbj kf gi\m\ek g\ijfeXc `ealip fi [XdX^\ kf k_\ Z_lZb fi cXk_\% ,% With a rocking motion, carefully remove the chuck from the spindle nose (see =`^li\(/). Kf`ejkXcck_\k_i\\$aXnjZifccZ_lZb#[fk_\j\jk\gj1 Spindle Nose Taper =`^li\(/%Installing and removing a small chuck. (% DISCONNECT POWER TO THE LATHE! FG<I8K@FEJ )% Lay a chuck cradle or protective layer of plywood over the bedways to protect the precision ground surfaces from damage and to prevent fingers from being pinched. *% If the three-jaw scroll chuck does not have the camlock studs assembled, screw the cam-lock studs into the chuck body. +% Measure the height of the cam-lock studs from the previously installed chuck (see =`^li\(0). ,% Adjust the cam-lock studs in the three-jaw chuck to match the measurement from the previous chuck. =`^li\(0% Measuring height of cam-lock studs. Efk\1 Ki`Xc$Xe[$\iifiX[aljkd\ekn`ccY\e\\[\[`] pfl[fefk_Xm\Xgi\m`fljZXd$cfZbjkl[kfi\]\i$ \eZ\% -% Once the proper length is obtained, thread the cap screws to lock the cam-lock studs into position. .% Lift the chuck, and insert the studs onto the spindle nose. /% Tighten each cam-lock clockwise until you feel the cam-lock engage the cam-lock stud. Continue to turn until you can't turn any further. You will see the chuck body draw-up to the spindle nose. Ideally the cam-lock mark will fall between the two pointed arrows on the spindle nose (see =`^li\)'). -18- =`^li\)'%Tightening the cam-locks. D('0/(*o+'>\Xi?\X[CXk_\ KfcfX[Xnfibg`\Z\#[fk_\j\jk\gj1 (% With the chuck key, open the jaws so the workpiece lays flat against the chuck face and jaw step, or fits in the through hole. For jaw and work holding options, see=`^li\)(. )% Turn each jaw until it makes contact with the workpiece. :cXdg`e^feXeFlkj`[\;`Xd\k\i *% Turn the chuck by hand to make sure you have even contact with all three jaws and the workpiece is not off center. • If the workpiece is off center, loosen the jaws and adjust the workpiece. :cXdg`e^`eXe@ej`[\;`Xd\k\i =`^li\)(% Loading a workpiece. • If the workpiece is seated correctly, tighten the jaws. I\gcXZ`e^AXnj =`^li\))% Jaw number identification. Three-jaw scroll chucks come with two sets of hardened steel jaws. The outside jaws are used to hold the workpiece from the outer diameter. The inside jaws are for holding larger work usually from the inside diameter. The inside jaws can hold a workpiece from the outside when held in the central position (see =`^li\)(). The jaws are numbered 1–3 and must be installed in this sequence (see =`^li\))). -19- FG<I8K@FEJ J\Zli\cp ZcXdg pfli nfibg`\Z\ Xe[ i\dfm\ k_\ Z_lZb b\p K_ifne fYa\Zkj ]ifdXcXk_\ZXeZXlj\j\i`flj`ealipfi [\Xk_kfk_\fg\iXkfiXe[kfYpjkXe[\ij dXep]\\kXnXp% D('0/(*o+'>\Xi?\X[CXk_\ Kfi\dfm\Xj\kf]aXnj#[fk_\j\jk\gj1 (% DISCONNECT POWER TO THE LATHE! )% Identify the jaw position by the number usually stamped on the side of the jaw groove (see =`^li\ )*). Jaw Number Efk\1K_\Z_lZb_XjXeldY\i`ek_\aXn^l`[\k_Xk Zfii\jgfe[jkfk_\aXneldY\ij\\=`^li\)* %@] `k[f\jefk#cfZXk\k_\aXneldY\ifek_\aXnXe[ dXibk_\Z_lZbkf`[\ek`]pk_Xkgfj`k`fe% *. +. Turning the chuck key counterclockwise, back the jaws out of the chuck body. They will be released from the scroll thread in a reverse sequence. =`^li\)*%Typical jaw number location. Jaw Guide Number Set the jaws aside in a safe place. Kf`ejkXccXj\kf]aXnj#[fk_\j\jk\gj1 (% DISCONNECT POWER TO THE LATHE! FG<I8K@FEJ )% Identify the jaw by the number stamped on the side. *% Locate the corresponding jaw guide on the chuck body (see =`^li\)+). +. Insert the chuck key into the chuck. ,. Look into the jaw guide and you will see the scroll rotating as you turn the chuck key. When the leading thread of the scroll comes into view at the top of the #1 jaw guide, stop turning the chuck key (see =`^li\),). -. Slide jaw #1 into the jaw guide until it stops. .. Turn the chuck key so the leading thread of the scroll picks up the first thread on the jaw. When the lead thread engages, you will see the jaw being drawn to the center of the chuck (see =`^li\),). =`^li\)+% This chuck has jaw references on the inside of the jaw guide. (Chuck removed from spindle for clarity). Lead Thread =`^li\),% Lead thread on scroll. -20- D('0/(*o+'>\Xi?\X[CXk_\ /% Continue to turn the chuck key until the leading thread of the scroll comes to the second jaw guide (see =`^li\)-). 0% Repeat Jk\gj,Æ. with jaw #2. Lead Thread ('% Continue to turn the chuck key until the leading thread of the scroll comes to the third jaw guide. ((% Repeat Jk\gj,Æ. with jaw #3. =`^li\)-%Lead thread coming in to view for jaw #2. Lead Thread -21- FG<I8K@FEJ =`^li\).%Lead thread coming in to view for jaw #3. D('0/(*o+'>\Xi?\X[CXk_\ =fli$AXn;`i\ZkDflek @e[\g\e[\ek:_lZb Four-jaw chucks feature hardened steel jaws that are adjusted independently. Each jaw can be removed from the chuck body and reversed. Independent jaw adjustment and reversal allows for a wide range of work holding versatility. The four-jaw direct mount independent chuck featured in these instructions mounts the same way as the three-jaw chuck. Refer to the three-jaw chuck instructions beginning on GX^\(.% FG<I8K@FEJ CXi^\Z_lZbjXi\m\ip_\Xmp%8cnXpj_Xm\Xjj`jkXeZ\ n_\e i\dfm`e^ fi `ejkXcc`e^ cXi^\ Z_lZbj kf gi\m\ek g\ijfeXc `ealip fi [XdX^\ kf k_\ Z_lZb fi cXk_\% G@E:? ?8Q8I; Gifk\Zk pfli _Xe[j Xe[ gi\Z`j`fe ^ifle[ Y\[nXpj n`k_ gcpnff[ n_\e i\dfm`e^ cXk_\ Z_lZb K_\ _\Xmp n\`^_k f] X ]Xcc$ `e^ Z_lZb ZXe ZXlj\ j\i`flj `ealip% =`^li\(%Simple chuck cradle made of scrap lumber. -22- D('0/(*o+'>\Xi?\X[CXk_\ KfcfX[Xnfibg`\Z\`ek_\]fli$aXnZ_lZb#[fk_\j\ jk\gj1 (% Using the chuck key, open each jaw so the workpiece will lay flat against the chuck face. )% Support the workpiece. *% Lock the tailstock and then turn the tailstock quill so the dead center makes contact or is close to the center point of your workpiece (see=`^li\)/). +% Turn each jaw until it just makes contact with the workpiece. =`^li\)/% Clamping workpiece. ,% In an opposing pattern, tighten each jaw in small increments. After you have adjusted the first jaw, continue tightening the opposing jaw. Check the dead center alignment frequently to make sure you have not wandered off your index point due to applying too much pressure to a single jaw. After the workpiece is held in place, back the tailstock away and rotate the chuck by hand. The center point will move if the workpiece is out of center. .% Make fine adjustments by slightly loosening one jaw and tightening the opposing jaw until the workpiece is precisely aligned. Use a dial indicator for fine tuning adjustments in alignment (see=`^li\)0). /% Use a lower RPM when machining heavy eccentric workpieces. -23- =`^li\)0% Centering workpiece. FG<I8K@FEJ -% D('0/(*o+'>\Xi?\X[CXk_\ =XZ\gcXk\ The faceplate can be used to turn non-cylindrical parts or for off-center turning by clamping the workpiece to the faceplate. Kf`ejkXcck_\]XZ\gcXk\#[fk_\j\jk\gj1 Installing the faceplate follows the same steps as any of the lathe chucks. Install according to the instructions for three-jaw chucks found on GX^\(.. FG<I8K@FEJ KfcfX[Xnfibg`\Z\#[fk_\j\jk\gj1 (. Support the workpiece. )% Slide the tailstock to the workpiece. *% Lock the tailstock and then turn the tailstock quill so the dead center makes contact with the center point of your workpiece. For more information refer to :\ek\ij in this section on GX^\)0% +% Lock the tailstock quill when sufficient pressure is applied to hold the workpiece in place. Depending on the workpiece, some additional support may be needed. ,% Secure the workpiece with a minimum of three independent clamping devices (see =`^li\*'). Failure to follow this step may lead to deadly injury to yourself or bystanders. Take into account rotation and the cutting forces applied to the workpiece when clamping to the faceplate. DXb\jli\pfliZcXdg`e^ Xggc`ZXk`fen`ccefk]X`c -% Use a lower RPM when machining heavy eccentric workpieces. =`^li\*'% Typical faceplate with properly clamped workpiece in four locations. Lj\ X d`e`dld f] k_i\\ `e[\g\e[\ek ZcXdg`e^[\m`Z\jn_\eklie`e^\ZZ\eki`Z nfibg`\Z\j% =X`cli\ kf gifm`[\ X[\hlXk\ ZcXdg`e^ n`cc ZXlj\ nfibg`\Z\ kf \a\Zk% J\Zli\cp ZcXdg pfli nfibg`\Z\ Xe[ i\dfm\k_\Z_lZbb\pK_ifnefYa\Zkj ]ifdXcXk_\ZXeZXlj\j\i`flj`ealipfi [\Xk_kfk_\fg\iXkfiXe[kfYpjkXe[\ij dXep]\\kXnXp% -24- D('0/(*o+'>\Xi?\X[CXk_\ >XgG`\Z\I\dfmXc The Model M1098 comes equipped with a gap piece below the spindle that can be removed for turning large diameter parts or when using a large diameter faceplate. The gap piece is installed, then ground at the factory during lathe assembly for precise fit and alignment. Factors during the remaining assembly apply additional forces to the gap; therefore, replacing the gap to the original position will be very difficult. @]pflZ_ffj\kf i\dfm\k_\^Xgg`\Z\#n\[feki\Zfdd\e[Xkk\dgk$ `e^kfi\gcXZ\`k% Taper Pins Kfi\dfm\k_\^Xgg`\Z\#[fk_\j\jk\gj1 Find the two taper pin nuts located on the bed of the gap piece (see =`^li\ *(). )% Using an open-ended wrench, tighten the nut. This will cause the taper pin to release. Remove the taper pin and repeat for the second nut. *% Remove the four socket head cap screws. +% Tap the outside of the gap piece with a dead blow hammer to loosen, and remove the gap piece. -25- =`^li\*(% Lathe gap piece. FG<I8K@FEJ (% D('0/(*o+'>\Xi?\X[CXk_\ KX`cjkfZb The tailstock (=`^li\*)) of the Model M1098 lathe can be used to support workpieces with the use of a live or dead center. It can drill or bore holes in the center of a part, using a drill chuck fitted with a #3 taper and a drill bit, or bypass the drill chuck and use a #3 tapered shank drill bit. Tthe tailstock can also be used for cutting shallow tapers by using the offset adjustment. Kffg\iXk\k_\kX`cjkfZb#[fk_\j\jk\gj1 Tailstock Lock (% Slide the tailstock to the desired position. )% Pull up on the tailstock lock handle to lock the tailstock in place. Quill Lock Lever Stop Posts =`^li\ *)% Tailstock and quill lock handles in locked position. Kffg\iXk\k_\kX`cjkfZbhl`cc#[fk_\j\jk\gj1 FG<I8K@FEJ Quill Feed (% With the tailstock locked, push down the quill lock handle to unlock. )% Turn the quill feed handle clockwise to feed/move the quill towards the spindle, or counterclockwise to move away from the spindle. *% Pull up on the quill lock handle to lock the quill in place. ;i`cc`e^n`k_k_\KX`cjkfZb Kf`ejkXcck_\kXg\i\[[i`ccZ_lZb#[fk_\j\jk\gj1 (% With the tailstock locked, push down to unlock the quill lock handle. )% Turn the quill feed handle clockwise to extend the quill about one inch. *% Insert a tapered drill arbor (=`^li\**), or the tapered drill shank (=`^li\*+), into the quill until the taper is firmly seated. The matching tapers hold the arbor. +% Turn the quill feed handle clockwise to feed the drill bit into the rotating workpiece. ,% To remove the chuck taper, turn the quill feed handle counterclockwise until the chuck is pushed out from the tailstock taper. -26- =`^li\**% Setting up tailstock for drilling. =`^li\*+% Tapered shank drill fitting into quill taper. D('0/(*o+'>\Xi?\X[CXk_\ :lkk`e^J_XccfnKXg\ij n`k_k_\KX`cjkfZb The tailstock can be offset to cut a shallow taper on a part. Lock Screw Right Jack Screw Kfj\klgk_\kX`cjkfZbkfZlkkXg\ij#[fk_\j\jk\gj1 (% Lock the tailstock in position. )% Loosen the lock screw (see =`^li\*,). *% Alternately loosen and tighten the left and right jack screws until the desired offset is indicated on the scale (see =`^li\*-). +% Retighten the lock screw. Efk\1 Kfi\kliek_\kX`cjkfZbYXZbkfk_\fi`^`eXc gfj`k`fe#i\g\Xkk_\gifZ\jjlek`ck_\Z\ek\i\[gfj`$ k`fe`j`e[`ZXk\[fek_\jZXc\% =`^li\ *,% Tailstock off-set adjustments. KX`cjkfZb8c`^ed\ek Left Jack Screw Scale KfXc`^ek_\kX`cjkfZb#[fk_\j\jk\gj1 (% Using a precision level on the bedways, make sure the lathe is level side-to-side and front-to-back. If the lathe is not level, correct this condition before proceeding. )% Get two pieces of steel round stock, 2.00" in diameter x 6.00" long. *% Center drill both ends of one piece of the round stock. Set it aside for use in Jk\g-% +% Using the other piece of stock, make a dead center by turning a shoulder to make a shank. Flip the piece over in the chuck and turn a 60º point (see =`^li\ *.)% Continued on next page -27- =`^li\*-% Off-set scale. =`^li\*.% Tailstock centering dead center. FG<I8K@FEJ The tailstock on the Model M1098 is aligned at the factory with the headstock. We recommend that you take the time to ensure that the tailstock is aligned to your own desired tolerances. D('0/(*o+'>\Xi?\X[CXk_\ Efk\1 8jcfe^Xjk_\[\X[Z\ek\ii\dX`ej`ek_\ Z_lZb#k_\gf`ekf]pfliZ\ek\in`cci\dX`ekil\kf k_\jg`e[c\Xo`j%B\\g`ed`e[k_Xkk_\gf`ekn`cc _Xm\kfY\i\]`e`j_\[n_\e\m\i`k`ji\dfm\[Xe[ i\klie\[kfk_\Z_lZb%=fidfi\`e]fidXk`fei\]\i kf:\ek\ijfeGX^\)0`ek_`jj\Zk`fe% ,% Place the live center in the tailstock. -% Attach a lathe dog to the bar stock and mount it between centers (see =`^li\*/)% .% Turn approximately 0.010" off the diameter. /% Measure the stock with a micrometer. =`^li\*/% Checking tailstock alignment. • If the stock is fat at the tailstock end, the tailstock needs to be moved toward the operator half the distance of the amount of the taper (see =`^li\*0). FG<I8K@FEJ • If the stock is thinner at the tailstock end, the tailstock needs to be moved away from the operator half the distance of the amount of the taper (see =`^li\+'). 0% Mount a dial indicator so the dial plunger is on the tailstock barrel before making adjustments to the tailstock. ('% Refer to :lkk`e^J_XccfnKXg\ijN`k_K_\KX`cjkfZb on GX^\).for making adjustments to the tailstock center. Turn another 0.010" off of the diameter and check for a taper. Repeat this process as necessary until the desired amount of accuracy is achieved. =`^li\*0% Tailstock adjustment option #1. =`^li\+'% Tailstock adjustment option #2. -28- D('0/(*o+'>\Xi?\X[CXk_\ :\ek\ij The dead center is used in the tailstock to support workpieces. When used in the tailstock, make sure to keep the dead center tip and workpiece lubricated. The Model M1098 lathe is supplied with two MT#3 dead centers, one is HSS and one is carbide tipped. The supplied MT#5-#3 sleeve fits into the spindle taper to hold the MT#3 center. Kf`ejkXccX[\X[fic`m\Z\ek\i#[fk_\j\jk\gj1 Feed the quill out about 1" so that the dead center can be inserted. )% Insert the dead center into the quill opening. Matching tapers provide the locking action (see =`^li\+(). *% Move the tailstock into position and lock in place. +% Feed the quill into the workpiece. Efk\1DXb\jli\k_\i\`jXZ\ek\i[i`cc\[_fc\`e k_\\e[f]k_\nfibg`\Z\]fik_\[\X[Z\ek\i% ,% Lock the quill into place once the live center and the part rotate together. The quill may need to be adjusted during operation. -% To remove the dead center, retract the quill until the dead center pops free. The dead center can also be used in the spindle. The most common application is when using the faceplate (see =`^li\ +)). Kf `ejkXcc k_\ [\X[ Z\ek\i `e k_\ jg`e[c\# [f k_\j\ jk\gj1 (% Remove the chuck from the spindle. )% Install the dead center in the spindle sleeve. *% Install the sleeve and center into the spindle opening. +% Attach the faceplate to the spindle. Efk\1 N_\elj`e^k_\[\X[Z\ek\i`ek_\jg`e[c\# lj\XcXk_\[f^jfk_XkpfligXikn`ccifkXk\n`k_ k_\jg`e[c\Xe[efkjg`efek_\[\X[Z\ek\ik`g% -29- =`^li\+(% Inserting dead center. =`^li\+)% Faceplate and dead center setup. EFK@:< =X`cli\kfb\\g[\X[Z\ek\igf`ekn\cc clYi`ZXk\[n`cc[XdX^\[\X[Z\ek\iXe[ nfibg`\Z\% FG<I8K@FEJ (% D('0/(*o+'>\Xi?\X[CXk_\ Jk\X[pI\jk The steady rest serves as a support for long shafts (l/d ratio of 3:1 or greater). The steady rest can be placed anywhere along the length of the part. Kf`ejkXcc&lj\k_\jk\X[pi\jk#[fk_\j\jk\gj1 Knurled Knob (% Place the steady rest on the lathe bedways so the triangular notch fits over the angled portion of the rear bedway. )% FG<I8K@FEJ *% Loosen the three set screws so the finger position can be adjusted (see =`^li\ +*). Loosen the knurled knob (see =`^li\+*) and open the steady rest so a workpiece can fit inside of the fingers (see =`^li\ ++). +% Position the steady rest where desired. Tighten the bolt at the base of the steady rest to secure in place. ,% Close the steady rest so that the workpiece is inside the fingers and tighten the knob. -% Set the fingers snug to the workpiece and secure by tightening the three set screws. Fingers should be snug and allow rotational movement of the workpiece. Lubricate the finger tips with an anti-seize grease during operation. .% After prolonged use, the fingers will show wear. Either mill or file the tips for a new contact surface. Knob Set Screws =`^li\+*% Steady rest adjustments. Finger Adjustment Knobs =`^li\++% Positioning workpiece in steady rest. =fccfnI\jk The follow rest in =`^li\+, is mounted on the saddle and follows the movement of the tool. It can be attached/removed by two socket head cap screws located at the base of the follow rest. The follow rest requires only two fingers, as the cutting tool acts as the third. The follow rest is used on long, slender parts to prevent flexing of the workpiece from the pressure of the cutting tool. The sliding fingers are set similar to those of the steady rest—free of play but not binding. Always lubricate during operation. Remove the follow rest from the saddle when not in use. After prolonged use, the fingers will need to be milled or filed to cleanup the contact surface. -30- =`^li\+,% Follow rest attachment. D('0/(*o+'>\Xi?\X[CXk_\ J\kk`e^:fdgfle[Jc`[\ The compound slide is used to cut tapers on parts or to set the proper infeed angle when threading. It may also be used to cut specific lengths longitudinally, when set parallel to the spindle axis. Cap Screws Compound Slide The compound slide handwheel has a graduated dial for precise inch feed increments. The base of the compound slide has a graduated scale for angular setup. Kfj\kk_\Xe^lcXigfj`k`fe#[fk_\j\jk\gj1 (% Loosen the two cap screws, one on each side of the compound slide (see =`^li\+-). )% Rotate the compound slide to the desired angular position. Use the scale at the base of the slide and the indicator marks on the carriage to set the position. *% =`^li\+-% Compound slide set at an angle. Tool Post Bolts Tighten the two cap screws. Be sure to not overtighten, as you may strip threads. =fli$NXpKffcGfjk FG<I8K@FEJ The four-way tool post is mounted on top of the compound slide, and allows a maximum of four tools to be loaded simultaneously. The four-way tool post allows for quick indexing to new tools. This is accomplished by rotating the top handle counterclockwise and then rotating the tool post to the desired position. Rotate the top handle clockwise to lock the tool into position. =`^li\+.% Tool holder and tool post. EFK@:< KfcfX[k_\kffcgfjk#[fk_\j\jk\gj1 @dd\[`Xk\cp i\dfm\ kffc gfjk ni\eZ_ X]k\i lj\% Kffc gfjk ni\eZ_ Zflc[ Y\ g`Zb\[lgYpZ_`gXe[k_ifne% (% Choose the desired cutting tool. )% Loosen the tool post bolts so that the cutting tool can fit underneath. *% Use a minimum of two tool post bolts to hold down the cutting tool and tighten firmly (see =`^li\+.). +% Repeat Jk\gj($* for the three remaining openings, as needed. -31- D('0/(*o+'>\Xi?\X[CXk_\ =ffk9iXb\ The Model M1098 lathe comes equipped with a foot brake (see =`^li\+/ % The foot brake is intended to be used primarily as a time saving tool. The best method for using the foot break is turn the spindle F== and then apply pressure to the foot brake with your foot, slowing the spindle to a stop. Stepping on the foot brake while the spindle is FEwill kill the power to the spindle control lever and will bring the spindle to a stop. Stopping the spindle in this manner is harder on the machine and should be reserved for emergency situations. Once stopped, the control lever will then need to be returned to the neutral position. The power light will show the power is still FE. Only the circuit to the Spindle Rotation ON/OFF Lever will be interrupted. Efk\1 ;fefkZfe]lj\k_`j]\Xkli\n`k_k_\\d\i^\eZp jkfgYlkkfe%K_\\d\i^\eZpjkfgYlkkfeZlkjgfn\ikf k_\dXZ_`e\Xe[dljkY\i\j\kkfi\jkfi\gfn\ikfk_\ cXk_\% Spindle Control Lever Foot Brake =`^li\+/% Foot brake and spindle control lever. Compound Slide Handwheel Cross Feed Handwheel FG<I8K@FEJ DXelXc=\\[ You can manually move the cutting tool around the lathe with three methods. This section will review the individual controls on the carriage and provide descriptions of their uses (see =`^li\+0). Cfe^`kl[`eXc?Xe[n_\\c Longitudinal Handwheel The longitudinal handwheel moves the carriage left or right along the bed. This control is helpful when setting up the machine for turning or when manual movement is desired during turning operations. :ifjj=\\[?Xe[n_\\c The cross slide handwheel moves the top slide toward and away from the work. Turning the dial clockwise moves the slide toward the workpiece. The graduated dial can be adjusted by holding the handwheel with one hand and turning the dial with the other. :fdgfle[Jc`[\?Xe[n_\\c The compound slide handwheel controls the position of the cutting tool relative to the workpiece. The compound slide is adjustable for any angle within its range. The graduated dial is adjustable using the same method as the dial on the cross slide. Angle adjustment is controlled by cap screws on the base of the compound slide. -32- =`^li\+0% Carriage controls. D('0/(*o+'>\Xi?\X[CXk_\ J\kk`e^IGD Kf[\k\id`e\Xe[j\kk_\e\\[\[Zlkk`e^IGD1 (% :lkk`e^Jg\\[j]fi?`^_Jg\\[Jk\\c ?JJ :lkk`e^Kffcj Use the table in =`^li\,' to determine the cutting speed required for the material of your workpiece. =X`cli\ kf ]fccfn IGD Xe[ ]\\[ iXk\ ^l`[\c`e\j dXp k_i\Xk\efg\iXkfijX]\kp]ifd\a\Zk\[gXikjfiYif$ b\ekffcj% )% Determine the final diameter, in inches, for the cut you are about to take. Efk\1 =fik_`jjk\gpfln`cce\\[kfXm\iX^\flkk_\ [`Xd\k\ijfinfibn`k_k_\]`e`j_[`Xd\k\i]fipfli ZXcZlcXk`fej% *% :lkk`e^Jg\\[o+ 4IGD ;`Xd\k\if]:lk +% With the calculated RPM, decide on the closest cutting RPM to what you need. ,% Make sure the spindle is completely stopped before proceeding. -% Move the levers to the RPM that is closest to your calculated RPM. The long lever (Range Lever) selects High or Low range, and the shorter lever (RPM Lever) selects the RPM in that range (=`^li\,(). Efk\1 PfldXpe\\[kfifkXk\k_\jg`e[c\Yp_Xe[ kf^\kk_\c\m\ijkfgifg\icp\e^X^\% Cutting Speed (sfm) Aluminum & alloys 300 Brass & Bronze 150 Copper 100 Cast Iron, soft 80 Cast Iron, hard 50 Mild Steel 90 Cast Steel 80 Alloy Steel, hard 40 Tool Steel 50 Stainless Steel 60 Titanium 50 Plastics 300-800 Wood 300-500 Efk\1 =fiZXiY`[\Zlkk`e^kffcj#[flYc\ k_\Zlkk`e^jg\\[%K_\j\mXcl\jXi\X ^l`[\c`e\fecp% Refer to the D8:?@E<IPJ?8E;9FFB for more detailed information. =`^li\,'% Cutting speed table for HSS cutting tools. Range Lever RPM Lever =`^li\ ,(% Spindle speed selector levers. -33- FG<I8K@FEJ Use the following formula to determine the needed RPM for your operation: Workpiece Material D('0/(*o+'>\Xi?\X[CXk_\ Jg`e[c\9i\Xb$@e It is essential to closely follow the proper break-in procedure to ensure correct bearing and gear tooth seating and mating. Complete this process once you have familiarized yourself with all instructions in this manual. KfY\^`ek_\Yi\Xb$`egifZ\[li\#[fk_\j\jk\gj1 EFK@:< =X`cli\ kf ]fccfn jkXik lg Xe[ jg`e[c\ Yi\Xb$`e gifZ\[li\j n`cc ZXlj\ iXg`[ [\k\i`fiXk`fef]jg`e[c\[i`m\jpjk\d% FG<I8K@FEJ (% Check oil levels in headstock and apron. Correct oil levels if required. Refer to ClYi`ZXk`fein the D8@EK<E8E:<section on GX^\*0of this manual. )% Make sure there are no obstructions around or underneath the spindle. +% Set the spindle speed to 190 RPM, refer to section J\kk`e^IGD on GX^\**% ,% Turn the lathe power FE#andmove the Jg`e[c\ IfkXk`feFE&F==C\m\i(=`^li\,)) to either the FORWARD or REVERSE position, and verify that the spindle rotates in the proper direction. -% Let the lathe run for a minimum of 10 minutes. .% Turn the lathe F==, change gears to the next highest RPM and repeat this step for each RPM setting in Low and High Range. /% Change the headstock lubricant, refer to GX^\*0. =`^li\,)% Spindle Rotation ON/OFF Lever. Cross slide feed rate will be 0.438" travel per revolution of the chuck, and the longitudal feed rate will be 0.127" travel per revolution of the chuck. J\kk`e^Gfn\i=\\[IXk\ The carriage has longitudinal and cross slide power feed capabilities. Efk\1 K_\j\`ejkilZk`fejXi\mXc`[n`k_X Zflek\iZcfZbn`j\ifkXk`fef]k_\jg`e[c\cffb`e^Xkk_\ Z_lZb%8cc[`i\Zk`feji\m\ij\n_\ejg`e[c\ifkXk`fe`j i\m\ij\[% Kfj\kXe[\e^X^\k_\gfn\i]\\[#[fk_\j\jk\gj1 (% From your cutting and feed rate calculations, select the feed rate that you need from the chart (see =`^li\,*). )% Install the 40 tooth change gear at location X shown on the chart. *% Turn the feed dials to the setting indicated on the chart. Efk\1PfldXpe\\[kfifkXk\k_\Z_lZbYp _Xe[fidfm\k_\cfe^`kl[`eXc_Xe[n_\\ckf^\k j\c\ZkfijXe[^\Xijkf\e^X^\% -34- =`^li\,*% Selecting power feed rate. D('0/(*o+'>\Xi?\X[CXk_\ +% Make sure the half nut lever shown in =`^li\,+ is disengaged. ,% Use the feed selector lever shown in =`^li\,, to engage the cross feed or longitudal feed when needed. -% Use the Jg`e[c\IfkXk`feFE&F==C\m\i(=`^li\ ,,) to start the lathe and the power feed operation when needed. Spindle Rotation ON/OFF Lever Half Nut Lever EFK@:< =\\[iXk\`jYXj\[fejg`e[c\IGD%?`^_]\\[iXk\j ZfdY`e\[n`k__`^_jg`e[c\jg\\[ji\jlck`eXiXg`[cp dfm`e^ZXii`X^\fiZifjjjc`[\%GXpZcfj\Xkk\ek`fekf k_\]\\[iXk\pfl_Xm\Z_fj\eXe[Y\i\X[pkfglj_ k_\]ffkYiXb\%=X`cli\kf]lccple[\ijkXe[k_`jn`cc ZXlj\k_\ZXii`X^\kfZiXj_`ekfk_\jg`e[c\% EFK@:< Up: Cross Feed Central: Feeds is Disengaged Down: Longitudinal Feed =`^li\,,% Feed selector lever. -35- FG<I8K@FEJ DXb\ jli\ Xcc gfn\i ]\\[ j\kk`e^j Xi\ [`j\e^X^\[ Y\]fi\ jkXik`e^ k_\ cXk_\ K_fifl^_cp ]Xd`c`Xi`q\ pflij\c] n`k_ Xcc k_\ Zfekifcj Xe[ k_\`i ]leZk`fej Y\]fi\lj`e^gfn\i]\\[ =`^li\,+% Disengaging half nut lever. D('0/(*o+'>\Xi?\X[CXk_\ K_i\X[J\kk`e^j The Model M1098 lathe is capable of cutting inch and metric threads. Most inch threads can be cut without changing out gears. Metric threads and a few inch threads require that you change the gears. Thread cutting will be three threads per inch. Kf[\k\id`e\k_i\X[j\kk`e^j#[fk_\j\jk\gj1 (% Calculate your required cutting speed, and move the spindle RPM levers so it will run at the closest RPM. )% Determine the threads per inch (TPI) for inch threads or pitch for metric threads. *% Install the +' tooth gear at position X, and the *' tooth gear at position Y as shown on the chart (see =`^li\,-). +% Turn the feed dials to the setting indicated on the chart (see =`^li\,-). FG<I8K@FEJ Efk\1PfldXpe\\[kfifkXk\k_\Z_lZbYp_Xe[fi dfm\k_\cfe^`kl[`eXc_Xe[n_\\ckf^\kj\c\Zkfij Xe[^\Xijkf\e^X^\% ,% Move the feed selector lever to the central position shown in =`^li\,. to disengage the cross feed or longitudal feed. -% Use the Jg`e[c\IfkXk`feFE&F==C\m\ito start the lathe when needed. .% Use the half nut lever to engage and disengage the apron for threading operations. =`^li\,-% Feed and thread chart in TPI and metric pitch. Half Nut Lever Central Position: Feed is Disengaged =`^li\ ,.% Apron control levers. -36- D('0/(*o+'>\Xi?\X[CXk_\ :_Xe^\>\Xij The Model M1098 lathe comes with 40, 127, 120, and 30 tooth gears installed. One extra 40 tooth gear is included so gear ratios can be altered for threading operations. The charts on the machine indicate which ratios are applicable for an intended operation. Thumb Knob KfZ_Xe^\k_\^\Xij#[fk_\j\jk\gj1 (% DISCONNECT POWER TO THE LATHE! )% Remove two thumb knobs and remove the headstock gear cover to expose the change gears (=`^li\,/). Loosen the gear adjuster (=`^li\,0),and let the gear swing down. +% Remove the appropriate change gear according to your the chart, and install the required gear (see =`^li\,0). ,% Mesh the gear teeth, and tighten the gear adjuster back in place so there is a slight amount of geartooth backlash, approximately from 0.002" to 0.005". Efk\1J\kk`e^k_\^\Xijkffk`^_kn`ccZXlj\\oZ\j$ j`m\n\XiXe[ef`j\%J\kk`e^k_\^\Xijkffcffj\dXp ZXlj\jc`ggX^\Xe[gfjj`YcpYi\Xb^\Xik\\k_% Gear Adjuster -% Oil the gears, reinstall the gear cover, and reconnect power to the machine. >\XiiXk`f`jXj]fccfnj1 +'KÇ5()'K ().KÇ5+'K =`^li\,0% Change gear locations. -37- FG<I8K@FEJ *% =`^li\ ,/% Gear cover. D('0/(*o+'>\Xi?\X[CXk_\ K_i\X[`e^Fg\iXk`fe FG<I8K@FEJ (% Set the compound rest to the appropriate angle for the given thread you want to cut. For a Unified National Series thread, this is 29º off of perpendicular to the spindle axis. )% Set the tool tip perpendicular to the workpiece and center it vertically. *% Make sure the thread dial is engaged with the lead screw. If not, use a hex wrench to loosen the screw and rotate the thread dial until the gear engages with the lead screw, then tighten the screw to hold the dial in place. +% Select the RPM you want to use. A slower RPM will give you more time to react especially if threading over a short distance or threading up to a shoulder. ,% Set the feed direction lever for either right or lefthanded threads. -% With the feed rate selectors to the appropriate settings, turn FE the spindle to verify settings. Check to see that the lead screw is turning and verify that the apron moves in the correct direction by engaging the half nut lever shown in =`^li\-'. .% Once you are confident the settings are correct, disengage the half nut and turn F== the spindle. /% Examine the indicator table on the machine or in =`^li\-(to determine which numbers (on the thread dial) will engage the half nut. Efk\1 K_\i\Xi\XkfkXcf]\`^_kdXibjfek_\ k_i\X[[`Xc#`eZcl[`e^k_\eldY\ij($+%8epdXib ZXeY\lj\[kfZlk\m\eeldY\i\[k_i\X[j%Lj\k_\ eldY\i\[c`e\j#(#)#*#fi+kfZlkf[[eldY\i\[ k_i\X[j%KfdX`ekX`eXZZliXZpXe[Zfej`jk\eZp# \e^X^\k_\_Xc]elkfek_\jXd\dXibfe\XZ_gXjj% =X`cli\kfjkXikfek_\jXd\eldY\i\XZ_k`d\dXp c\X[kfZlkk`e^f]]k_\k_i\X[dX[\`ek_\gi\m`flj gXjj% 0% If cutting metric threads, you will not use the thread dial. Once the half nut is engaged, you must leave it engaged until the threads are complete. -38- EFK@:< =X`cli\ kf ]fccfn IGD Xe[ ]\\[ iXk\ ^l`[\c`e\j `e k_`j dXelXc n`cc glk le[l\jkiX`efedfm`e^gXikj#j_fik\e kffc c`]\# Xe[ Zi\Xk\ gffi nfibg`\Z\ i\jlckj% Thread Dial Half Nut Lever =`^li\-'% Half nut and thread dial location. =`^li\-(% Thread dial chart. D('0/(*o+'>\Xi?\X[CXk_\ D8@EK<E8E:< >\e\iXc Regular periodic maintenance on your E:AB8AJ® Model M1098 will ensure its optimum performance. Make a habit of inspecting your machine each time you use it. :_\Zb]fik_\]fccfn`e^Zfe[`k`fejXe[i\gX`ifi i\gcXZ\n_\ee\Z\jjXip1 Loose mounting bolts. Worn switch or safety features. Worn or damaged cords and plugs. Damaged V-belt. Any other condition that could hamper the safe operation of this machine. :c\Xe`e^ Make sure to unplug the lathe before cleaning it. Clean your machine every day or more often as needed. Remove chips as they accumulate. Chips left on the machine soaked with water based coolant will eventually invite oxidation and gummy residue to build up around moving parts. Cleaning will help keep your lathe running smoothly. Always be safe and responsible with the use and disposal of cleaning products. D8B< JLI< k_Xk pfli dXZ_`e\ `j legcl^^\[ [li`e^ Xcc dX`ek\eXeZ\ gif$ Z\[li\j@]k_`jnXie`e^`j`^efi\[#j\i`$ fljg\ijfeXc`ealipdXpfZZli% Headstock Oil Sight Glass Gear Box Oil Sight Glass ClYi`ZXk`fe =`^li\-)% Oil sights and filler locations. Headstock Oil Drain Behind Gear Gear Box Oil Drain =`^li\-*% Headstock and gear box drain locations. -39- D8@EK<E8E:< The headstock, gear box and apron can use any quality ISO 32 hydraulic oil. Keep the oil levels at 3/4-full as seen in the sight glasses (see =`^li\j-), -*#and-+). After break-in, change the oil in the headstock after three months. After that change the all oils at the same time on an annual basis or more frequently if extreme machine use requires it. D('0/(*o+'>\Xi?\X[CXk_\ For daily lubrication, use the manual oil gun with the same gear box lubricant to lubricate all oil fittings. To control surface rust on machined surfaces, wipe the unprotected metal as required with this same oil. Apron Oil Fill KfclYi`ZXk\k_\cXk_\#[fk_\j\jk\gj1 (% Wipe off the oil port before and after oiling to keep out contaminants. Apron Oil Sight Glass )% Oil all ball fittings daily with one to two shots of oil. See =`^li\-,for some typical locations. These areas include: • Cross Slide, Compound Rest, and Carriage • Tailstock, Lead Screw, and Feed Rod • Handwheels, Ways, Change Gear Teeth, and Axles Apron Oil Drain =`^li\-+% Apron lubrication references. :ffcXekJpjk\d KfdX`ekX`ek_\ZffcXekjpjk\d#[fk_\j\jk\gj1 (% Remove the four screws and pump access cover, and slide out the pump and reservoir (see =`^li\--). )% Empty the old coolant and remove large chips from 1st and 2nd stage separators. *% Fill the reservoir with approximately three gallons of coolant solution. D8@EK<E8E:< +% =`^li\-,%Typical ball fitting locations. Open the valve on the coolant nozzle. ,% Turn the coolant pump FEto prime the coolant system and to see if the coolant is cycling properly. -% Reinstall the pump access cover. 9@FCF>@:8CXe[GF@JFE ?8Q8I; The reservoir on this machine is designed to store coolant. During storage some fluids grow dangerous microbes, or collect toxic heavy metals in the fluid making it a biological and poison hazard. • To prevent infections and poisoning, use the correct personal protection equipment when handling coolant. • To properly dispose of toxic coolant, follow federal, state, and fluid manufacturer procedures. -40- =`^li\--%Coolant pump and reservoir. EFK@:< =X`cli\kf]fccfnclYi`ZXk`fe^l`[\c`e\j n`cc c\X[ kf iXg`[ [\k\i`fiXk`fe f] cXk_\Zfdgfe\ekj% D('0/(*o+'>\Xi?\X[CXk_\ J<IM@:< >\e\iXc This section covers the most common service adjustments or procedures that may need to be made during the life of your machine. :ifjj=\\[9XZbcXj_ Backlash is the amount of play found in a lead screw. It can be found by turning the cross slide handwheel in one direction, and then turning the handwheel the other direction. When the cross slide begins to move, the backlash has been taken up. Kfi\dfm\\oZ\jj`m\YXZbcXj_#[fk_\j\jk\gj1 (% Tighten the socket head cap screw in small increments (see =`^li\-.). )% Test after each adjustment until the backlash meets the needs of the operator and operation. D8B< JLI< k_Xk pfli dXZ_`e\ `j legcl^^\[ [li`e^ Xcc j\im`Z\ gifZ\$ [li\j @] k_`j nXie`e^ `j `^efi\[# j\i`$ fljg\ijfeXc`ealipdXpfZZli% Cross Feed Backlash Adjustment Cap Screw Efk\18mf`[k_\k\dgkXk`fekffm\ik`^_k\ek_\jfZb$ \k_\X[ZXgjZi\n%Fm\ik`^_k\e`e^n`ccZXlj\\oZ\j$ j`m\n\Xikfk_\jc`[`e^YcfZbXe[c\X[jZi\n% >`Yj The saddle, cross feed, compound rest, and tailstock gibs can all be adjusted on the Model M1098 lathe. Efk\1 N_\eX[aljk`e^^`Yj#b\\g`ed`e[k_Xkk_\^fXcf] ^`YX[aljkd\ek`jkfi\dfm\jcfgg`e\jjn`k_flkZXlj`e^ k_\jc`[\jkfY`e[%Cffj\^`YjdXpZXlj\gffi]`e`j_\jfe k_\nfibg`\Z\Xe[dXpZXlj\le[l\n\Xifek_\jc`[\% Fm\i$k`^_k\e`e^dXpZXlj\gi\dXkli\n\Xifek_\jc`[\# c\X[jZi\n#Xe[elk% =`^li\-.%Cross feed backlash adjustment socket head cap screw. KfX[aljkk_\jX[[c\^`Y#[fk_\j\jk\gj1 J<IM@:< (% Loosen four hex nuts found at the bottom rear of the cross slide and back off one full turn each (see =`^li\-/). =`^li\-/%Saddle gib adjustments. -41- D('0/(*o+'>\Xi?\X[CXk_\ )% Turn the four square head bolts with a hex wrench until a slight resistance is felt when moving the saddle. DO NOT overtighten. *% Move the carriage with the handwheel to feel the current drag. Adjust the bolts until the desired drag is achieved. Efk\1 Fm\ik`^_k\e`e^n`ccZXlj\\oZ\jj`m\gi\dXkli\ n\Xifek_\^`YjfiZiXZbk_\_flj`e^% +% Rear Gib Screw Tighten the four hex nuts. KfX[aljkk_\Zifjj]\\[Xe[Zfdgfle[i\jk^`Yj#[f k_\j\jk\gj1 (% Loosen the gib locking set screw and the rear gib screw approximately one turn. (see =`^li\-0). )% Tighten the front gib screw a quarter turn (see =`^li\.'). =`^li\-0% Rear cross feed gib screw. Gib Locking Set Screws *% Turn the cross feed handwheel to feel the current drag and adjust the front screw until the desired drag is achieved. +% When satisfied with the adjustment, snug the gib locking set screw. Front Gib Screw ,% Repeat Jk\gj($+ on the compound rest. =`^li\.'% Front cross feed gib screw. J<IM@:< KfX[aljkk_\kX`cjkfZbcfZb#[fk_\j\jk\gj1 (% Move the tailstock lock handle to the unlocked position. )% Slide the tailstock to an area that will allow access to the hex nut under the tailstock block. *% Tighten the tailstock hex nut 1/4 turn. Test to see that sufficient clamping pressure is applied so the tailstock will not move. Repeat as necessary (see =`^li\.(). Hex Nut is Under Block =`^li\.(% Tailstock lock adjustment. -42- D('0/(*o+'>\Xi?\X[CXk_\ I\gcXZ`e^M$9\ck Kfi\gcXZ\k_\M$Y\ckjfek_\cXk_\#[fk_\j\jk\gj1 (% DISCONNECT POWER TO THE LATHE! )% Remove the change gear cover at from the headstock. *% Remove the tension off the old V-belts by loosening the motor mount hex bolts (see=`^li\.)). +% Remove the old belts and install the new ones. Always replace these belts in pairs. ,% Tighten the motor mount bolts until you achieve 1⁄4" of belt deflection when lightly pushed with your finger tips. -% Close the change gear cover, and reconnect the lathe to the power source. Motor Mounting Bolts =`^li\.)%V-belt adjustments. J<IM@:< -43- D('0/(*o+'>\Xi?\X[CXk_\ DX`e<c\Zki`ZXc9fo Transformer Circuit Breaker Circuit Breaker Spindle Motor Contactors Pump Relay Change Gear Cover Anti-Start Limit Switch Ground Block J<IM@:< Terminal Bar =`^li\.*% M1098 Electrical panel. -44- D('0/(*o+'>\Xi?\X[CXk_\ N`i`e^;`X^iXdD('0/))'M*$G_Xj\ WARNING 1& , , 2 6 7 5 5 , 7 3 4 6 Disconnect power to the lathe before performing any electrical work, service, or adjustment. +- 7 5 6 +- +- 5 6 7 - 3PINDLE 0H OFF - 0UMP 0H 0% 2 4 4# 2 6 1& 3" 31 8 4 31 31 +! 31 (, LEGEND %, + +! 3! +- +! +- +- 3" 31 +! +- +- J<IM@:< M = Motor KM = Contactor KA = Relay EL = Work Lamp HL = Indicator Lamp SB = Button SA = Button SQ = Limit Switch TC = Transformer QF = Circuit Breaker FR = Relay 31 31 -45- D('0/(*o+'>\Xi?\X[CXk_\ Dfkfi:fee\Zk`fejD('0/))'M*$G_Xj\ Chuck Guard Limit Switch Inside. =`^li\.+% M1098 chuck guard limit switch. Brown Red Spindle Motor 220V 3-Ph W2 U2 v2 U1 V1 W1 Ground Yellow/Green Blue =`^li\.-% M1098 spindle motor. Black Black Black Pump Motor 220V 3-Ph Black Blue Red Ground Yellow/Green Foot Brake Limit Switch J<IM@:< Cover Anti-Start Limit Switch. Spindle Rotation Limit Switches. =`^li\..% M1098 coolant pump motor. =`^li\.,% M1098 limit switches. -46- D('0/(*o+'>\Xi?\X[CXk_\ KiflYc\j_ffk`e^ This section covers the most common Gear Head Lathe problems. DO NOT make any adjustments until the Gear Head Lathe is unplugged and moving parts have come to a complete stop. JPDGKFD Motor will not start. GFJJ@9C<:8LJ< :FII<:K@M<8:K@FE 1. Limit switch is triggered. 2. Emergency switch is pushed in. 3. No voltage or open connection. 4. Faulty start capacitor. Fuses or circuit breakers trip open. 1. Short circuit in line cord or plug. 2. Short circuit in motor or loose connections. 3. Incorrect fuses or circuit breakers in power supply. 1. Install headstock cover, close chuck guard. 2. Rotate emergency switch so it pops out. 3. Test for voltage, close circuit breakers, replace fuses, test magnetic switches—replace as required. 4. Replace start capacitor. 1. Inspect cord or plug for damaged insulation and shorted wires and replace extension cord. 2. Inspect all connections on motor for loose or shorted terminals or worn insulation. 3. Install correct fuses or circuit breakers. Motor overheats. 1. Motor overloaded. 2. Air circulation through the motor restricted. 1. Reduce load on motor. 2. Clean out motor to provide normal air circulation. Carriage hard to move. 1. Carriage lock is tightened down. 2. Chips have loaded up on bedways. 1. Check to make sure table locks are fully released. 2. Frequently clean away chips that load up during turning operations. 3. Lubricate bedways and handles. 3. Bedways are dry and in need of lubrication. 4. Longitudinal stops are interfering. 5. Gibs are too tight. 4. Check to make sure that stops are floating and not hitting the center stop. 5. Loosen gib screw(s) slightly. Loud, repetitious noise coming from machine. 1. Chuck is hitting the carriage or tool post. 1. Shut lathe F== Hit emergency stop button or step on foot pedal. Machine is loud when cutting. Overheats or bogs down in the cut. 1. Excessive depth of cut. 2. RPM or Feed Rate wrong for operation. 3. Dull cutters. 1. Decrease depth of cut. 2. Refer to RPM Feed rate chart for appropriate rates. Tailstock quill will not feed out of tailstock. 1. Quill lock is tightened down. 1. Unlock. Bad surface finish. 1. Wrong RPM or feed rate. 2. Dull tooling or poor tool selection. 3. Too much play in gibs. 1. Adjust for appropriate RPM and feed rate. 2. Sharpen tooling or select a better tool for the intended operation. 3. Tighten gibs. Gear change levers will not shift into position. 1. Gears not aligned in headstock. 1. Rotate spindle by hand until gear falls into place. Can't remove tapered tool from quill. 1. Quill had not retracted all the way back into the tailstock. 2. Debris was not removed from taper before inserting into quill. 1. Turn the quill handwheel until it forces taper out of quill. 2. Always make sure that taper surfaces are clean. J<IM@:< -47- 3. Sharpen or replace cutters. D('0/(*o+'>\Xi?\X[CXk_\ 9\[#C\X[JZi\n#Xe[=\\[If[;`X^iXd ''''J\i`\jGXikj +0 .' ,* +.$( -0 + * ( ,+$( (* ) (( .( -( ,) +- ,( , ,( )* )) (- ,* ,+ (0 . (' ,( ), ,/ )/ -. ,+ ,0 ). ,* +' )- +* -($( ,) +( -/ *0 0 +) )+ +, G8IKJ ++ -48- D('0/(*o+'>\Xi?\X[CXk_\ 9XZbjgcXj_#:_`gKiXp#Xe[JkXe[;`X^iXd ''''J\i`\jGXikj ., .) .* .- .0 .+ ./ /* .. /' /( /) 0( /+ 0) /, 0' /- /. G8IKJ // /0 -49- D('0/(*o+'>\Xi?\X[CXk_\ <d\i^\eZp9iXb\;`X^iXd ''''J\i`\jGXikj 0* 0+ 0, ('('. ('- ('( 00 0- 0/ (', ('' 0. ('/ ('+ ('* (') ('0 200 ((( G8IKJ ((' -50- D('0/(*o+'>\Xi?\X[CXk_\ ''''J\i`\jGXikjC`jk REF PART # DESCRIPTION REF PART # DESCRIPTION 1 XM10980001 MOTOR BASE 71 XPS03M PHLP HD SCR M6-1 X 8 2 3 XM10980002 XM10980003 PULLEY BED 72 73 XPS19M M10980073 PHLP HD SCR M5-.8 X 6 COVER 4 XM10980004 GAP 74 M10980074 ELECTRICAL BOX 5 6 XM10980005 XM10980006 END COVER L-BRACKET 75 76 M10980075 XPS68M SPALSH GUARD PHLP HD SCR M6-1 X 10 7 XM10980007 COLLAR-BRACKET 77 XPS47M PHLP HD SCR M6-1 X 25 9 10 XM10980009 XM10980010 COLLAR HANDLE 78 79 XPN01M M10980079 HEX NUT M6-1 OIL PLATE 11 XM10980011 RACK (LONG) 80 XPS68M PHLP HD SCR M6-1 X 10 13 16 XM10980013 XM10980016 RACK (SHORT) LEAD SCREW 81 82 M10980081 M10980082 COVER LEFT BED STAND 19 XM10980019 FEED ROD 83 M10980083 BED STAND 22 23 XM10980022 XM10980023 SHAFT COLLAR 84 85 M10980084 XPS68M COVER PHLP HD SCR M6-1 X 10 24 25 26 XM10980024 XM10980025 XM10980026 SHAFT HANDLE BRAKE RING 86 87 88 XPS68M M10980087 XPSB73M PHLP HD SCR M6-1 X 10 COVER CAP SCREW M12-1.75 X 50 27 28 XM10980027 XM10980028 COLLAR KEY 89 90 M10980089 XPS68M LEFT PLATE BRACKET PHLP HD SCR M6-1 X 10 39 40 41 XM10980039 XM10980040 XM10980041 KNOB M8-1.25 PLUG PLUG 91 92 93 M10980091 M10980092 M10980093 PLATE RIGHT PLATE BRACKET BREAK SHAFT 42 43 44 XM10980042 XM10980043 XM10980044 PLUG SPECIAL SCREW COVER 94 95 96 XPRP40M M10980095 M1098096 ROLL PIN 2.5 X 12 BRAKE PULL ROD CAP-SHAPE SCREW 45 46 47-1 XM10980045 XPSS05M XPSS11M KNOB M8-1.25 SET SCREW M5-.8 X 10 SET SCREW M6-1 X 16 97 98 99 XPN01M XPRP40M M10980099 HEX NUT M6-1 ROLL PIN 2.5 X 12 PEDAL ARM 49 51 52 53 54 54-1 58 59 61 61-1 67 68 69 70 XPSB47M XPSB02M XPSB60M XPN03M XPSS19M XPSB63M XPRP16M XPRP71M XPRP46M XPRP34M M10980067 M1098068 XM10980069 XPB14M CAP SCREW M10-1.5 X 40 CAP SCREW M6-1 X 20 CAP SCREW M8-1.25 X 55 HEX NUT M8-1.25 SET SCREW M8-1.25 X 30 CAP SCREW M12-1.75 X 60 ROLL PIN 3 X 25 ROLL PIN 6 X 22 ROLL PIN 6 X 28 ROLL PIN 6 X 55 COMPRESSION SPRING 1 X 7.5 X 25 OIL BALL 8MM SET SCREW M8-1.25 X 60 HEX BOLT M10-1.5 X 35 100 101 102 103 104 105 106 107 108 109 110 111 200 M10980100 M10980101 M10980102 XPS39M XPRP28M M10980105 XPRP05M M10980107 M10980108 XPSB71M XPN02M M10980111 M10980200 CONNECTING SHAFT DRAW SPRING SWITCH BLOCK PHLP HD SCR M8-1.25 X 10 ROLL PIN 5 X 40 DRIVING SHAFT (LONG) ROLL PIN 5 X 30 DRVING SHAFT (SHORT) PEDAL CAP SCREW M10-1.5 X 60 HEX NUT M10-1.5 BRAKE ROD SUPPORT SPINDLE MOTOR G8IKJ -51- D('0/(*o+'>\Xi?\X[CXk_\ ?\X[jkfZb:Xj\Xe[J_`]k:fekifcj;`X^iXd ('''J\i`\jGXikj ('/. (''0 (((- ('(( ('./ (',( ((** ('+/ (',' ('** (''. ((+/ ((+0 (',. (('* ('00 ('0. ('(* ((,( ('-0 (('* ('0. ('-/ ((,' ('(' (((+ ('(('-+ ((+) ((*+ (',- ((*- ((+. (',) ((+. ((+) ('0* ((*' ((*0 ((*+ ('-, (('' ('(, ('-('() ('0, ('(+ G8IKJ ('// ((+. (()' (()0 ('0* ((+( ((+' ('0- -52- ('0- D('0/(*o+'>\Xi?\X[CXk_\ Gi`dXipXe[J\Zfe[Xip;i`m\;`X^iXd ('''J\i`\jGXikj ('). (()+ ('.+ (''+ ((*/ (()- ('/+ ('+( ('+' ('*0 ('*/ ('*. (('/ ('), (')(')/ (()((,+ ('.* (')0 ((,* (((0 ((,((,, ('', ((,) ('*) ('/- ((,. (',0 ('/' ((,/ ((,0 ('*('*, ('*' (('0 ('*+ ('** (((( ((', ('*( ('*' ('0* ((*. (''- G8IKJ ((), -53- D('0/(*o+'>\Xi?\X[CXk_\ Jg`e[c\Xe[=\\[>\Xi;i`m\;`X^iXd ('''J\i`\jGXikj (''* (()/ ('., ('') (')+ ('+) (((' ('/0 ('+* (()( ('+. (')* (('/ ((). ('++ (('(()* ('++ ('+- (''/ ('+, ('/. ('.. (()* (''( (()* ('-. ('.- ('-. (()) (('. (',* (((* (()) (',+ (')' ((*, ('/, (('+ ('(0 (')) (((. ('.0 ((') (',, (')( (((. G8IKJ ('(/ -54- ('(. D('0/(*o+'>\Xi?\X[CXk_\ ('''J\i`\jGXikjC`jk DESCRIPTION REF PART# DESCRIPTION 1001 XM10981001 COLLAR 1051 XM10981051 ANCHORPIN 1002 XM10981002 1003 XM10981003 COLLAR REARCOVER 1052 XM10981052 1053 XM10981053 SHAFT GEAR30T 1004 XM10981004 REARCOVER 1054 XM10981054 SHAFT 1005 XM10981005 1006 XM10981006 PULLEY PLUG 1055 XM10981055 1056 XM10981056 SHAFT THRUSTWASHER 1007 XM10981007 MAINCASTING 1057 XM10981057 GEARSHAFT17T 1008 XM10981008 1009 XM10981009 FRONTCOVER SHIFTLEVER 1059 XM10981059 1064 XM10981064 SPECIALSHOULDERSCREW LEVER 1010 XM10981010 SHAFTHOUSING 1065 XM10981065 LEVER 1011 XM10981011 1012 XM10981012 COVER HANDLEBODY 1066 XM10981066 1067 XM10981067 LEVER COLLAR 1013 XM10981013 CRANKSHAFT 1068 XM10981068 SHIFTFORK 1014 XM10981014 1015 XM10981015 HANDLEBODY HANDLEBLOCK 1069 XM10981069 1073 XM10981073 SHIFTFORK GASKET 1016 XM10981016 1017 XM10981017 1018 XM10981018 HUB GEAR37T SPACER 1074 XM10981074 1075 XM10981075 1076 XM10981076 GASKET GASKET GASKET 1019 XM10981019 1020 XM10981020 SLOTTEDCOLLAR THRUSTWASHER 1077 XM10981077 1078 XM10981078 GASKET GASKET 1021 XM10981021 1022 XPW06M 1023 XM10981023 GEAR40T FLATWASHERM12-1.75 GEAR37T 1079 XM10981079 1080 XM10981080 1084 XPS02M OILSEAL OILSEAL PHLPHDSCRM4-.7X12 1024 XM10981024 1025 XM10981025 1026 XM10981026 SPANNERNUT GEAR43T GEAR51T 1085 XPSB24M 1086 XPSB01M 1087 XPSB14M CAPSCREWM5-.8X16 CAPSCREWM6-1X16 CAPSCREWM8-1.25X20 1027 XM10981027 1028 XM10981028 1029 XM10981029 SPACER GEARSHAFT16T COVER 1088 XPSB02M 1089 XPSB06M 1093 XPSS04M CAPSCREWM6-1X20 CAPSCREWM6-1X25 SETSCREWM6-1X12 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1050 CASTWASHER SHAFT SPACER COLLARW/GEAR21T GEAR29T GEAR46T GEAR38T COLLAR GEAR26T GEAR34T GEAR53T PLUG GEAR74T GEAR37T SPINDLE SPRING PIN CAM SHAFT GEAR51T 1095 1096 1097 1099 1100 1102 1103 1104 1105 1106 1107 1108 1109 1110 1111 1113 1114 1117 1119 SETSCREWM8-1.25X8 SETSCREWM8-1.25X10 SETSCREWM8-1.25X12 PHLPHDSCRM8-1.25X35 PHLPHDSCRM4-.7X10 HEXNUTM12-1.75 KEY5X5X15 KEY5X5X18 KEY5X5X50 KEY6X6X40 KEY6X6X55 KEY6X6X120 KEY6X6X120 KEY8X8X18 KEY5X5X20 ROLLPIN3X10 ROLLPIN4X18 EXTRETAININGRING20 EXTRETAININGRING35 XM10981030 XM10981031 XM10981032 XM10981033 XM10981034 XM10981035 XM10981036 XM10981037 XM10981038 XM10981039 XM10981040 XM10981041 XM10981042 XM10981043 XM10981044 XM10981045 XM10981046 XM10981047 XM10981048 XM10981050 -55- XPSS20M XPSS16M XPSS14M XPS42M XPS38M XPN09M XPK20M XPK14M XPK36M XPK11M XPK49M XPK50M XPK50M XPK51M XPK34M XPRP44M XPRP01M PR09M PR12M G8IKJ REF PART# D('0/(*o+'>\Xi?\X[CXk_\ ('''J\i`\jGXikjC`jk DESCRIPTION REF PART# DESCRIPTION 1120 PR43M EXTRETAININGRING50MM 1138 XM10981138 O-RING3.1X47 1121 XPR44M 1122 XM1019322 EXTRETAININGRING72 E-CLIP42 1139 XM10981139 1140 XM10981140 COMPRESSIONSPRING1X6X7 COMPRESSIONSPRING1X6X25 1123 XM10981123 BEARING700104E 1141 XM10981141 COMPRESSIONSPRING0.9X4.4X19 1124 XM10981124 1125 XP203 BEARING240E BEARING203 1126 XM10981126 BEARING204D 1142 XM10981142 1147 XM10981147 1148 XM10981148 SHIFTHUB LEVERSLEEVE COVER 1127 XM10981127 1128 XM10981128 BEARING7210E BEARING7212D 1151 XPSB84M 1152 XM10981152 CAPSCREWM10-1.5X35 CONNECTINGBOARD 1129 XM10981129 STEELBALL5 1153 XPRP49M ROLLPIN5X25 1130 XM10981130 1133 XM10981133 STEELBALL6 O-RING2.4X14 1154 XM10981154 1155 XM10981155 SHAFT BREAKSHAFT 1134 XM10981134 O-RING2.4X20 1156 PR03M EXTRETAININGRING12 1135 XM10981135 1136 XM10981136 O-RING2.4X25 O-RING3.1X30 1157 XM10981157 1158 XM10981158 BREAKSHOE POSITIONINGAXLE 1137 XM10981137 O-RING3.1X40 1159 PR39M EXTRETAININGRING8 G8IKJ REF PART# -56- D('0/(*o+'>\Xi?\X[CXk_\ >\XiYfo?flj`e^Xe[J_`]k:fekifcj;`X^iXd )'''J\i`\jGXikj )'(/ )'(- )'(* )'(+ )'(' )'(. )'(, )'(. )''( )'') )'(0 )'(/ )'() )''* )'(( )'()'(. )')) )'(+ )')* )''0 )'(0 )'(. )'(+ )')( )''+ )')' )'', )''- )'', )')+ )''- )''/ )''+ )'), )''. )')- )''. )'). )')- )')/ )')0 )'). )'*' )'*/ )'*' )'))'). )'*( )'+( )'*' )'*' )'*) )'** )'+' )'))'). )'*( )'*' )'*' )'*' )'*0 )'*+ )'*, )'*- )'*. )'*/ )'*' G8IKJ -57- D('0/(*o+'>\Xi?\X[CXk_\ >\XiYfo;i`m\kiX`e;`X^iXd )'''J\i`\jGXikj )'+0 )',) )',( )',' )',+ )'-)'-, )'+/ )'+- )',* )',( )'+. )'-+ )'), )'-* )'+, )'-) )',+ )',)',+ )'-( )',)'), )'., )'-' )'+) )',0 )'-. )'.+ )'.) )'.* )'-/ )',/ )',. )',+ )'/)'.( )',)',+ )'.' )',, )'/, )'/+ )'-0 )',+ )',+ )'/* )'-/ )'0' )'-. )'/) )'/( )'), )'/' )'-( )',)'.0 )'-' )',0 )'./ )'.. )',/ )',. )'.)',)',+ )'0. )'/0 )',)'0)'/)',)',+ )'// )'), )'0, )'/. )'0+ )'), )'0* )'++ )'+* )'-) )'0) G8IKJ )',* )',+ )'0( )',, -58- )'), D('0/(*o+'>\Xi?\X[CXk_\ >\XiYfo:_Xe^\>\XiXe[8[aljk\i;`X^iXd )'''J\i`\jGXikj )('+ )(', )('/ )('. )('- )(') )('' )('* )'+- )('( )'+* )'+. )('( )(')'0/ )((' )((( )(() )'0/ )'00 )('0 )('' )'0/ G8IKJ -59- D('0/(*o+'>\Xi?\X[CXk_\ )'''J\i`\jGXikjC`jk REF PART# DESCRIPTION REF PART# DESCRIPTION 2001 XM10982001 CASTING 2048 XPK33M KEY5X5X45 2002 XM10982002 2003 XM10982003 LARGECASTINGCOVER LARGECASTINGCOVER 2049 XP6203 BEARING6203 2050 XM10982050 BUSHING 2004 XM10982004 DRAINOILFITTING 2051 XM10982051 SPECIALCLIP 2005 XM10982005 2006 XM10982006 "O"-RING17X1.8 SLIDINGBLOCK 2052 XM10982052 GEAR 2053 XM10982053 THRUSTWASHER 2007 XPSB66M CAPSCREWM8-1.25X65 2054 XP6204 2008 XM10982008 2009 XM10982009 TAPERPIN6X30 EXTENSIONFASTNERM8-1.25 2055 XM10982055 THRUSTWASHER 2056 XPR09M EXTRETAININGRING20MM 2010 XM10982010 BLOCK 2057 XPR19M 2011 XPRP08M 2012 XM10982012 ROLLPIN6X30 RACK 2058 XM10982058 GEAR 2059 XM10982059 GEAR 2013 XM10982013 BLOCK 2060 XPK38M 2014 XPRP08M 2015 XM10982015 ROLLPIN6X30 RACK 2061 XM10982061 GEAR 2062 XP6204 BEARING6004 2016 XM10982016 2017 XM10982017 2018 XM10982018 SHAFT RETAININGDOG "O"-RING8.75X1.8 2063 XM10982063 GASKET 2064 XM10982064 BEARINGCOVER 2065 XM10982065 XIAXLE 2019 XPSS31M 2020 XM10982020 SETSCREWM5-.8X8 BLOCK 2066 XPRP29M ROLLPIN5X45 2067 XM10982067 BEARINGCOVER 2021 XM10982021 2022 XM10982022 2023 XM10982023 RACK BLOCK RACK 2068 XM10982068 GASKET 2069 XM10982069 GEAR 2070 XM10982070 GEAR 2024 XM10982024 2025 XPSB24M 2026 XM10982026 CONTROLRODSUPPORT CAPSCREWM5-.8X16 GEAR 2071 XM10982071 BUSHING 2072 XM10982072 GEAR 2073 XM10982073 BUSHING 2027 XM10982027 2028 XM10982028 2029 XM10982029 "O"-RING7X1.9 GASKET FEEDBOXCOVER 2074 XM10982074 VIIIAXLE 2075 XPK71M KEY4X4X45 2076 XM10982076 BUSHING 2030 2031 2032 2033 2034 2035 2036 2037 2038 2039 2040 2041 2042 2043 2044 2045 2046 2047 CAPSCREWM6-1X25 TAPERPIN5X25 ROLLPIN5X40 LEVERSUPPORT STEELBALL6MM COMPRESSIONSPRING1X5X20 SETSCREWM8-1.25X16 LABEL SPECIALSCREWM3-.5X4 SETSCREWM6-1X8 OILSIGHTGLASS LABEL SPECIALRING26X2.4 BEARINGCOVER GASKET THRUSTWASHER KEY5X5X45 VIIAXLE 2077 2078 2079 2080 2081 2082 2083 2084 2085 2086 2087 2088 2089 2090 2091 2092 2093 G8IKJ XPSB06M XM10982031 XPRP28M XM10982033 XM10982034 XM10982035 XPSS06M XM10982037 XM10982038 XPSS03M XM10982040 XM10982041 XM10982042 XM10982043 XM10982044 XM10982045 XPK33M XM10982047 -60- XM10982077 XM10982078 XM10982079 XM10982080 XM10982081 XM10982082 XM10982083 XPK93M XM10982085 XPK102M XM10982087 XM10982088 XM10982089 XM10982090 XM10982091 XM10982092 XM10982093 BEARING6004 EXTRETAININGRING28MM KEY4X4X22 GEAR BUSHING GEAR GEAR GEAR BUSHING GEAR KEY4X4X80 XAXLE KEY4X4X18 BEARINGCOVER GASKET GEAR IXAXLE BUSHING GEAR GASKET D('0/(*o+'>\Xi?\X[CXk_\ )'''J\i`\jGXikjC`jk REF PART# DESCRIPTION REF PART# DESCRIPTION 2094 XM10982094 BEARINGCOVER 2104 XM10982104 GEARCOVER 2095 XM10982095 2096 XM10982096 SPECIALRING25X40X7 XIIAXLE 2105 XM10982105 2106 XM10982106 SPECIALSHOULDERBOLT WIDE-CASTWASHER 2097 XPRP10M ROLLPIN5X35 2107 XPN02M HEXNUTM10-1.5 2098 XPN09M 2099 XM10982099 HEXNUTM12-1.75 THRUSTWASHER 2108 XM10982108 2109 XM10982109 STUDM10-1.5 WIDE-CASTWASHER 2100 XM10982100 BEARING600 2110 XM10982110 GEAR 2101 XPR21M 2102 XM10982102 INTRETAININGRING35MM GEAR 2111 XM10982111 2112 XPSB06M THRUSTWASHER CAPSCREWM6-1X25 2103 XM10982103 SLEEVE G8IKJ -61- D('0/(*o+'>\Xi?\X[CXk_\ 8gife?flj`e^Xe[J_`]k`e^:fekifcj;`X^iXd *'''J\i`\jGXikj *''. *'// *'.+ *'.* *'-. *'/. *')/ *'-/ *'.* *')0 *'-, *'/* *'., *'(* *'-/ *',' *'+' *',( *''0 *'// *'(*'/( *''/ *''( *',) *'0*',. *'.( *'0/ *'0. *'/+ *')+ *',* *'.0 *'), *'(-$( *'-* *''+ *'-+ *''* *',+ *',0 G8IKJ *'-) *'*' -62- *'0*',/ *'.( D('0/(*o+'>\Xi?\X[CXk_\ 8gife?flj`e^Xe[J_`]k`e^:fekifcj;`X^iXd *'''J\i`\jGXikj *'./ *'.) *'(/ *'-' *'/) *'(0 *'(( *')) *'(. *')* *'-' *'*+ *'/' *'(+ *'** *'(, *'-0 *'+) *'-0 *'/' *'++ *'*( *'0, *')*'*) *'/+ *'0) *'.' *'() *'+( *'', *'-+ *',, *',- *'(' *'+* *'.. *'') G8IKJ -63- D('0/(*o+'>\Xi?\X[CXk_\ K_i\X[;`Xc;`X^iXd *'''J\i`\jGXikj *'0( *'',$( *'/+ *'-*''- *'*, *'*0 *'*/ *'*0 *'/- G8IKJ *'/0 -64- D('0/(*o+'>\Xi?\X[CXk_\ *'''J\i`\jGXikjC`jk REF PART# DESCRIPTION REF PART# DESCRIPTION 3001 XM10983001 CASTING 3051 XM10983051 OILSIGHTCOLLAR 3002 3003 XM10983002 XM10983003 HANDWHEEL BOX 3052 XM10983052 OILSIGHT 3053 XM10983053 HANDLE 3004 XM10983004 COVER 3054 XM10983054 PLUG"A" 3005 XM10983005 THREADINGDIALBODY 3055 XM10983055 PLUG"B" 3005-1 XM10983005-1 HUB 3006 XM10983006 SPACER 3056 XM10983056 HANDLE 3057 XM10983057 COMPRESSIONSPRING 3007 3008 XM10983007 XM10983008 GIB HUB 3058 XM10983058 CPMPRESSIONSPRING 3059 XM10983059 SPECIALKEY 3009 XM10983009 SHAFT 3060 XPSB33M CAPSCREWM5-.8X12 3010 XM10983010 INDEXRING 3062 XPSB26M CAPSCREWM6-1X12 3011 3012 XM10983011 XM10983012 COVER SHAFT 3063 XPSB01M 3064 XPSB06M CAPSCREWM6-1X16 CAPSCREWM6-1X25 3013 3014 3015 XM10983013 XM10983014 XM10983015 GEARROLLPIN60T GEARSHAFT18T GEAR 3065 XPSB13M 3066 XPSB05M 3067 XPS40M CAPSCREWM8-1.25X30 CAPSCREWM8-1.25X50 PHLPHDSCRM5-.8X16 3016 XM10983016 SHAFT 3016-1 XM10983016-1 BRACKET 3017 XM10983017 COVER 3068 XPSB26M 3069 XPS68M 3070 XPSS26M CAPSCREWM6-1X12 PHLPHDSCRM6-1X10 SETSCREWM5-.8X6 3018 3019 3022 XM10983018 XM10983019 XM10983022 GEAR30T GEAR46T GEAR63T 3071 XPSS02M 3072 XPSS01M 3073 XPSS34M SETSCREWM6-1X6 SETSCREWM6-1X10 SETSCREWM5-.8X16 3023 3024 XM10983023 XM10983024 SHIFTFORK SHIFTLEVER 3074 XPSS29M 3075 XPSS01M SETSCREWM6-1X35 SETSCREWM6-1X10 3025 3026 3028 XM10983025 XM10983026 XM10983028 SHIFTHANDLE GEAR40T BRACKET 3077 XPS14M 3078 XPRP16M 3079 XPRP03M PHLPHDSCRM6-1X12 ROLLPIN3X25 ROLLPIN5X20 3029 3030 3031 3032 3033 3034 3035 3038 3039 3040 3041 3042 3043 3044 3050 XM10983029 XM10983030 XM10983031 XM10983032 XM10983033 XM10983034 XM10983035 XM10983038 XM10983039 XM10983040 XM10983041 XM10983042 XM10983043 XM10983044 XM10983050 HALFNUT WORM GEAR22T SHAFT GEAR18T SHAFT THREADINGDIALBODY COMBOGEAR32T/30T/28T SPACER BAR HANDLESTUD CASTWASHER CASTWASHER CASTWASHER OILSIGHTCOLLAR 3080 3081 3082 3083 3084 3086 3087 3088 3089 3091 3092 3095 3096 3097 3098 ROLLPIN5X30 ROLLPIN5X32 ROLLPIN5X25 ROLLPIN6X12 OILER8MM FLATWASHER8MM HEXNUTM5-.8 HEXNUTM6-1 HEXNUTM8-1.25 RIVET3X8 O-RING20X2.4 KEY5X5X18 STEELBALL FLATWASHER10MM PLUGM10X1 XPRP05M XPRP45M XPRP49M XPRP41M XM10983084 XPW01M XPN06M XPN01M XPN03M XM10983091 XM10983092 XPK14M XM10983096 XPW04M XM10983098 G8IKJ -65- D('0/(*o+'>\Xi?\X[CXk_\ KffcGfjk#KfgJc`[\#Xe[Jn`m\cJc`[\;`X^iXd +'''J\i`\jGXikj +'*' +'-) +'*/ +'(* +'(+ +')0 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