Woodstock Technical Support... 3 About Your New 13 x 40 Gear Head Lathe... 3 Specifications... 4

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3 Woodstock Technical Support... 3 About Your New 13 x 40 Gear Head Lathe... 3 Specifications... 4 Standard Safety Instructions... 6 Additional Safety Instructions for Gear Head Lathes... 8 Avoiding Potential Injuries V 3-phase Operation Extension Cords Grounding Unpacking Items Needed for Set Up Inventory Cleaning Machine Machine Placement Mounting Lathe on Shop Floor Handwheel Handles Test Run General Turning On Power Three-Jaw Direct Mount Scroll Chuck Replacing Jaws Four-Jaw Direct Mount Independent Chuck Faceplate Gap Piece Removal Tailstock Drilling with the Tailstock Cutting Shallow Tapers with the Tailstock Tailstock Alignment Centers Steady Rest Follow Rest Setting Compound Slide Four-Way Tool Post Foot Brake Manual Feed Setting RPM Spindle Break-In Setting Power Feed Rate Thread Settings Change Gears Threading Operation... 38

4 General Cleaning Lubrication Coolant System General Cross Feed Backlash Gibs Replacing V-Belt Main Electrical Box Wiring Diagram (M V 3-Phase) Motor Connections (M V 3-Phase) Troubleshooting Base Assembly Base Parts List Headstock Assembly Headstock Assembly Headstock Assembly Headstock Parts List Headstock Parts List Gearbox Assembly Gearbox Assembly Gearbox Assembly Gearbox Parts List Gearbox Parts List Apron Assembly Apron Assembly Apron Parts List Carriage Assembly Carriage Parts List Tool Post Assembly Tool Post Parts List Tailstock Assembly Tailstock Parts List Bed Assembly Bed Parts List End Gear Assembly End Gear Parts List Coolant, Work Light, & Thread Dial Assembly Coolant, Work Light, & Thread Dial Parts List Steady & Follow Rest Assemblies Steady & Follow Rest Parts List Warranty... 77

5 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) or send to:. 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. If you still have questions after reading the latest manual, or if you have comments please contact us at: Your new 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-

6 Spindle Motor...2 HP, 6.5 A, 1.5 KW, 220V, Three-Phase, 1725 RPM Overall Length...78" Overall Depth " Footprint " x 15.5" Height " Bed Width...7.3" Swing Over Bed... 13" Swing Over Gap " Swing Over Saddle...7.8" Distance Between Centers...40" Height of Center Line " Compound Slide Travel...3.2" Cross Slide Travel " Tailstock Barrel Travel...3.9" Leadscrew Diameter mm Feed Rod mm Cutting Tool Maximum Size X 16 mm Camlock System... D1-4 Spindle Bore " Spindle Taper... MT#5 Tailstock Diameter mm Tailstock Taper... MT#3 Spindle Speeds RPM Feed Rate Range mm/r Thread Range (Inch) TPI Thread Range (Metric) mm Bed Ways x 186 x 308 mm Longitudal Feed mm/r Cross Feed mm/r Approximate Shipping Weight lbs. Approximate Net Weight lbs. -4-

7 A B C D H F E I L G J K M N O P AM Q AF AK AH R S T U AO AO W V Z AG AJ AI AE AD AN AC AB AA X Y The Model M1098 lathe. 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 Feed Rod Rack Thread Dial Apron Oil Level Sight Glass Spindle Rotation ON/OFF Half-Nut Lever Power Feed Lever Carriage Apron Longitudinal Feed Handwheel Headstock Oil Level Sight Glass Foot Brake Coolant Pump ON/OFF Thread Selection Dials Jog Button Emergency Stop Oil Level Sight Glass Power Lamp Lead Screw/Feed Rod Direction Lever Gap Lathe lifting location (4 locations) -5-

8 Learn the applications, limitations and potential hazards of this machine. Keep the manual in a safe and convenient place for future reference. Clutter and inadequate lighting invite potential hazards. 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. Use safety glasses with side shields or safety goggles that meet the appropriate standards of the American National Standards Institute (ANSI). Do not operate this machine in wet or open flame environments. Airborne dust particles could cause an explosion and severe fire hazard. and in working condition. before connecting power to machine. free of clutter, grease, etc. 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. 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. Visitors must be kept at a safe distance while operating unit. with padlocks, master switches or by removing starter keys. -6-

9 The machine will do a safer and better job at the rate for which it was designed. Do not force machine or attachment to do a job for which it was not designed. Do not wear loose clothing, neck ties, gloves, jewelry, and secure long hair away from moving parts. Before turning the machine on, make it a habit to check that all chuck keys and wrenches have been removed. 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. at all times.. Wait until it comes to a complete stop before leaving the area. Follow lubrication and accessory attachment instructions in the manual. 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. 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., 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. Develop good habits in your shop and safety will become second-nature to you. -7-

10 Use a brush, and never clear chips while the lathe is turning., The right tool decreases strain on the lathe components and provides a better finish. Never walk away from the lathe with the key in the chuck. A workpiece thrown from the chuck will severely injure you or a bystander. The lathe must be turned and the spindle brought to a complete stop before changing gears. 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. if 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. Check tool and tool post clearance, chuck clearance, and saddle clearance before starting the lathe. Never leave lathe unattended while it is running. 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.. Release any automatic feeds after completing a job. -8-

11 Always protect the bed ways, and unplug the lathe when retooling the lathe. Always wear face and eye protection when using lathes. Never walk away from the lathe leaving the chuck key inserted in the chuck. Never use hands to stop or slow the chuck when shutting down the lathe. Never wear loose clothing or gloves when working with the lathe. -9-

12 The 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. If you must use a plug and receptacle, you will need a NEMA-style plug and receptacle (). Using a circuit breaker rated higher than 10 amps will increase the risk of fire! 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 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. X G Z Z G X W W 15-15P 15-15R Typical 220V 3-phase 15 Amp 4-prong plug and receptacle. -10-

13 The Model M1098 has been carefully packaged for safe transporting. If you notice the machine has been damaged, please contact your authorized dealer immediately. 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 -11-

14 The following is a description of the main components shipped with the Model M1098. Lay the components out to inventory them. D B C Model M1098 Gear Head Lathe...1 Steady Rest...1 Follow Rest...1 Three-Jaw Chuck...1 A 10" Faceplate...1 8" Four-Jaw Universal Chuck...1 Four-Jaw Chuck Key...1 Hardware Bag Camlock Studs...3 Camlock Stud Fasteners...3 Main contents. Tool Box...1 Oil Gun...1 Open End Wrenches 10/12, 14/17, 17/ EA Slotted Screwdriver...1 Phillips Head Screwdriver...1 Three-Jaw Chuck Jaws...3 Hex Wrenches 3, 4, 5, 6, 8, 10MM...1 EA MT#3 Dead Centers...2 MT#5-#3 Morse Taper Sleeve...1 Center Sleeve MT#5 to MT#3...1 Three-Jaw Chuck Key...1 Tool Post Wrench...1 Change Gear 40T)...1 G F E H 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) or at tech-support@shopfox.biz R I S Q P T U N J O K L M Tool box contents. -12-

15 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. 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. 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 ). Lighting should be bright enough to eliminate shadow and prevent eye strain. Electrical 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. Minimum wall clearances. -13-

16 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. Lag shield anchors with lag bolts ( ) and anchor studs ( ) 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. Typical lag shield anchor and lag bolt. Using machine mounts, shown in, 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. Typical anchor stud. Machine mount example. -14-

17 Using the screwdriver, attach the handles ( ) to the threaded hole in the handwheels. 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. Cross feed Handwheel Longitudinal Handwheel Longitudinal and cross feed handle locations. Make sure there are no obstructions around or underneath the spindle. Make sure the lathe is lubricated and all gear box oil levels are full. Refer to on. Set the lathe to. Refer to 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. 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 position. Move the 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 immediately and unplug the machine. Correct any problem before further operation. If the the problem is not readily apparent, refer to on. Turn the lathe and complete the on before using the lathe. -15-

18 Complete the procedure on before using this lathe for any cutting or threading operations. 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. The instructions in this section are written with the understanding that the operator has the necessary knowledge and skills to operate this machine. 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. See, 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 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 position. Power Light Emergency Stop -16- Power light and emergency stop locations.

19 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. 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) DISCONNECT POWER TO THE LATHE! 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 ).. 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 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. Simple chuck cradle made of scrap lumber. Loosening the cam-locks. -17-

20 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. With a rocking motion, carefully remove the chuck from the spindle nose (see ). DISCONNECT POWER TO THE LATHE! Spindle Nose Taper Installing and removing a small chuck. 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 ). Adjust the cam-lock studs in the three-jaw chuck to match the measurement from the previous chuck. Measuring height of cam-lock studs. 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 ). Tightening the cam-locks. -18-

21 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. Turn each jaw until it makes contact with the workpiece. 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. If the workpiece is seated correctly, tighten the jaws. Loading a workpiece. 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 ). Jaw number identification. The jaws are numbered 1 3 and must be installed in this sequence (see ). -19-

22 DISCONNECT POWER TO THE LATHE! Identify the jaw position by the number usually stamped on the side of the jaw groove (see ). Jaw Number. 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.. Set the jaws aside in a safe place. Typical jaw number location. Jaw Guide Number DISCONNECT POWER TO THE LATHE! Identify the jaw by the number stamped on the side. Locate the corresponding jaw guide on the chuck body (see ).. 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 ). This chuck has jaw references on the inside of the jaw guide. (Chuck removed from spindle for clarity).. 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 ). Lead Thread Lead thread on scroll. -20-

23 Continue to turn the chuck key until the leading thread of the scroll comes to the second jaw guide (see ). Repeat with jaw #2. Continue to turn the chuck key until the leading thread of the scroll comes to the third jaw guide. Lead Thread Repeat with jaw #3. Lead thread coming in to view for jaw #2. Lead Thread Lead thread coming in to view for jaw #

24 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 re versal 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 Simple chuck cradle made of scrap lumber. -22-

25 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). Turn each jaw until it just makes contact with the 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. Clamping workpiece. 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). Use a lower RPM when machining heavy eccentric workpieces. Centering workpiece. -23-

26 The faceplate can be used to turn non-cylindrical parts or for off-center turning by clamping the workpiece to the faceplate. Installing the faceplate follows the same steps as any of the lathe chucks. Install according to the instructions for three-jaw chucks found on.. 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 in this section on 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 ). 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. Typical faceplate with properly clamped workpiece in four locations. Use a lower RPM when machining heavy eccentric workpieces. -24-

27 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. Taper Pins Find the two taper pin nuts located on the bed of the gap piece (see ). Lathe gap piece. 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-

28 The tailstock ( ) 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. Quill Feed Quill Lock Slide the tailstock to the desired position. Pull up on the tailstock lock handle to lock the tailstock in place. Tailstock Lock Lever Stop Posts Tailstock and quill lock handles in locked position. 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. With the tailstock locked, push down to unlock the quill lock handle. Setting up tailstock for drilling. Turn the quill feed handle clockwise to extend the quill about one inch. Insert a tapered drill arbor ( ), or the tapered drill shank ( ), 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. Tapered shank drill fitting into quill taper. -26-

29 The tailstock can be offset to cut a shallow taper on a part. Lock the tailstock in position. Loosen the lock screw (see ). Alternately loosen and tighten the left and right jack screws until the desired offset is indicated on the scale (see ). Lock Screw Right Jack Screw Retighten the lock screw. Tailstock off-set adjustments. 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. Left Jack Screw Scale 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. Off-set scale. 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 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 ) Continued on next page Tailstock centering dead center. -27-

30 Place the live center in the tailstock. Attach a lathe dog to the bar stock and mount it between centers (see ) Turn approximately 0.010" off the diameter. Measure the stock with a micrometer. 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 ). Checking tailstock alignment. 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 ). Mount a dial indicator so the dial plunger is on the tailstock barrel before making adjustments to the tailstock. Refer to on 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. Tailstock adjustment option #1. Tailstock adjustment option #

31 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. 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 ). Inserting dead center. Move the tailstock into position and lock in place. Feed the quill into the workpiece. 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 ). Remove the chuck from the spindle. Faceplate and dead center setup. Install the dead center in the spindle sleeve. Install the sleeve and center into the spindle opening. Attach the faceplate to the spindle. -29-

32 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. Knurled Knob Place the steady rest on the lathe bedways so the triangular notch fits over the angled portion of the rear bedway. Loosen the three set screws so the finger position can be adjusted (see ). Knob Set Screws Loosen the knurled knob (see ) and open the steady rest so a workpiece can fit inside of the fingers (see ). Steady rest adjustments. 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. The follow rest in 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. Finger Adjustment Knobs Positioning workpiece in steady rest. 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. Follow rest attachment. -30-

33 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. 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. Loosen the two cap screws, one on each side of the compound slide (see ). Cap Screws Compound Slide 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. Tighten the two cap screws. Be sure to not overtighten, as you may strip threads. Compound slide set at an angle. Tool Post Bolts 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. Choose the desired cutting tool. Loosen the tool post bolts so that the cutting tool can fit underneath. Tool holder and tool post. Use a minimum of two tool post bolts to hold down the cutting tool and tighten firmly (see ). Repeat for the three remaining openings, as needed. -31-

34 The Model M1098 lathe comes equipped with a foot brake (see 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 and then apply pressure to the foot brake with your foot, slowing the spindle to a stop. Spindle Control Lever Stepping on the foot brake while the spindle is will 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. Only the circuit to the Spindle Rotation ON/OFF Lever will be interrupted. Foot Brake Foot brake and spindle control lever. Compound Slide Handwheel Cross Feed Handwheel 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 ). 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. Longitudinal Handwheel Carriage controls. 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. 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-

35 Use the table in to determine the cutting speed required for the material of your workpiece. Determine the final diameter, in inches, for the cut you are about to take. Use the following formula to determine the needed RPM for your operation: With the calculated RPM, decide on the closest cutting RPM to what you need. Make sure the spindle is completely stopped before proceeding. Workpiece Material 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 Wood Refer to the for more detailed information. Cutting speed table for HSS cutting tools. Range Lever 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 ( ). RPM Lever Spindle speed selector levers. -33-

36 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. Check oil levels in headstock and apron. Correct oil levels if required. Refer to in the section on of this manual. Make sure there are no obstructions around or underneath the spindle. Set the spindle speed to 190 RPM, refer to section on Turn the lathe power and move the ( ) 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. 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. Turn the lathe, 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. The carriage has longitudinal and cross slide power feed capabilities. From your cutting and feed rate calculations, select the feed rate that you need from the chart (see ). Install the 40 tooth change gear at location shown on the chart. Turn the feed dials to the setting indicated on the chart Selecting power feed rate.

37 Make sure the half nut lever shown in is disengaged. Spindle Rotation ON/OFF Lever Use the feed selector lever shown in to engage the cross feed or longitudal feed when needed. Half Nut Lever Use the ( ) to start the lathe and the power feed operation when needed. Disengaging half nut lever. Up: Cross Feed Central: Feeds is Disengaged Down: Longitudinal Feed Feed selector lever. -35-

38 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. 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, and the tooth gear at position as shown on the chart (see ). Turn the feed dials to the setting indicated on the chart (see ). Move the feed selector lever to the central position shown in to disengage the cross feed or longitudal feed. Use the to start the lathe when needed. Use the half nut lever to engage and disengage the apron for threading operations. Feed and thread chart in TPI and metric pitch. Half Nut Lever Central Position: Feed is Disengaged Apron control levers. -36-

39 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 DISCONNECT POWER TO THE LATHE! Remove two thumb knobs and remove the headstock gear cover to expose the change gears ( ). Loosen the gear adjuster ( ), and let the gear swing down. Gear cover. Remove the appropriate change gear according to your the chart, and install the required gear (see ). 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". Oil the gears, reinstall the gear cover, and reconnect power to the machine. Gear Adjuster Change gear locations. -37-

40 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. Thread Dial Half Nut Lever Set the feed direction lever for either right or lefthanded threads. With the feed rate selectors to the appropriate settings, turn 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. Once you are confident the settings are correct, disengage the half nut and turn the spindle. Examine the indicator table on the machine or in to determine which numbers (on the thread dial) will engage the half nut. Half nut and thread dial location. 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. Thread dial chart. -38-

41 Regular periodic maintenance on your Model M1098 will ensure its optimum performance. Make a habit of inspecting your machine each time you use it. 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. 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. 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, 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. Headstock Oil Sight Glass Gear Box Oil Sight Glass Oil sights and filler locations. Headstock Oil Drain Behind Gear Gear Box Oil Drain -39- Headstock and gear box drain locations.

42 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 Wipe off the oil port before and after oiling to keep out contaminants. Oil all ball fittings daily with one to two shots of oil. See 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 Sight Glass Apron Oil Drain Apron lubrication references. Remove the four screws and pump access cover, and slide out the pump and reservoir (see ). Empty the old coolant and remove large chips from 1st and 2nd stage separators. Fill the reservoir with approximately three gallons of coolant solution. Open the valve on the coolant nozzle. Typical ball fitting locations. Turn the coolant pump to prime the coolant system and to see if the coolant is cycling properly. Reinstall the pump access cover. 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. Coolant pump and reservoir. -40-

43 This section covers the most common service adjustments or procedures that may need to be made during the life of your machine. 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. Tighten the socket head cap screw in small increments (see ). Test after each adjustment until the backlash meets the needs of the operator and operation. Cross Feed Backlash Adjustment Cap Screw The saddle, cross feed, compound rest, and tailstock gibs can all be adjusted on the Model M1098 lathe. Cross feed backlash adjustment socket head cap screw. Loosen four hex nuts found at the bottom rear of the cross slide and back off one full turn each (see ). Saddle gib adjustments. -41-

44 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. Tighten the four hex nuts. Loosen the gib locking set screw and the rear gib screw approximately one turn. (see ). Tighten the front gib screw a quarter turn (see ). Rear cross feed gib screw. Gib Locking Set Screws Rear Gib Screw 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. Repeat on the compound rest. Front Gib Screw Front cross feed gib screw. 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 ). Hex Nut is Under Block Tailstock lock adjustment. -42-

45 DISCONNECT POWER TO THE LATHE! Remove the change gear cover at from the headstock. Motor Remove the tension off the old V-belts by loosening the motor mount hex bolts (see). 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. Mounting Bolts V-belt adjustments. Close the change gear cover, and reconnect the lathe to the power source. -43-

46 Transformer Circuit Breaker Circuit Breaker Spindle Motor Contactors Pump Relay Change Gear Cover Anti-Start Limit Switch Ground Block Terminal Bar M1098 Electrical panel. -44-

47 WARNING Disconnect power to the lathe before performing any electrical work, service, or adjustment. OFF LEGEND 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 -45-

48 Chuck Guard Limit Switch Inside. M1098 chuck guard limit switch. Spindle Motor 220V 3-Ph Brown Red W2 U2 v2 Blue Ground Yellow/Green Black Black Black U1 V1 W1 Pump Motor 220V 3-Ph M1098 spindle motor. Black Blue Red Ground Yellow/Green Cover Anti-Start Limit Switch. Foot Brake Limit Switch Spindle Rotation Limit Switches. M1098 limit switches. M1098 coolant pump motor. -46-

49 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. Motor will not start. 1. Limit switch is triggered. 2. Emergency switch is pushed in. 3. No voltage or open connection. 4. Faulty start capacitor. 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. Fuses or circuit breakers trip open. Motor overheats. Carriage hard to move. Loud, repetitious noise coming from machine. Machine is loud when cutting. Overheats or bogs down in the cut. Tailstock quill will not feed out of tailstock. Bad surface finish. Gear change levers will not shift into position. Can't remove tapered tool from quill. 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. Motor overloaded. 2. Air circulation through the motor restricted. 1. Carriage lock is tightened down. 2. Chips have loaded up on bedways. 3. Bedways are dry and in need of lubrication. 4. Longitudinal stops are interfering. 5. Gibs are too tight. 1. Chuck is hitting the carriage or tool post. 1. Excessive depth of cut. 2. RPM or Feed Rate wrong for operation. 3. Dull cutters. 1. Quill lock is tightened down. 1. Unlock. 1. Wrong RPM or feed rate. 2. Dull tooling or poor tool selection. 3. Too much play in gibs. 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. 1. Reduce load on motor. 2. Clean out motor to provide normal air circulation. 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. 4. Check to make sure that stops are floating and not hitting the center stop. 5. Loosen gib screw(s) slightly. 1. Shut lathe Hit emergency stop button or step on foot pedal. 1. Decrease depth of cut. 2. Refer to RPM Feed rate chart for appropriate rates. 3. Sharpen or replace cutters. 1. Adjust for appropriate RPM and feed rate. 2. Sharpen tooling or select a better tool for the intended operation. 3. Tighten gibs. 1. Gears not aligned in headstock. 1. Rotate spindle by hand until gear falls into place. 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. -47-

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53 REF PART # DESCRIPTION REF PART # DESCRIPTION 1 XM MOTOR BASE 71 XPS03M PHLP HD SCR M6-1 X 8 2 XM PULLEY 72 XPS19M PHLP HD SCR M5-.8 X 6 3 XM BED 73 M COVER 4 XM GAP 74 M ELECTRICAL BOX 5 XM END COVER 75 M SPALSH GUARD 6 XM L-BRACKET 76 XPS68M PHLP HD SCR M6-1 X 10 7 XM COLLAR-BRACKET 77 XPS47M PHLP HD SCR M6-1 X 25 9 XM COLLAR 78 XPN01M HEX NUT M XM HANDLE 79 M OIL PLATE 11 XM RACK (LONG) 80 XPS68M PHLP HD SCR M6-1 X XM RACK (SHORT) 81 M COVER 16 XM LEAD SCREW 82 M LEFT BED STAND 19 XM FEED ROD 83 M BED STAND 22 XM SHAFT 84 M COVER 23 XM COLLAR 85 XPS68M PHLP HD SCR M6-1 X XM SHAFT 86 XPS68M PHLP HD SCR M6-1 X XM HANDLE 87 M COVER 26 XM BRAKE RING 88 XPSB73M CAP SCREW M X XM COLLAR 89 M LEFT PLATE BRACKET 28 XM KEY 90 XPS68M PHLP HD SCR M6-1 X XM KNOB M M PLATE 40 XM PLUG 92 M RIGHT PLATE BRACKET 41 XM PLUG 93 M BREAK SHAFT 42 XM PLUG 94 XPRP40M ROLL PIN 2.5 X XM SPECIAL SCREW 95 M BRAKE PULL ROD 44 XM COVER 96 M CAP-SHAPE SCREW 45 XM KNOB M XPN01M HEX NUT M XPSS05M SET SCREW M5-.8 X XPRP40M ROLL PIN 2.5 X XPSS11M SET SCREW M6-1 X M PEDAL ARM 49 XPSB47M CAP SCREW M X M CONNECTING SHAFT 51 XPSB02M CAP SCREW M6-1 X M DRAW SPRING 52 XPSB60M CAP SCREW M X M SWITCH BLOCK 53 XPN03M HEX NUT M XPS39M PHLP HD SCR M X XPSS19M SET SCREW M X XPRP28M ROLL PIN 5 X XPSB63M CAP SCREW M X M DRIVING SHAFT (LONG) 58 XPRP16M ROLL PIN 3 X XPRP05M ROLL PIN 5 X XPRP71M ROLL PIN 6 X M DRVING SHAFT (SHORT) 61 XPRP46M ROLL PIN 6 X M PEDAL 61-1 XPRP34M ROLL PIN 6 X XPSB71M CAP SCREW M X M COMPRESSION SPRING 1 X 7.5 X XPN02M HEX NUT M M OIL BALL 8MM 111 M BRAKE ROD SUPPORT 69 XM SET SCREW M X M SPINDLE MOTOR 70 XPB14M HEX BOLT M X

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57 REF PART # DESCRIPTION REF PART # DESCRIPTION 1001 XM COLLAR 1051 XM ANCHOR PIN 1002 XM COLLAR 1052 XM SHAFT 1003 XM REAR COVER 1053 XM GEAR 30T 1004 XM REAR COVER 1054 XM SHAFT 1005 XM PULLEY 1055 XM SHAFT 1006 XM PLUG 1056 XM THRUST WASHER 1007 XM MAIN CASTING 1057 XM GEAR SHAFT 17T 1008 XM FRONT COVER 1059 XM SPECIAL SHOULDER SCREW 1009 XM SHIFT LEVER 1064 XM LEVER 1010 XM SHAFT HOUSING 1065 XM LEVER 1011 XM COVER 1066 XM LEVER 1012 XM HANDLE BODY 1067 XM COLLAR 1013 XM CRANK SHAFT 1068 XM SHIFT FORK 1014 XM HANDLE BODY 1069 XM SHIFT FORK 1015 XM HANDLE BLOCK 1073 XM GASKET 1016 XM HUB 1074 XM GASKET 1017 XM GEAR 37T 1075 XM GASKET 1018 XM SPACER 1076 XM GASKET 1019 XM SLOTTED COLLAR 1077 XM GASKET 1020 XM THRUST WASHER 1078 XM GASKET 1021 XM GEAR 40T 1079 XM OIL SEAL 1022 XPW06M FLAT WASHER M XM OIL SEAL 1023 XM GEAR 37T 1084 XPS02M PHLP HD SCR M4-.7 X XM SPANNER NUT 1085 XPSB24M CAP SCREW M5-.8 X XM GEAR 43T 1086 XPSB01M CAP SCREW M6-1 X XM GEAR 51T 1087 XPSB14M CAP SCREW M X XM SPACER 1088 XPSB02M CAP SCREW M6-1 X XM GEAR SHAFT 16T 1089 XPSB06M CAP SCREW M6-1 X XM COVER 1093 XPSS04M SET SCREW M6-1 X XM CAST WASHER 1095 XPSS20M SET SCREW M X XM SHAFT 1096 XPSS16M SET SCREW M X XM SPACER 1097 XPSS14M SET SCREW M X XM COLLAR W/GEAR 21T 1099 XPS42M PHLP HD SCR M X XM GEAR 29T 1100 XPS38M PHLP HD SCR M4-.7 X XM GEAR 46T 1102 XPN09M HEX NUT M XM GEAR 38T 1103 XPK20M KEY 5 X 5 X XM COLLAR 1104 XPK14M KEY 5 X 5 X XM GEAR 26T 1105 XPK36M KEY 5 X 5 X XM GEAR 34T 1106 XPK11M KEY 6 X 6 X XM GEAR 53T 1107 XPK49M KEY 6 X 6 X XM PLUG 1108 XPK50M KEY 6 X 6 X XM GEAR 74T 1109 XPK50M KEY 6 X 6 X XM GEAR 37T 1110 XPK51M KEY 8 X 8 X XM SPINDLE 1111 XPK34M KEY 5 X 5 X XM SPRING 1113 XPRP44M ROLL PIN 3 X XM PIN 1114 XPRP01M ROLL PIN 4 X XM CAM 1117 PR09M EXT RETAINING RING XM SHAFT 1119 PR12M EXT RETAINING RING XM GEAR 51T -55-

58 REF PART # DESCRIPTION REF PART # DESCRIPTION 1120 PR43M EXT RETAINING RING 50MM 1138 XM O-RING 3.1 X XPR44M EXT RETAINING RING XM COMPRESSION SPRING 1 X 6 X XM E-CLIP XM COMPRESSION SPRING 1 X 6 X XM BEARING E 1141 XM COMPRESSION SPRING 0.9 X 4.4 X XM BEARING 240E 1142 XM SHIFT HUB 1125 XP203 BEARING XM LEVER SLEEVE 1126 XM BEARING 204D 1148 XM COVER 1127 XM BEARING 7210E 1151 XPSB84M CAP SCREW M X XM BEARING 7212D 1152 XM CONNECTING BOARD 1129 XM STEEL BALL XPRP49M ROLL PIN 5 X XM STEEL BALL XM SHAFT 1133 XM O-RING 2.4 X XM BREAK SHAFT 1134 XM O-RING 2.4 X PR03M EXT RETAINING RING XM O-RING 2.4 X XM BREAK SHOE 1136 XM O-RING 3.1 X XM POSITIONING AXLE 1137 XM O-RING 3.1 X PR39M EXT RETAINING RING 8-56-

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62 REF PART # DESCRIPTION REF PART # DESCRIPTION 2001 XM CASTING 2048 XPK33M KEY 5 X 5 X XM LARGE CASTING COVER 2049 XP6203 BEARING XM LARGE CASTING COVER 2050 XM BUSHING 2004 XM DRAIN OIL FITTING 2051 XM SPECIAL CLIP 2005 XM "O"-RING 17 X XM GEAR 2006 XM SLIDING BLOCK 2053 XM THRUST WASHER 2007 XPSB66M CAP SCREW M X XP6204 BEARING XM TAPER PIN 6 X XM THRUST WASHER 2009 XM EXTENSION FASTNER M XPR09M EXT RETAINING RING 20MM 2010 XM BLOCK 2057 XPR19M EXT RETAINING RING 28MM 2011 XPRP08M ROLL PIN 6 X XM GEAR 2012 XM RACK 2059 XM GEAR 2013 XM BLOCK 2060 XPK38M KEY 4 X 4 X XPRP08M ROLL PIN 6 X XM GEAR 2015 XM RACK 2062 XP6204 BEARING XM SHAFT 2063 XM GASKET 2017 XM RETAINING DOG 2064 XM BEARING COVER 2018 XM "O"-RING 8.75 X XM XI AXLE 2019 XPSS31M SET SCREW M5-.8 X XPRP29M ROLL PIN 5 X XM BLOCK 2067 XM BEARING COVER 2021 XM RACK 2068 XM GASKET 2022 XM BLOCK 2069 XM GEAR 2023 XM RACK 2070 XM GEAR 2024 XM CONTROL ROD SUPPORT 2071 XM BUSHING 2025 XPSB24M CAP SCREW M5-.8 X XM GEAR 2026 XM GEAR 2073 XM BUSHING 2027 XM "O"-RING 7 X XM VIII AXLE 2028 XM GASKET 2075 XPK71M KEY 4 X 4 X XM FEED BOX COVER 2076 XM BUSHING 2030 XPSB06M CAP SCREW M6-1 X XM GEAR 2031 XM TAPER PIN 5 X XM BUSHING 2032 XPRP28M ROLL PIN 5 X XM GEAR 2033 XM LEVER SUPPORT 2080 XM GEAR 2034 XM STEEL BALL 6 MM 2081 XM GEAR 2035 XM COMPRESSION SPRING 1 X 5 X XM BUSHING 2036 XPSS06M SET SCREW M X XM GEAR 2037 XM LABEL 2084 XPK93M KEY 4 X 4 X XM SPECIAL SCREW M3-.5 X XM X AXLE 2039 XPSS03M SET SCREW M6-1 X XPK102M KEY 4 X 4 X XM OIL SIGHT GLASS 2087 XM BEARING COVER 2041 XM LABEL 2088 XM GASKET 2042 XM SPECIAL RING 26 X XM GEAR 2043 XM BEARING COVER 2090 XM IX AXLE 2044 XM GASKET 2091 XM BUSHING 2045 XM THRUST WASHER 2092 XM GEAR 2046 XPK33M KEY 5 X 5 X XM GASKET 2047 XM VII AXLE -60-

63 REF PART # DESCRIPTION REF PART # DESCRIPTION 2094 XM BEARING COVER 2104 XM GEAR COVER 2095 XM SPECIAL RING 25 X 40 X XM SPECIAL SHOULDER BOLT 2096 XM XII AXLE 2106 XM WIDE-CAST WASHER 2097 XPRP10M ROLL PIN 5 X XPN02M HEX NUT M XPN09M HEX NUT M XM STUD M XM THRUST WASHER 2109 XM WIDE-CAST WASHER 2100 XM BEARING XM GEAR 2101 XPR21M INT RETAINING RING 35MM 2111 XM THRUST WASHER 2102 XM GEAR 2112 XPSB06M CAP SCREW M6-1 X XM SLEEVE -61-

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67 REF PART # DESCRIPTION REF PART # DESCRIPTION 3001 XM CASTING 3051 XM OIL SIGHT COLLAR 3002 XM HANDWHEEL 3052 XM OIL SIGHT 3003 XM BOX 3053 XM HANDLE 3004 XM COVER 3054 XM PLUG"A" 3005 XM THREADING DIAL BODY 3055 XM PLUG"B" XM HUB 3056 XM HANDLE 3006 XM SPACER 3057 XM COMPRESSION SPRING 3007 XM GIB 3058 XM CPMPRESSION SPRING 3008 XM HUB 3059 XM SPECIAL KEY 3009 XM SHAFT 3060 XPSB33M CAP SCREW M5-.8 X XM INDEX RING 3062 XPSB26M CAP SCREW M6-1 X XM COVER 3063 XPSB01M CAP SCREW M6-1 X XM SHAFT 3064 XPSB06M CAP SCREW M6-1 X XM GEAR ROLL PIN 60T 3065 XPSB13M CAP SCREW M X XM GEAR SHAFT 18T 3066 XPSB05M CAP SCREW M X XM GEAR 3067 XPS40M PHLP HD SCR M5-.8 X XM SHAFT 3068 XPSB26M CAP SCREW M6-1 X XM BRACKET 3069 XPS68M PHLP HD SCR M6-1 X XM COVER 3070 XPSS26M SET SCREW M5-.8 X XM GEAR 30T 3071 XPSS02M SET SCREW M6-1 X XM GEAR 46T 3072 XPSS01M SET SCREW M6-1 X XM GEAR 63T 3073 XPSS34M SET SCREW M5-.8 X XM SHIFT FORK 3074 XPSS29M SET SCREW M6-1 X XM SHIFT LEVER 3075 XPSS01M SET SCREW M6-1 X XM SHIFT HANDLE 3077 XPS14M PHLP HD SCR M6-1 X XM GEAR 40T 3078 XPRP16M ROLL PIN 3 X XM BRACKET 3079 XPRP03M ROLL PIN 5 X XM HALF NUT 3080 XPRP05M ROLL PIN 5 X XM WORM 3081 XPRP45M ROLL PIN 5 X XM GEAR 22T 3082 XPRP49M ROLL PIN 5 X XM SHAFT 3083 XPRP41M ROLL PIN 6 X XM GEAR 18T 3084 XM OILER 8 MM 3034 XM SHAFT 3086 XPW01M FLAT WASHER 8MM 3035 XM THREADING DIAL BODY 3087 XPN06M HEX NUT M XM COMBO GEAR 32T/30T/28T 3088 XPN01M HEX NUT M XM SPACER 3089 XPN03M HEX NUT M XM BAR 3091 XM RIVET 3 X XM HANDLE STUD 3092 XM O-RING 20 X XM CAST WASHER 3095 XPK14M KEY 5 X 5 X XM CAST WASHER 3096 XM STEEL BALL 3044 XM CAST WASHER 3097 XPW04M FLAT WASHER 10 MM 3050 XM OIL SIGHT COLLAR 3098 XM PLUG M10 X 1-65-

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70 REF PART # DESCRIPTION REF PART # DESCRIPTION 4001 XM SADDLE 4034 XM GIB STRIP 4002 XM CROSS SLIDE 4035 XM T-BLOCK 4003 XM SWIVEL SLIDE 4036 XM BLOCK 4004 XM TOPSLIDE 4037 XM DRAG NUT 4005 XM COLLAR 4038 XM FEMALE KNOB M XM GIB 4039 XM WIPER 4007 XM HUB 4040 XM WIPER 4008 XM STRIP 4043 XP8102 THRUST BEARING XM GIB 4044 XPS02M PHLP HD SCR M4-.7 X XM STRIP 4045 XPS76M PHLP HD SCR M X XM FRONT STRIP 4046 XPB09M HEX BOLT M X XM T-BOLT 4047 XPB09M HEX BOLT M X XM HANDLE BASE 4048 XPSB01M CAP SCREW M6-1 X XM HANDLE SHAFT 4049 XPSB02M CAP SCREW M6-1 X XM STOP 4050 XPSB06M CAP SCREW M6-1 X XM LEAD SCREW 4052 XPSB11M CAP SCREW M X XM INDEX RING 4053 XPSS02M SET SCREW M6-1 X XM BALL END CRANK 4054 XPSS03M SET SCREW M6-1 X XM HANDLE 4055 XPSS01M SET SCREW M6-1 X XM COLLAR 4056 XPSS11M SET SCREW M6-1 X XM THRUST WASHER 4057 XPSS20M SET SCREW M X XM SPECIAL NUT 4058 XPSS16M SET SCREW M X XM INDEX RING 4059 XPN01M HEX NUT M XM PLATE 4060 XPN03M HEX NUT M XM PLATE W/WIPER 4061 XPW01M FLAT WASHER 8MM 4027 XM PLATE 4062 XM TOOL POST SCREW M X XM LEAD SCREW 4063 XM COMPRESSION SPRING 0.64 X 4 X XM LOAD WASHER 4064 XM OIL BALL XM POST BASE 4066 XPRP02M ROLL PIN 3 X XM GIB ADJUSTING SCREW 4067 XPRP42M ROLL PIN 3 X XM GIB ADJUSTING SCREW 4069 XM BALL BEARING 4033 XM BALL END CRANK -68-

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73 REF PART # DESCRIPTION REF PART # DESCRIPTION 5001 XM CASTING 5023 XM PIVOT BLOCK 5002 XM FLANGE COVER 5026 XM HANDLE 5003 XM HANDWHEEL 5029 XM FEMALE KNOB M XM CLAMP PLATE 5030 XM FEMALE KNOB M XM BASE 5031 XPSB17M CAP SCREW M4-.7 X XM QUILL 5032 XPSB01M CAP SCREW M6-1 X XM LEAD SCREW 5033 XPSS57M SET SCREW M5-.8 X XM SHOULDER WASHER 5034 XPSS01M SET SCREW M6-1 X XM SPECIAL SCREW 5035 XM SPECIAL STOP SCREW 5011 XM SPECIAL SCREW 5036 XPSS74M SET SCREW M X XM LEVER STUD M X XPN03M HEX NUT M XM SHAFT 5038 XPN09M HEX NUT M XM SPECIAL STOP SCREW 5039 XPK47M KEY 4 X 4 X XM COLLAR 5040 XPW06M FLAT WASHER 12MM 5016 XM PIVOT STUD 5041 XPRP06M ROLL PIN 5 X XM SHAFT 5042 XP51102 THRUST BEARING XM LEVER STUD M X XM OIL BALL 8 MM 5021 XM SHOULDER NUT XM LIVE CENTER MT XM INDEX RING -71-

74 -72-

75 REF PART # DESCRIPTION REF PART # DESCRIPTION 6001 XM PINNED KNOB 6007 XPSS02M SET SCREW M6-1 X XPRP15M ROLL PIN 3 X XPN01M HEX NUT M XM BUSHING 6009 XPSS25M SET SCREW M6-1 X XM SPECIAL SCREW 6010 XM BASE CASTING 6005 XM SLEEVE 6011 XPSB45M CAP SCREW M X XM BRASS FINGER -73-

76 -74-

77 REF PART # DESCRIPTION REF PART # DESCRIPTION 7001 XM PINNED KNOB 7011 XPB29M HEX BOLT M6-1 X XPRP64M ROLL PIN 3 X XM PIVOT BOLT 7003 XM BUSHING 7013 XM BASE CASTING 7004 XM SPECIAL SCREW 7014 XPN09M HEX NUT M XM SLEEVE 7015 XPW06M FLAT WASHER 12MM 7006 XM BRASS FRINGER 7016 XPSS02M SET SCREW M6-1 X XM KNOB M XM CLAMP PAD 7008 XPN01M HEX NUT M XM CLAMP SCREW 7009 XPSS25M SET SCREW M6-1 X XM TOP CASTING 7010 XPN01M HEX NUT M

78 -76-

79 REF PART # DESCRIPTION REF PART # DESCRIPTION 8001 XM WORK LIGHT 8007 XM RUBBER TUBE 8002 XPS15M PHLP HD SCR M6-1 X XPSB38M CAP SCREW M5-.8 X XM LAMP BRACKET 8009 XM COOLANT PUMP 1/8 HP 8004 XPSB02M CAP SCREW M6-1 X XM WATER TANK 8005 XM CONNECTED TUBE 8011 XPN06M HEX NUT M XM COOLANT PUMP -77-

80