Grizzly M1099 Bench Metal Lathe Owner Manual

Grizzly M1099 Bench Metal Lathe Owner Manual

READ THIS FIRST

Model M1099

***IMPORTANT UPDATE***

Applies to Models Mfd. Since 03/18 and Owner's Manual Revised 05/12

Phone #: (360) 734-3482 • Tech Support: tech-support@shopfox.biz • Web: www.shopfox.biz

We made the following changes to this machine since the manual was printed:

Aside from the information contained in this update, all other content in the owner's manual is applicable and MUST be read and understood for your own safety.

IMPORTANT: Keep this update with the owner's manual for future reference

.

If you have any further questions, contact our Technical Support.

Revised Apron Handwheel Parts

146 134V2 136V2 145 144 143 133V2

REF

133V2 XM1099133V2 HANDWHEEL V2.03.18

134V2 XM1099134V2 SET SCREW M6-1 X 12 136V2 XM1099136V2 GEAR SHAFT V2.03.18

143

PART #

XM1099143

DESCRIPTION

PLATE SPRING 144 XM1099144 GRADUATED DIAL 145 146 XM1099145 XM1099146 ROLL PIN 5 X 12 KEY 3 X 3 X 12

#9052KB

COPYRIGHT © APRIL, 2018 BY WOODSTOCK INTERNATIONAL, INC.

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.

Printed in China

MODEL M1099 10" x 26" BENCHTOP LATHE

OWNER'S MANUAL

(FOR MODELS MANUFACTURED SINCE 8/07)

Phone: (360) 734-3482 • Online Technical Support: tech-support@shopfox.biz

COPYRIGHT © FEBRUARY, 2007 BY WOODSTOCK INTERNATIONAL, INC., REVISED APRIL, 2011 (BLTS)

#9052CR WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.

Printed in China

This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators. Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.

The owner of this machine/tool is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and compre hension, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal protective equipment.

The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equip ment, such as those dust masks that are specially designed to filter out microscopic particles.

Table of Contents

INTRODUCTION .....................................2

Woodstock Technical Support .................. 2 Machine Specifications .......................... 3 Identification ..................................... 5

MAINTENANCE .................................... 32

Basic Maintenance ............................. 32 General Lubrication ............................ 32 Belt Adjustment or Replacement ............ 34

SAFETY ...............................................6

Standard Machinery Safety Instructions ...... 6 Additional Safety Instructions for Lathes .... 8

ELECTRICAL .........................................9

Circuit Requirements ............................ 9 Grounding Requirements ...................... 10 Extension Cords ................................ 10

SETUP .............................................. 11

Unpacking ....................................... 11 Inventory ........................................ 11 Machine Placement ............................ 12 Cleaning Machine ............................... 12 Test Run & Break-In ............................ 13

OPERATIONS....................................... 15

General .......................................... 15 Power Control ................................... 15 Mounting Chuck or Faceplate ................ 16 Replacing Jaws ................................. 17 Four-Jaw Chuck ................................ 18 Faceplate ........................................ 19 Tailstock ......................................... 20 Drilling With the Tailstock .................... 20 Cutting Shallow Tapers with Tailstock ...... 21 Aligning Tailstock .............................. 22 Centers........................................... 23 Steady Rest ...................................... 24 Follow Rest ...................................... 24 Compound Rest ................................. 25 Tool Post ......................................... 25 Manual Feed Handwheels ..................... 26 Determining Correct Spindle RPM ........... 27 Spindle RPM ..................................... 28 Power Feed Rate ............................... 29 Inch Threads .................................... 30 Metric Threads .................................. 31

SERVICE ............................................ 35

Troubleshooting ................................. 35 Cross Slide Backlash Adjustment ............ 37 Gib Adjustments ................................ 37 Electrical Component Connections .......... 38 Wiring Diagram ................................. 39

PARTS .............................................. 40

Spindle and Drive Belt ......................... 40 Apron ............................................. 42 Apron Parts ...................................... 43 Tool Holder and Compound Rest ............. 44 Tailstock ......................................... 45 Bed and Leadscew ............................. 46 Steady Rest and Follow Rest ................. 47 Motor and Electrical ........................... 48 Gearbox Diagram A ............................. 49 Gearbox Diagram B ............................ 51 Cross Feed and Carriage ...................... 53

WARRANTY ........................................ 55

USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST!

Model M1099 (Mfg Since 8/07)

INTRODUCTION

Woodstock Technical Support

Your new

SHOP FOX

® Model M1099 Benchtop 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.

Woodstock International, Inc. is committed to customer satisfaction. Our intent with this manual is to include the basic information for safety, setup, operation, maintenance, and service of this product. We stand behind our machines! In the event that questions arise about your machine, please contact Woodstock International Technical Support at (360) 734-3482 or send e-mail to:

tech-support@shopfox.

biz

. Our knowledgeable staff will help you troubleshoot problems and process warranty claims.

If you need the latest edition of this manual, you can download it from

http://www.shopfox.biz

. If you have comments about this manual, please contact us at:

Woodstock International, Inc.

Attn: Technical Documentation Manager P.O. Box 2309 Bellingham, WA 98227 Email: manuals@woodstockint.com

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Model M1099 (Mfg Since 8/07)

Motors Main

Type................................................. Reversible TEFC Capacitor Start and Run Induction Horsepower................................................................................................. 1 HP Voltage...................................................................................................... 110V Phase.............................................................................................. Single-Phase Amps....................................................................................................... 13.6A

Speed.................................................................................................. 1725 RPM Cycle....................................................................................................... 60 Hz Number of Speeds............................................................................................. 1 Power Transfer ............................................................................ Cogged Belt Drive Bearings............................................................................. Shielded and Lubricated

Main Specifications Operation Info

Swing Over Bed....................................................................................... 9-5/8 in.

Distance Between Centers.............................................................................. 26 in.

Swing Over Cross Slide.............................................................................. 6-1/8 in.

Swing Over Saddle................................................................................... 6-3/8 in.

Maximum Tool Bit Size................................................................................. 3/8 in.

Compound Travel..................................................................................... 3-1/2 in.

Carriage Travel...................................................................................... 22-1/2 in.

Cross Slide Travel.................................................................................... 6-1/2 in.

Headstock Info

Spindle Bore................................................................................................ 1 in.

Spindle Size........................................................................................... 1-3/4 in.

Spindle Taper.............................................................................................. MT#4 Spindle Threads................................................................................................ 8 Number of Spindle Speeds................................................................................... 6 Spindle Speeds....................................................... 150, 300, 560, 720, 1200, 2400 RPM Spindle Type......................................................................................... Threaded Spindle Bearings............................................................................... Tapered Roller

Tailstock Info

Tailstock Quill Travel................................................................................ 2-1/2 in.

Tailstock Taper........................................................................................... MT#3 Model M1099 Machine Specifications, Page 1 of 3 -3-

Model M1099 (Mfg Since 8/07)

Threading Info

Number of Longitudinal Feeds............................................................................... 9 Range of Longitudinal Feeds............................................................ 0.0023 — 0.013 in.

Number of Inch Threads..................................................................................... 33 Range of Inch Threads............................................................................. 8 — 72 TPI Number of Metric Threads.................................................................................. 26 Range of Metric Threads.......................................................................... 0.25 — 3.5

Dimensions

Bed Width............................................................................................. 6-1/8 in.

Leadscrew Diameter................................................................................... 3/4 in.

Leadscrew TPI................................................................................................ 12 Leadscrew Length........................................................................................... in.

Faceplate Size............................................................................................ 12 in.

Construction

Headstock............................................................................................. Cast Iron Headstock Gears.......................................................................................... Steel Bed......................................................................................... Hardened Cast Iron Body.................................................................................................... Cast Iron Paint....................................................................................................... Epoxy

Product Dimensions

Weight.......................................................................................................... 330 lbs.

Width (side-to-side) x Depth (front-to-back) x Height................................... 50 x 32 x 16-5/8 in.

Footprint (Length x Width).................................................................... 53-1/2 x 12-1/2 in.

Shipping Dimensions

Type....................................................................................................... Wood Crate Content........................................................................................................ Machine Weight.......................................................................................................... 475 lbs.

Length x Width x Height........................................................................... 62 x 23 x 23 in.

Electrical

Power Requirement.................................................................... 110V, Single-Phase, 60 Hz Minimum Circuit Size............................................................................................. 20A Switch..................................................................................................... Push Button Switch Voltage.................................................................................................... 110V Cord Length....................................................................................................... 5 ft.

Cord Gauge.................................................................................................. 14 Gauge Plug Included....................................................................................................... Yes Included Plug Type........................................................................................ NEMA 5-15

Other

Country Of Origin ............................................................................................... China Warranty ........................................................................................................ 2 Year Serial Number Location ................................................................ Data Label on Headstock Assembly Time ................................................................................................. 1 Hour

Features

Hardened and Ground V-Ways Chip Tray Included Back Splash Full Featured Carriage and Apron Assemblies Provide Super Accurate Cuts and Finishes Long Bed Accommodates 26 in. Between Cuts Model M1099 Machine Specifications, Page 2 of 3 -4-

Model M1099 (Mfg Since 8/07)

A B C D E

Identification

F G H I J K U T S R

A. B. C. D. E. F. G. H. I. J. K.

Emergency Stop Button Motor Direction Selector Knob Power ON Push Button 3-Jaw Chuck Steady Rest 4-Way Tool Holder Follow Rest Compound Feed Handwheel Tailstock Barrel Lock Lever Tailstock Back Splash Q P O N M L

L. M.

Chip Tray Thread Dial

N.

Half Nut Lever

O.

Cross Feed Handwheel

P.

Carriage Feed Handwheel

Q.

Lead Screw

R.

Threading Dial (Alpha)

S.

Gearbox Oil Level Sight Glass

T.

Threading Dial (Numeric)

U.

Change Gear and Belt Safety Cover

READ and understand this entire instruction manual before using the machine. Serious personal injury may occur if safety and operational information is not understood and fol lowed. DO NOT risk your safety by not reading!

-5-

Model M1099 (Mfg Since 8/07)

SAFETY

For Your Own Safety, Read Manual Before Operating Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention mea sures—this responsibility is ultimately up to the operator!

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

NOTICE

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

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.

OWNER’S MANUAL.

Read and understand this owner’s manual BEFORE using machine. Untrained users can be seriously hurt.

EYE PROTECTION.

glasses.

Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are not approved safety

HAZARDOUS DUST.

Dust created while using machinery may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with workpiece materials, and always wear a NIOSH-approved respirator to reduce your risk.

WEARING PROPER APPAREL.

of workpiece control.

Do not wear clothing, apparel, or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to avoid accidental slips which could cause a loss

HEARING PROTECTION.

Always wear hearing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.

MENTAL ALERTNESS.

when distracted.

Be mentally alert when running machinery. Never operate under the influence of drugs or alcohol, when tired, or

DISCONNECTING POWER SUPPLY.

Always disconnect machine from power supply before servicing, adjusting, or changing cutting tools (bits, blades, cutters, etc.). Make sure switch is in OFF position before reconnecting to avoid an unexpected or unintentional start.

DANGEROUS ENVIRONMENTS.

Do not use machinery in wet or rainy locations, cluttered areas, around flammables, or in poorly-lit areas. Keep work area clean, dry, and well lighted to minimize risk of injury.

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Model M1099 (Mfg Since 8/07)

APPROVED OPERATION.

Untrained operators can be seriously hurt by machinery. Only allow trained or properly supervised people to use machine. When machine is not being used, disconnect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make workshop kid proof!

ONLY USE AS INTENDED.

Only use machine for its intended purpose. Never modify or alter machine for a purpose not intended by the manufacturer or serious injury may result!

USE RECOMMENDED ACCESSORIES.

injury.

Consult this owner’s manual or the manufacturer for recommended accessories. Using improper accessories will increase the risk of serious

CHILDREN & BYSTANDERS.

Keep children and bystanders a safe distance away from work area. Stop using machine if children or bystanders become a distraction.

REMOVE ADJUSTING TOOLS.

Never leave adjustment tools, chuck keys, wrenches, etc. in or on machine—especially near moving parts. Verify removal before starting!

SECURING WORKPIECE.

When required, use clamps or vises to secure workpiece. A secured workpiece protects hands and frees both of them to operate the machine.

FEED DIRECTION.

Unless otherwise noted, feed work against the rotation of blades or cutters. Feeding in the same direction of rotation may pull your hand into the cut.

GUARDS & COVERS.

Guards and covers can protect you from accidental contact with moving parts or flying debris. Make sure they are properly installed, undamaged, and working correctly before using machine.

NEVER STAND ON MACHINE.

damaged.

Serious injury or accidental contact with cutting tool may occur if machine is tipped. Machine may be

STABLE MACHINE.

Unexpected movement during operations greatly increases the risk of injury and loss of control. Verify machines are stable/secure and mobile bases (if used) are locked before starting.

FORCING MACHINERY.

Do not force machine. It will do the job safer and better at the rate for which it was designed.

AWKWARD POSITIONS.

Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury.

UNATTENDED OPERATION.

before walking away.

Never leave machine running while unattended. Turn machine off and ensure all moving parts completely stop

MAINTAIN WITH CARE.

Follow all maintenance instructions and lubrication schedules to keep machine in good working condition. An improperly maintained machine may increase the risk of serious injury.

CHECK DAMAGED PARTS.

machine. Regularly inspect machine for damaged parts, loose bolts, mis-adjusted or mis-aligned parts, binding, or any other conditions that may affect safe operation. Always repair or replace damaged parts, wires, cords, or plugs before operating

MAINTAIN POWER CORDS.

When disconnecting cord-connected machines from power, grab and pull the plug—NOT the cord. Pulling the cord may damage the wires inside. Do not handle the cord/plug with wet hands. Avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, and wet or damp locations.

EXPERIENCING DIFFICULTIES.

(360) 734-3482.

If at any time you are experiencing difficulties performing the intended operation, stop using the machine! Contact our Technical Support for help at -7-

Model M1099 (Mfg Since 8/07)

Additional Safety Instructions for Lathes

CLEARING CHIPS.

Metal chips can easily cut bare skin—even through a piece of cloth. Avoid clear ing chips by hand or with a rag. Use a brush or vacuum to clear metal chips.

CHUCK KEY SAFETY.

the chuck.

A chuck key left in the chuck can become a deadly projectile when the spindle is started. Always remove the chuck key after using it. Develop a habit of not taking your hand off of a chuck key unless it is away from

SAFE CLEARANCES.

Workpieces that crash into other components on the lathe may throw dan gerous projectiles in all directions, leading to impact injury and damaged equipment. Before starting the spindle, make sure the workpiece has adequate clearance by hand-rotating it through its entire range of motion. Also, check the tool and tool post clearance, chuck clear ance, and saddle clearance.

TOOL SELECTION.

Cutting with an incorrect or dull tool bit will often overload the bit and cause it to dig into the workpiece and snap. As a result, hot razor-sharp shards may be ejected that can result in a burn or blinding injury. To increase safety, decrease tool bit load, and provide the best finish possible, always use the correct tool and one that is sharp.

REMOVING/INSTALLING CHUCKS.

Chucks are heavy and often oily and slippery to hold. Losing your grip on a chuck can lead to crushed hands or amputated fingers. To reduce this risk and protect the lathe bed, cover the bed with a sheet of wood and use a chuck cradle. For large chucks, also get the assistance of one or more people, and use an appropriate hoisting appara tus when installing or removing.

SPEED RATES.

Operating the lathe at the wrong speed can cause nearby parts to break or the workpiece to come loose, which will result in dangerous projectiles that could cause severe impact injury. Large workpieces must be turned at slow speeds. Always use the appropriate feed and speed rates.

SECURING WORKPIECE.

A thrown workpiece may cause severe injury or even death. When swap ping the chuck jaw positions, double-check that the jaw fasteners are tight and that the top jaw is fully seated with the lower jaw no gaps exist between the two. When clamping a workpiece, maximum gripping force is attained at full jaw and scroll gear engagement. If jaw and scroll gear are only partially engaged, clamping force is reduced.

STOPPING SPINDLE BY HAND.

Stopping the spin dle by putting your hand on the workpiece or chuck creates an extreme risk of entanglement, impact, crushing, friction, or cutting hazards. Never attempt to slow or stop the lathe spindle with your hand. Allow the spindle to come to a stop on its own or use the brake (if equipped).

CRASHES.

lathe. Tooling or components that contact a spinning chuck may shatter sending metal frag ments in all directions resulting in severe impact injuries and major damage to the lathe. Reduce this risk by releasing automatic feeds after use and checking clearances before starting the

LONG STOCK SAFETY.

at slow speeds.

Long stock can whip vio lently if not properly supported, causing serious impact injury and damage to the lathe. Reduce this risk by supporting any stock that extends from the chuck/headstock more than three times its own diameter. Always turn long stock

CUTTING FLUID SAFETY.

Contaminated cutting fluid is a toxic biohazard that can cause poison ing from skin contact. Incorrectly positioned cutting fluid nozzles can splash on the operator or the floor, resulting in an exposure or slipping hazard. To decrease your risk, change cutting fluid regularly and use the system carefully.

-8-

Model M1099 (Mfg Since 8/07)

ELECTRICAL

Circuit Requirements

This machine must be connected to the correct size and type of power supply circuit, or fire or electrical damage may occur. Read through this section to determine if an adequate power supply circuit is available. If a correct circuit is not available, a qualified electrician MUST install one before you can connect the machine to power.

The machine must be properly set up before it is safe to operate. DO NOT connect this machine to the power source until instructed to do later in this manual.

A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine. The power supply circuit used for this machine must be sized to safely handle the full load current drawn from the machine for an extended period of time. (If this machine is connected to a circuit protected by fuses, use a time delay fuse marked D.)

Full-Load Current Rating

The full-load current rating is the amperage a machine draws at 100% of the rated output power. On machines with multiple motors, this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations.

Full-Load Current Rating at 110V ................13.6 Amps

This machine is prewired to operate on a 110V power supply circuit that has a verified ground and meets the following requirements:

Circuit Type ............... 110V/120V, 60 Hz, Single-Phase Circuit Size ............................................. 15 Amps Plug/Receptacle .................................... NEMA 5-15 Incorrectly wiring or grounding this machine can cause electrocution, fire, or machine damage. To reduce this risk, only a qualified electrician or service personnel should do any required electrical work for this machine.

NOTICE

The circuit requirements listed in this manual apply to a dedicated circuit— where only one machine will be running at a time. If this machine will be connected to a shared circuit where multiple machines will be running at the same time, consult a qualified electrician to ensure that the circuit is properly sized for safe operation.

-9-

Model M1099 (Mfg Since 8/07)

Grounding Requirements

This machine MUST be grounded. In the event of certain types of malfunctions or breakdowns, grounding provides a path of least resistance for electric current to travel—in order to reduce the risk of electric shock.

Improper connection of the equipment-grounding wire will increase the risk of electric shock. The wire with green insulation (with/without yellow stripes) is the equipment grounding wire. If repair or replacement of the power cord or plug is necessary, do not connect the equipment grounding wire to a live (current carrying) terminal.

Check with a qualified electrician or service personnel if you do not understand these grounding requirements, or if you are in doubt about whether the tool is properly grounded. If you ever notice that a cord or plug is damaged or worn, disconnect it from power, and immediately replace it with a new one.

For 110V Connection

The plug provided with the machine has a ground prong that must be attached to the equipment-grounding wire inside the included power cord. The plug must only be inserted into a matching receptacle that is properly installed and grounded in accordance with all local codes and ordinances.

The machine must be properly set up before it is safe to operate. DO NOT connect this machine to the power source until instructed to do later in this manual.

GROUNDED 5-15 RECEPTACLE

Grounding Prong

Extension Cords

We do not recommend using an extension cord with this machine. Extension cords cause voltage drop, which may damage electrical components and shorten motor life. Voltage drop increases with longer extension cords and the gauge smaller gauge sizes (higher gauge numbers indicate smaller sizes).

Any extension cord used with this machine must contain a ground wire, match the required plug and receptacle, and meet the following requirements:

Minimum Gauge Size at 220V ...................... 12 AWG Maximum Length (Shorter is Better) ................50 ft.

5-15 PLUG

Neutral Hot

Figure 1 .

NEMA 5-15 plug & receptacle.

DO NOT modify the provided plug or use an adapter if the plug will not fit your receptacle. This is an indication that your power supply circuit does NOT meet the requirements for the machine; have an electrician install the correct power supply circuit. If the machine must be reconnected for use on a different type of electric circuit, the reconnection should be made by a qualified electrician or service personnel; after reconnection, the machine must comply with all local codes and ordinances.

-10-

Model M1099 (Mfg Since 8/07)

SETUP

Unpacking

This machine has been carefully packaged for safe transportation. If you notice the machine has been damaged during shipping, please contact your authorized Shop Fox dealer immediately.

Some hardware/fasteners on the inven tory list may arrive pre-installed on the machine. Check these locations before assuming that any items from the inventory list are missing.

Inventory

After all the parts have been removed from your shipment, you should have the following items: A B C D

Installed Accessories (Figure 1) .........................Qty.

A.

Three-Jaw Chuck (5") .................................... 1

B.

Steady Rest ................................................ 1

C.

4-Way Tool Post and Compound Rest .................. 1

D.

Compound Slide ........................................... 1

Packaged Accessories (Figure 2) E.

Hex Wrench Set (2.5, 3, 4, 5, 6 mm) ............. 1 EA

F.

Tool Box .................................................... 1

G.

Faceplate (8") ............................................. 1

H.

Four-Jaw Universal Chuck (6 1 ⁄ 2 ") ...................... 1

I.

Low Range Belt ........................................... 1 High Range Belt (Installed) ............................. 1

J.

Phillips and Standard #2 Screwdriver ............. 1 EA

K.

Wrench Set (12/14, 12/14, 19/17 mm) ............1 EA

L.

Three-Jaw Chuck Internal Jaw Set .................... 1

M.

Three-Jaw Chuck Key .................................... 1

N.

Four-Jaw Chuck Key ...................................... 1

O.

Oil Bottle .................................................. 1

P. Q. R.

Cross Feed Handle ........................................ 1 Carriage Feed Handle .................................... 1 Dead Center MT#3 ....................................... 1

S.

Change Gear Set .......................................... 1 — Change Gear (27-tooth, Installed) .........................1

— Change Gear (36-tooth) ........................................1

— Change Gear (40-tooth) ........................................1

— Change Gear (44-tooth) ........................................1

— Change Gear (46-tooth) ........................................1

— Change Gear (48-tooth, Installed) .........................1

— Change Gear (52-tooth) ........................................1

— Change Gear (45-tooth) ........................................1

— Change Gear (56-tooth, Installed) .........................1

— Change Gear (60-tooth) ........................................1

— Plastic Drive Gear (60-tooth, Installed) .................1

— Change Gear (104-tooth, Installed) .......................1 — Change Gear (120-tooth) ......................................1

— Change Gear (127-tooth, Installed) .......................1

E

Figure 1.

Installed accessories.

J K F G L I N H P Q R S

Figure 2.

Packaged accessories.

O M -11-

Machine Placement

• Workbench Load:

This machine distributes a heavy load in a small footprint. Some workbenches may require additional bracing to support both machine and workpiece.

• Working Clearances:

your Machine Type. 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

• Lighting:

Lighting should be bright enough to eliminate shadow and prevent eye strain.

• Electrical:

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.

Model M1099 (Mfg Since 8/07)

Cleaning Machine

The bed and other unpainted parts of your 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.

NEVER clean with gasoline or other petroleum based solvents. Most have low flash points, which make them extremely flammable. A risk of explosion and burning exists if these products are used. Serious personal injury may occur if this warning is ignored!

USE helpers or power lifting equipment to lift this Machine Name. Otherwise, serious per sonal injury may occur. MAKE your shop “child safe.” Ensure that your workplace is inaccessible to children by closing and locking all entrances when you are away. NEVER allow untrained visitors in your shop when assembling, adjusting or operating equipment. ALWAYS work in well ventilated areas far from possible ignition sources when using solvents to clean machinery. Many solvents are toxic when inhaled or ingested. Use care when disposing of waste rags and towels to be sure they DO NOT create fire or environmental hazards.

-12-

Model M1099 (Mfg Since 8/07)

Test Run & Break-In

The purpose of the test run is to make sure the lathe and safety features operate correctly before proceeding with additional setup.

To begin the test run & break-in procedure, do these steps: 1.

Make sure the lathe is lubricated and the headstock oil level is full. Refer to

General Lubrication

on

Page 32

.

2.

Make sure the chuck is correctly secured to the spin dle. Refer to

Mounting Chuck and Faceplate

on

Page 16

for details.

3.

Change the belt position so the spindle will rotate at 150 RPM, and disengage the half nut with the lever shown in

Figure 3

. Refer to

Determining Correct Spindle RPM

on

Page 27

for clarification.

4.

Rotate the red emergency stop button ( direction selector points to STOP.

Figure 4

) clockwise so it pops out, and make sure the motor

5.

Move the numeric gearbox dial to

I

, and the alpha gearbox dial to

C

(see

Figure 4

).

Note:

You may have to slightly rotate the chuck by hand to engage the gears.

6.

Push the green power button, then turn the motor direction dial to FWD. The top of the chuck should now be turning toward you.

7.

Push the emergency stop button. The lathe should stop. If not, disconnect power and refer to

Troubleshooting

on

Page 35

.

8.

Return the motor direction dial to STOP, reset the emergency stop button, restart the lathe, and let the lathe run for a minimum of 10 minutes.

— If you hear squealing or grinding noises, turn the lathe

OFF

immediately and correct any problem before further operation.

— If the problem is not readily apparent, refer to

Troubleshooting

on

Page 35

.

Make sure the half nut lever is disengaged before you start the lathe! Thoroughly familiarize yourself with all the controls and their functions before using the longitudinal feed! NEVER SHIFT LATHE GEARS WHEN MACHINE IS OPERATING.

Half-Nut Lever Pulled Up (Disengaged)

Figure 3.

Half nut lever in the disengaged position.

Numeric Dial Emergency Stop Button Motor Direction Selector Pointing to STOP Alpha Dial

Figure 4.

Headstock and gearbox controls.

-13-

9.

Turn the lathe

OFF

, disconnect power, move the drive belt to the next highest RPM and then run the lathe for 10 minutes.

10.

Repeat

Step 9

for the rest of the speeds, progres sively increasing the speed.

11.

Change the lubricant in the headstock with Mobil DTE

®

Oil or an equivalent, and re-lubricate the lathe. Refer to

General Lubrication

on

Page 32

for steps and locations.

Model M1099 (Mfg Since 8/07)

-14-

Model M1099 (Mfg Since 8/07)

OPERATIONS

General

The Model M1099 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.

operation, stop using the machine!

If at any time you are experiencing difficulties performing any

If you are an inexperienced operator, we strongly recom mend that you read books, trade articles, or seek train ing from an experienced lathe operator before perform ing any unfamiliar operations.

Above all, your safety should come first!

READ and understand this entire instruc tion manual before using this machine. Serious personal injury may occur if safety and operational information is not understood and followed. DO NOT risk your safety by not reading!

Disconnect power to the lathe, and make sure the spindle is stopped before proceeding with any adjustments or maintenance. Failure to comply may result in serious personal injury or death.

Always wear safety glasses when oper ating the lathe. Failure to comply may result in serious personal injury.

Emergency Stop Button

Power Control

Pressing the red emergency stop button ( tions can begin again.

Figure 5

) cuts power to the machine. Twisting the emergency stop but ton clockwise and letting it pop out resets the lathe, so when you push the green power ON button lathe opera Motor Direction Switch Power ON Button

Complete the Test Run & Break-In procedure on

Page 13

before using this lathe for any cutting or threading operations; otherwise, gear box damage will occur.

-15-

Figure 5.

Lathe electrical controls.

Model M1099 (Mfg Since 8/07)

Mounting Chuck or Faceplate

The three-jaw scroll chuck will automatically self-center the workpiece. It has hardened steel external jaws that hold the workpiece on the outside diameter of the part. An extra set of jaws is included for holding larger workpieces on the inside diameter of the part. The four-jaw chuck has hardened steel jaws that must be independently adjusted to center the workpiece. Each jaw can be removed from the chuck body and reversed for clamping odd-shaped workpieces. If either chuck cannot hold your workpiece, the cast-iron faceplate has slots for T-bolts that hold standard or cus tom clamping fixtures. With the correct clamping hard ware, this faceplate will hold non-cylindrical parts such as castings.

Both chucks and the faceplate are removed and installed the same way.

To remove and install the chuck or faceplate, do these steps: 1.

DISCONNECT POWER TO THE LATHE!

2.

Lay a piece of plywood over the bedways to protect the precision-ground way surfaces.

3

. Use a 5mm hex wrench to remove the two cap screws and the chuck locks (

Figure 6

).

4

. Insert the chuck keys as shown in

Figure 7

, hold the spindle, and loosen the chuck.

Note:

The chuck loosens in the counterclockwise direction.

5

. Support the chuck from falling off of the spindle; unscrew and remove the chuck.

6

. Clean, inspect, deburr, and lightly oil all threads and mating surfaces (

Figure 8

).

7

. Install the faceplate or the other chuck in the reverse order of the previous steps.

Spindle Lock Hole Cap Screw Chuck Lock

Figure 6.

Cap screw, chuck lock and lock hole.

Figure 7.

Inserting chuck keys to loosen or tighten the chuck onto the spindle.

Clean, de-burr, and oil threads and all mating surfaces shown.

Figure 8.

Spindle.

-16-

Model M1099 (Mfg Since 8/07)

Replacing Jaws

The three-jaw scroll chuck has removable hardened steel jaws (

Figure 9

). The outside of the jaws are used to hold the workpiece from the outer diameter. Numbered from 1–3, the jaws must be used in the match ing numbered jaw guides (see

Figure 10

).

Note:

The chuck need not be removed from the spindle to swap the jaws.

To remove a set of jaws, do these steps: 1.

DISCONNECT POWER TO THE LATHE!

2

. Place a piece of wood over the ways to protect them from potential damage.

3

. Turn the chuck key counterclockwise and back the jaws out.

4

. Clean the jaw mating surfaces and apply a film of white lithium grease to the mating surfaces.

5

. Set the old jaws aside in a safe place free of mois ture and abrasives.

6.

Rotate the chuck key clockwise until you see the tip of the scroll-gear lead thread just begin to enter jaw guide #1 (see

Figure 11

).

7.

Insert jaw #1 into jaw guide #1 and hold the jaw against the scroll-gear.

8.

Rotate the chuck key clockwise one turn to engage the tip of the scroll-gear lead thread into the jaw. To verify the jaw is engaged with the lead thread, pull the jaw; it should be locked into the jaw guide.

9

. Install the other jaws in the same manner. —If installed correctly, the three jaws will converge together at the center of the chuck.

—If the jaws do not come together, repeat this procedure until they do.

Figure 9.

Chuck and jaw selection.

Jaw Guide #1 Jaw Numbers

Figure 10.

Jaw guide number.

Lead Thread

Figure 11.

Lead thread on scroll gear.

-17-

Model M1099 (Mfg Since 8/07)

Four-Jaw Chuck

To install the four-jaw chuck, do these steps:

Refer to the

Mounting Chuck or Faceplate

procedures on

Page 16

to mount the four-jaw chuck.

To hold a workpiece in the four-jaw chuck, do these steps: 1.

DISCONNECT POWER TO THE LATHE!

2.

Using the chuck key, open each jaw so the workpiece will lay flat against the chuck face.

3.

Support the workpiece.

4.

Lock the tailstock, then turn the tailstock quill so the dead center makes contact or is close to the center point of your workpiece (see

Figure 12

).

5.

Turn each jaw until it just makes contact with the workpiece.

6.

In an opposite pattern, tighten each jaw in small increments. After you have adjusted the first jaw, continue tightening the opposing jaw. Frequently check the dead center alignment to make sure you have not wandered off your index point due to applying too much pressure to a single jaw.

7.

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.

8.

Make fine adjustments by slightly loosening one jaw and tightening the opposing jaw until the workpiece is precisely aligned. Use a dial indicator to fine tune adjustments into alignment (see

Figure 13

).

Use a low RPM when machining heavy eccentric workpieces; Objects thrown from a lathe can cause seri ous injury or death.

Figure 12.

Rough centering procedure with a typical 4-jaw chuck, using the dead center and the tailstock.

Figure 13.

Exact centering procedure with a typical 4-jaw chuck using a dial indicator.

-18-

Model M1099 (Mfg Since 8/07)

Faceplate

The faceplate can be used to turn non-cylindrical parts or for off-center turning by clamping the workpiece to the faceplate.

Refer to the

Mounting Chuck or Faceplate

procedures on

Page 16

to mount the faceplate.

To load a workpiece onto the faceplate: 1.

DISCONNECT POWER TO THE LATHE!

2

. Support the workpiece.

3.

Slide the tailstock to the workpiece.

4.

Lock the tailstock, then turn the tailstock quill so the dead center makes contact with the center point of your workpiece.

5.

Lock the tailstock quill when sufficient pressure is applied to hold the workpiece in place.

Note:

Depending on the workpiece, some additional support may be needed.

6.

Secure the workpiece with a minimum of three inde pendent clamping devices. 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 face plate.

Make sure your clamping application will not fail!

7.

Use a lower RPM when machining heavy eccentric workpieces.

Use a low RPM when machining heavy eccentric workpieces; Objects thrown from a lathe can cause seri ous injury or death.

Figure 14.

Faceplate installed.

Use a minimum of three indepen dent clamping devices when turning eccentric workpieces. Failure to pro vide adequate clamping will cause workpiece to eject.

-19-

Model M1099 (Mfg Since 8/07)

Tailstock

The tailstock (

Figure 15

) can be used to support workpieces with a live or dead center. The lathe can drill or bore holes in the center of a part with a drill bit held by the tailstock. The tailstock can also be offset for cut ting shallow tapers.

To use the tailstock, do these steps: 1.

Slide the tailstock to the desired position.

2.

Tighten the tailstock lock nut to lock the tailstock in place on the ways.

3.

Loosen the quill lock lever to unlock the quill.

4.

Turn the quill feed handwheel clockwise to move the quill towards the spindle or counterclockwise to move away from the spindle.

5.

Tighten the quill lock lever to lock the quill in place.

Quill Lock Lever Offset Scale Tailstock Lock Nut Offset Adjustment

Figure 15.

Tailstock and quill lock handles in locked position.

Drilling With the Tailstock

To setup the tailstock for drilling, do these steps: 1.

With the tailstock locknut tight, unlock the quill lock lever.

2.

Turn the quill feed handwheel clockwise to extend the quill about one inch.

3.

Insert the MT#3 arbor and chuck or an MT#3 tapered drill shank into the quill until the taper is firmly seated.

4.

Turn the quill feed handwheel clockwise to feed the drill bit into the rotating workpiece.

5.

To remove the chuck and arbor, turn the quill feed handle counterclockwise until the chuck is pushed out of the tailstock taper.

-20-

Model M1099 (Mfg Since 8/07)

Cutting Shallow Tapers with Tailstock

To setup the tailstock to cut tapers, do these steps: 1.

Loosen the tailstock lock nut.

2.

Using a 4mm hex wrench, alternately loosen and tighten the left and right offset adjustment set screws until the desired offset is indicated on the scale (see

Figure 16

).

3.

Tighten the tailstock lock nut.

Note:

To return the tailstock back to the original position, repeat the process until the centered posi tion is indicated on the scale.

Quill Lock Lever Offset Scale Tailstock Lock Nut Offset Adjustment

Figure 16.

Left offset adjustment.

-21-

Model M1099 (Mfg Since 8/07)

Aligning Tailstock

The tailstock is factory aligned with the headstock. We recommend that you take the time to ensure that the tailstock is aligned to your own desired tolerances.

To align the tailstock, do these steps: 1.

Using a precision level on the bedways, make sure the bedways are level side-to-side and front-to-back. If the lathe is not level, correct this condition by shimming the lathe base before proceeding.

2.

Get two pieces of steel round stock that are two inches in diameter and six inches long.

3.

Center drill both ends of one piece of the round stock. Set the round stock aside for use in

Step 6.

4.

Using the other piece of stock, make a dead cen ter by turning a shoulder to make a shank. Flip the piece over in the chuck and turn a 60º point (see

Figure 17

)

.

Note:

As long as the dead center remains in the chuck, the point of your center will remain true to the spindle axis. Keep in mind that the point will have to be refinished whenever it is removed and returned to the chuck.

5.

Place the live center in the tailstock.

6.

Attach a lathe dog to the round stock and mount it between centers

.

7.

Turn approximately 0.010" off the diameter.

8.

Mount a dial indicator so the dial plunger is on the tailstock barrel before moving the tailstock.

9.

Measure the stock diameter with a micrometer.

Figure 17.

Figure 18.

Tailstock adjustment option #1.

Figure 19.

Tailstock Lock Nut Chuck centering the dead center.

Tailstock adjustment option #2.

Offset Scale — If it is thicker at the tailstock end, move the tailstock toward you half of the diameter (

Figures 18 & 20

). — If it is thinner at the tailstock end, move the tailstock away from you half the distance of the diameter (

Figure 19 & 20

).

10.

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.

-22-

Figure 20 .

Left Offset Set Screw Left offset adjustment.

Model M1099 (Mfg Since 8/07)

Centers

A dead center can be used in the tailstock and lathe spindle to support workpieces. When used in this man ner, make sure to keep the dead center tip and workpiece lubricated to prevent tip galling.

To install a dead or live center, do these steps: 1.

Feed the quill out about 1" and insert the dead cen ter (

Figure 21

). The mating tapers provide the lock ing fit.

2.

Move the tailstock into position and lock in place.

Note:

Make sure there is a center drilled hole in the end of the workpiece for the dead center.

3.

Feed the quill into the workpiece.

4.

Lock the quill into place once the dead center and the workpiece rotate together. The quill may need to be adjusted during operation.

5.

To remove the dead center, retract the quill until the dead center pops free.

To install an MT#4 dead center in the spindle, do these steps: 1.

DISCONNECT POWER TO THE LATHE!

2.

Remove the chuck from the spindle.

3.

Install the MT#4 dead center in the spindle.

4.

Attach the faceplate to the spindle, see

Figure 22

. Refer to

Mounting Chuck and Faceplate

on

Page 16

for details if required.

Note:

When using the dead center in the spindle, use a lathe dog so that your part will rotate with the faceplate and not spin on the dead center tip.

Failure to keep dead center point well lubricated will gall the dead center and workpiece.

Figure 21.

Inserted dead center.

Figure 22.

Faceplate and dead center setup.

-23-

Model M1099 (Mfg Since 8/07)

Steady Rest

The steady rest serves as a support for long shafts. The steady rest can should be placed along the ways where the most support can be given to the workpiece and still allow for all of your intended lathe operations.

To use the steady rest, do these steps: 1.

Carefully place the steady rest on the lathe bedways.

2.

Loosen the finger lock nuts so the finger position can be adjusted (see

Figure 23

).

3.

Loosen the steady rest lock nut (see

Figure 23

), and position the steady rest where desired.

4.

Tighten the steady rest lock nut.

5.

Clamp the workpiece into the chuck and position the tailstock to support the workpiece.

6.

Turn the adjustment knobs so the fingers are snug against the workpiece, and then tighten the finger lock nuts.

7.

Lubricate the finger tips with an anti-seize lubricant during operation.

8.

After prolonged use, the fingers will show wear. Either mill or file the tips for a new contact surface.

Follow Rest

The follow rest in

Figure 24

is mounted on the front of the carriage directly above the ways and follows the movement of the tool. 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. After prolonged use, the fingers will need to be milled or filed to clean up the contact surface.

Finger Lock Nut Steady Rest Lock Nut

Figure 23.

Steady rest.

Adjustment Knob Finger Lock Nut Adjustment Knob Finger Carriage Cap Screw Finger

Figure 24.

Follow rest.

-24-

Model M1099 (Mfg Since 8/07)

Compound Rest

The compound rest 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.

To set the angular position, do these steps: 1.

Loosen the hex nuts on each side of the compound rest (see

Figure 25

).

2.

While watching the scale, rotate the compound rest to the desired angular position.

3.

Tighten the two hex nuts. Be sure to not overtight en, as you may strip threads or crack or distort the base casting.

Hex Nut Scale

Figure 25.

Compound rest, scale, and hex nuts.

Tool Post

The four-way tool post (

Figure 26

) is mounted on top of the compound rest and allows a maximum of four 3 ⁄ 8 " x 3 ⁄ 8 " tools to be loaded simultaneously.

The four-way tool post allows for quick indexing to new tools. This is accomplished by loosening the top handle, then rotating the tool post to the desired position. Tighten the top handle to lock the tool into position.

Top Handle

Figure 26.

Four-way tool post and top handle.

-25-

Model M1099 (Mfg Since 8/07)

Manual Feed Handwheels

You can manually move the cutting tool around the workpiece using the three handwheels shown in

Figure 27

.

Compound Rest Handwheel

The compound rest handwheel controls the position of the cutting tool relative to the workpiece. The graduated dial on the handwheel indicates the depth of compound rest movement. The angle adjustment is held by two hex nuts on the base of the compound rest.

Cross Slide Handwheel

The cross slide handwheel moves the top slide toward and away from the workpiece. Turning the handwheel clock wise moves the slide toward the workpiece. The gradu ated dial on the handwheel indicates the depth of cross slide movement.

Carriage Handwheel

The carriage 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.

Compound Rest Handwheel Cross Slide Handwheel Carriage Handwheel

Figure 27.

Manual handwheel controls.

-26-

Model M1099 (Mfg Since 8/07)

Determining Correct Spindle RPM

To determine the correct spindle RPM, do these steps: 1.

Use the table in

Figure 28

to determine the cutting speed required for the material of your workpiece.

2.

Measure the diameter of your workpiece in inches and subtract the depth of the cut that will be taken on the initial pass.

3.

Use the formula in

Figure 29

to determine the needed RPM for your operation.

Note:

Always round to the closest RPM given on the spindle speed chart, and adjust your speed as the workpiece diameter decreases.

Example 1

You have a piece of 1 ⁄ 2 " diameter aluminum stock, and you are using workpiece with a HSS cutting tool.

Step 1:

300 (SFM from chart) x 4 = 1200

Step 2:

1200 / 0.5" (Diameter of workpiece) = 2400 RPM

Result:

The needed speed for this workpiece is 2400 RPM.

Example 2

You have a piece of 1" diameter stainless steel stock, and you are using a workpiece with a carbide cutting tool.

Step 1:

60 (SFM from chart) x 2 (for carbide tool) = 120

Step 2:

120 (determined SFM) x 4 = 480

Step 3:

480 / 1" (Diameter of workpiece) = 480 RPM

Result:

The needed speed for this workpiece is 480 RPM.

Failure to follow RPM and feed rate guidelines may threaten operator safe ty from ejected parts or broken tools. Cutting Speeds for High Speed Steel (HSS) Cutting Tools

Workpiece Material Cutting Speed (sfm) Aluminum & alloys 300 Brass & Bronze 150 Copper Cast Iron, soft Cast Iron, hard Mild Steel Cast Steel Alloy Steel, hard Tool Steel Stainless Steel Titanium Plastics 100 80 50 90 80 40 50 60 50 300-800 Wood 300-500

Note:

For carbide cutting tools, double the cutting speed. These values are a guideline only.

Refer to the

MACHIN ERY'S HANDBOOK

for more detailed information.

Figure 28.

Cutting speed table for HSS cutting tools.

(SFM) x 4 Workpiece Diameter = RPM Figure 29.

Formula to determine required spindle speed for lathes.

-27-

Model M1099 (Mfg Since 8/07)

Spindle RPM

This lathe has six possible spindle speeds. Shown in

Figure 30

is an example of how you would use the chart to get a spindle RPM of 150.

To set the spindle RPM, do these steps: 1.

DISCONNECT THE LATHE FROM POWER!

2.

Refer to the RPM chart in ticular spindle RPM.

Figure 30

and determine which pulley combination you will need to get a par-

3.

Open the side cover and install the low range belt between pulleys

B

and

C

and in sheave

1

as shown in

Figure 30

.

Note:

The low range belt is always used on pulleys

B

and

C

with the tensioner. This belt is 27.5" long. The high range belt is always used on pulleys

A

and

C

without using the tensioner. This belt is 33" long.

4.

Close the side cover and secure it shut with the cap screw. The lathe is now ready to use at 150 RPM.

Use a low RPM when machining heavy eccentric workpieces; Objects thrown from a lathe can cause seri ous injury or death.

Use a minimum of three indepen dent clamping devices when turning eccentric workpieces on the faceplate. Failure to provide adequate clamping will cause workpiece to eject.

RPM Chart

B C

Tensioner

= 150 RPM A Figure 30.

Pulley combination (BC1) achieves 150 RPM at the spindle.

-28-

Model M1099 (Mfg Since 8/07)

Power Feed Rate

Use these steps to learn how to setup your lathe for a power feed operation. The example in reversed.

Figure 32

shows lathe setup for a power feed rate of 0.012". Remember, the carriage direction is reversed when spindle rotation is

To set and engage the power feed, do these steps: 1.

DISCONNECT LATHE FROM POWER!

2.

Turn the feed dials to the numeral and letter indi cated by the chart in

Figure 32

.

3.

Using the chart in

Figure 32

, gather the required change gears.

4.

Open the side cover and use a 6mm hex wrench to loosen the lash adjuster (

Figure 32

) and swing the change gear assembly out of the way.

5.

Remove the spindle E-clips and cap screw, lubricate, and swap out the change gears in the order shown on the chart in

Figure 32.

6.

Move the lash adjuster so the gear backlash is between 0.003" to 0.008", tighten the lash adjuster cap screw, and close the side cover.

7.

Using a 5mm hex wrench, loosen the carriage lock (

Figure 31

), and use the half nut lever to engage and disengage the power feed when required.

Feed rate is based on spindle RPM. Pay close attention to the feed rate you have chosen and be ready to disengage the carriage. Failure to do this may cause the carriage to crash into the chuck.

Carriage Lock Cap Screw Half Nut Lever

Figure 31.

Carriage lock and feed control.

40 27 60

Change Gears

56 127

Feed Chart

104 = 0.012" Feed

Lash Adjuster

Figure 32.

Power feed setup.

-29 Feed Dials

Model M1099 (Mfg Since 8/07)

Inch Threads

Use these steps to learn how to setup your lathe for inch threading. The example in

Figure 34

shows lathe setup for cutting 64 TPI (Teeth Per/Inch) thread.

To setup for inch threading, do these steps: 1.

DISCONNECT THE LATHE FROM POWER!

2.

Turn the feed dials to the numeral and letter indi cated by the chart in

Figure 34

.

3.

Using the chart in

Figure 34

, gather the required change gears.

4.

Open the side cover and use a 6mm hex wrench to loosen the lash adjuster (

Figure 32

) and swing the change gear assembly out of the way.

5.

Remove the spindle E-clips and cap screw, lubricate, and swap out the change gears in the order shown on the chart in

Figure 32.

6.

Move the lash adjuster so the gear backlash is between 0.003" to 0.008", tighten the lash adjuster cap screw, and close the side cover.

7.

Using a 5mm hex wrench, make sure the carriage lock is loose (

Figure 31

).

During threading keep your hand on the half-nut lever ready to disengage the half nut to avoid potential carriage/ chuck crash.

Figure 33.

Thread dial chart and thread dial.

8.

The lathe is now setup for threading.

Note:

For faster threading and manual carriage return, based on which TPI being cut, refer to the

Indicator Table

in

Figure 33

to know if you can use the thread dial scale to show when to re-enter the thread manually after dis engaging the half nut lever.

a

Inch Thread Chart

b Figure 34.

Inch threading setup.

= 64 TPI

-30-

Model M1099 (Mfg Since 8/07)

Metric Threads

Use these steps to learn how to setup your lathe for metric threading. The example in

Figure 35

shows lathe setup for cutting a metric thread pitch of 0.45mm.

To setup for metric threading, do these steps: 1.

DISCONNECT THE LATHE FROM POWER!

2.

Turn the feed dials to the numeral and letter indi cated by the chart in

Figure 35

.

Note:

You may have to rock the chuck by hand slightly to get the gearbox gears to engage one another.

3.

Using the chart in

Figure 34

, gather the required change gears.

4.

Open the side cover and use a 6mm hex wrench to loosen the lash adjuster (

Figure 32

) and swing the change gear assembly out of the way.

5.

Remove the spindle E-clips and cap screw, lubricate, and swap out the change gears in the order shown on the chart in

Figure 32.

Note:

All change gears are stamped with the num ber of teeth they have.

6.

Move the lash adjuster so the gear backlash is between 0.003" to 0.008", tighten the lash adjuster cap screw, and close the side cover.

7.

Using a 5mm hex wrench, make sure the carriage lock is loose (

Figure 31

).

8.

The lathe is now setup for threading.

During threading keep your hand on the half-nut lever ready to disengage the half nut to avoid potential carriage/ chuck crash.

Note:

Since this lathe has an inch lead screw, do not use the thread dial when cut ting metric threads. Instead you must leave the half nut engaged until the threading operation is totally complete.

Metric Thread Chart

a b = 0.45mm

Figure 35.

Metric threading setup.

-31-

Model M1099 (Mfg Since 8/07)

• • • •

MAINTENANCE

Basic Maintenance

Regular periodic maintenance of your lathe will ensure optimum performance. Make a habit of inspecting your machine each time you use it. Gearbox Oil Fill

Check for the following conditions and repair or replace when necessary:

Loose mounting bolts and chuck.

Worn switch or safety features.

Worn or damaged cords or plug.

Any other condition that could hamper the safe operation of this machine.

Gearbox Oil Level Sight Glass

Figure 36.

Headstock oil level sight glass.

General Lubrication

Make sure to unplug the lathe before lubrication and cleaning.

Keep the gearbox oil level at 3 ⁄ 4 full as shown by the sight glass (

Figure 36

). After break-in, change the oil in the gearbox with Mobil ® DTE ® Heavy-Medium or an equivalent grade of oil, then again after three months. After that, change the oil at the same time on an annual basis or more frequently if extreme machine use requires it. For daily lubrication, use a manual oil gun with a general 10W machine oil to lubricate the 11 ball oilers. Refer to

Figures 37

-

40

for ball oiler locations. Make sure you wipe off the fittings before you oil them.

To control surface rust on machined surfaces, wipe the unprotected metal as required with a rust inhibiting oil. Never blow the lathe off with compressed air, otherwise you will force metal shavings deep into mechanisms. Use a shop vacuum instead. Never use acetone, gasoline, or lacquer thinner to remove stains or oil from painted sur faces. These chemicals will melt the paint. Use mineral spirits or mild household degreasers.

Spindle Oil Balls Headstock

Figure 37.

Spindle ball oilers in headstock.

Ball Oiler Gearbox Drain

Figure 38.

Change gear ball oilers and gearbox drain.

-32-

Model M1099 (Mfg Since 8/07)

Figure 39.

Apron and carriage ball oilers.

Figure 40.

Leadscrew and tailstock ball oilers.

-33-

Model M1099 (Mfg Since 8/07)

Belt Adjustment or Replacement

ENTANGLEMENT HAZARD!

Disconnect this lathe from power and wait until all spinning parts have come to a complete stop before you access the belt and pulleys. Otherwise you may be severely injured!

To replace or adjust the V-belts, do these steps: 1.

DISCONNECT POWER TO THE LATHE!

2.

Open the side access door to expose the belt, pul leys, and change gears. — If the high range belt (

Figure 41

) needs to be replaced, carefully roll the belt off of pulleys

A

and

C

and reinstall the new one.

— If the low range belt (

Figure 42

) needs to be replaced, use the 17mm wrench to loosen the tensioner pulley arm that holds the pulley and replace the belt on pulleys

B

and

C.

Hold the ten sioner pulley against the new belt so the belt is tight, and tighten the tensioner pulley in place.

A C Figure 41.

High-range belt position (A-C).

B C

Tensioner Pulley

Figure 42.

Low-range belt position (B-C).

-34-

Model M1099 (Mfg Since 8/07)

SERVICE

Troubleshooting

This section covers the most common problems and corrections with this type of machine.

WARNING! DO NOT make any adjustments until power is disconnected and moving parts have come to a complete stop!

Motor & Gearbox

SYMPTOM

Motor will not start.

POSSIBLE CAUSE

1. Main power panel switch is

OFF

.

2. Emergency switch is pushed in.

3. Circuit breaker or fuse has tripped.

Fuses or circuit breakers trip open.

4. No voltage or open connection.

5. Capacitor is at fault.

6. Motor direction switch is at fault.

7. Power switch or magnetic contactor is at fault.

8. Motor is at fault.

1. Short circuit in line cord or plug.

2. Short circuit in motor or loose connections.

Machine is loud, belt slips when cutting. Overheats or bogs down in the cut.

3. Incorrect fuses or circuit breakers in power supply.

1. Excessive depth of cut.

2. RPM or feed rate wrong for operation.

3. Dull cutters.

4. Belt is slipping.

5. Belt is at fault.

CORRECTIVE ACTION

1. Turn the main power panel switch shop power supply.

required.

5. Replace capacitor.

6. Replace switch.

ON

.

2. Rotate emergency switch so it pops out.

3. Seek an electrician to troubleshoot and repair the 4. Test circuit, replace wires and connections as 7. Replace power switch or magnetic contactor.

8. Replace motor.

1. Inspect cord or plug for damaged insulation and shorted wires.

2. Inspect all connections on motor for loose or shorted terminals or worn insulation.

3. Install correct fuses or circuit breakers.

1. Decrease depth of cut.

2. Refer to RPM feed rate chart for appropriate rates.

3. Sharpen or replace cutters.

4. Remove grease or oil on belt or pulleys/tighten belt tensioner against low range belt.

5. Replace belt.

1. Rotate spindle by hand until gear falls into place.

Gear change levers will not shift into posi tion.

Loud, repetitious noise. Motor is loud when cutting. Overheats or bogs down in the cut.

1. Gears not aligned in headstock.

1. Pulley set screws or keys are missing or loose.

2. Motor fan is hitting the cover.

1. Excessive depth of cut or feed rate.

2. RPM or feed rate wrong for cutting operation.

3. Cutting tool is dull.

1. Inspect keys and set screws. Replace or tighten if necessary.

2. Replace fan and cover.

1. Decrease depth of cut or feed rate.

2. Refer to RPM feed rate chart for appropriate rates.

3. Sharpen or replace the cutting tool.

1. Rotate spindle by hand until gear falls into place.

Levers will not shift.

1. Gears not aligned in headstock.

-35-

Model M1099 (Mfg Since 8/07)

Operation and Work Results Troubleshooting

SYMPTOM

Lathe vibrates excessively.

Cutting tool vibrates exces sively during cut ting.

Can't remove tool from tailstock.

Cross slide, com pound rest, or carriage feed has lash.

Cross slide, com pound rest, or carriage feed handwheel is hard to move.

1. Gibs are out of adjustment.

2. Handwheel is loose.

3. Lead screw mechanism worn or out of adjustment.

1. Gibs are loaded up with shavings or grime.

2. Gib screws are too tight.

3. Backlash setting too tight (cross slide only).

Bad surface fin ish.

POSSIBLE CAUSE

1. Workpiece is unbalanced.

2. Worn or broken gear present.

3. Chuck or faceplate has become unbalanced.

4. Spindle bearings at fault.

1. Tool holder not tight enough.

2. Cutting tool sticks too far out of tool holder; lack of support.

3. Gibs are out of adjustment.

4. Dull cutting tool.

5. Incorrect spindle speed or feed rate.

1. Quill had not retracted all the way back into the tailstock.

CORRECTIVE ACTION

1. Reinstall workpiece so it is centered.

2. Inspect gears and replace if necessary.

3. Rebalance chuck or faceplate; contact a local machine shop for help.

4. Tighten or replace spindle bearings.

1. Check for debris, clean, and retighten.

2. Reinstall cutting tool so no more than 1/3 of the total length is sticking out of tool holder.

3. Tighten gib screws at affected component.

4. Replace or re-sharpen cutting tool.

5. Use the recommended spindle speed.

1. Turn the quill handwheel until it forces taper out of quill.

4. Bedways are dry.

1. Wrong RPM or feed rate.

2. Dull tooling or poor tool selection.

Inaccurate turn ing results from one end of the workpiece to the other.

Carriage won't feed, or is hard to move.

3. Too much play in gibs.

4. Tool too high.

1. Headstock and tailstock are not properly aligned with each other.

1. Gears are not all engaged or broken.

2. Gibs are too tight.

3. Loose screw on the feed handle. 4. Lead screw shear pin has sheared.

1. Tighten gib screw(s).

2. Tighten handwheel fasteners.

3. Tighten any loose fasteners on lead screw mecha nism.

1. Remove gibs, clean ways/dovetails, lubricate, and readjust gibs.

2. Loosen gib screw(s) slightly, and lubricate bedways.

3. Slightly loosen backlash setting by loosening the locking screw and adjusting the spanner ring at the end of the handle.

4. Lubricate bedways and handles.

1. Adjust RPM and feed rate.

2. Sharpen tooling or select a better tool for the intended operation.

3. Tighten gibs.

4. Lower the tool position.

1. Realign the tailstock to the headstock spindle bore center line.

1. Adjust gear positions or replace.

2. Loosen gib screw(s) slightly.

3. Tighten.

4. Correct for cause of shear pin breakage, and replace shear pin.

-36-

Model M1099 (Mfg Since 8/07)

Cross Slide Backlash Adjustment

Backlash is the amount of play found in a lead screw. It can be found by turning the cross slide handwheel in one direction, then turning the handwheel the other direction. When the cross slide begins to move, the backlash has been taken up.

Note:

Avoid the temptation to overtighten the cross slide backlash screw. Overtightening will cause excessive wear to the sliding block and lead screw.

Backlash is adjusted by tightening or loosening the screw shown in

Figure 43

. This screw draws a wedge-type nut against the lead screw and main nut. If it is too tight, loosen the screw a few turns and tap the cross slide a few times with a rub ber or wooden mallet. Then turn the handle slowly back and forth until the handle turns freely. To readjust the backlash, rock the handle back and forth and tighten the screw slowly until the backlash is at between 0.001" to 0.002" as indicated on the handwheel.

Note:

Reducing backlash to less than 0.001" is impractical and reduces the life of the cross slide.

1 of 3 Cross Slide Gib Adjustment Points Cross Slide Backlash Adjustment Cap Screw

Figure 43.

Cross slide adjustment.

3 Compound Rest Gib Adjustment Points

Figure 44.

Gib adjustment points.

Gib Adjustments

When adjusting gibs (

Figures 44 and 45

), the goal is to remove sloppiness in the ways without causing the slides or half nut to bind. Loose gibs will cause a poor finish on the workpiece and wear the slide. Tight gibs will damage the slide, lead screw, and half-nut. The cross slide gib is a tapered piece of iron. When the opposing front and rear gib adjustment screws are turned in opposing directions, the screws force the tapered gibs to fill the void in the way, thus tightening the play in the cross slide. If more play is needed turn the screws the other direction.

For the three saddle gibs ( ished.

Figure 44

), loosen the jam nuts and turn the three set screws until slight tension is felt and the gib plates are slightly pre-loaded against the underside of the flat-way. Tighten the jam nuts when fin Half Nut Gib Adjustments Points (Thread Dial Removed) 3 Saddle Gib Adjustment Points -37-

Figure 45.

Half-nut saddle gib locations.

Model M1099 (Mfg Since 8/07)

Electrical Component Connections

Figure 46.

Motor rotary switch and ON power switch (SA and SB1).

Figure 48.

Motor rotary switch and emergency stop switch (SA and SB2).

Figure 47.

External motor capacitors.

Figure 49.

Motor start contactor.

-38-

Model M1099 (Mfg Since 8/07)

Figure 51.

Motor connection detail.

Figure 50.

Motor data plate.

Wiring Diagram

LEGEND KM: Magnetic Contactor 110V SB1: ON Push Button Switch SB2: Emergency Stop Push Button Switch M: Motor 110V C1: Capacitor C2: Capacitor SA: Motor Direction Rotary Switch

-39-

11

Model M1099 (Mfg Since 8/07)

PARTS

Spindle and Drive Belt

1 2 5 6 7 8 10 12 13 14 15 27 28 26 29 30 16 40 41 25 17 19 20 42 31 43 32 22 21 33 34 23 24 35 49 51 52 53 44 45 46 36 37 38 39 18 47 48 -40-

Model M1099 (Mfg Since 8/07)

Spindle and Drive Belt Parts

REF PART
#

1 2 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

DESCRIPTION

XM1099001 CONTROL
PANEL
FACE XPS17M XPSB06M XPW03M PHLP
HD
SCR
M4-.7
X
6 CAP
SCREW
M6-1
X
25 FLAT
WASHER
6MM XM1099007 COMPRESSION
SPRING XM1099008 CLAMP XPSB06M CAP
SCREW
M6-1
X
25 XM1099011 SPINDLE XPK123M KEY
10
X
10
X
55 XM1099013 SPACER XM1099014 BALL
BEARING
(45
X
75
X
20) XM1099015 HEADSTOCK XPSB14M CAP
SCREW
M8-1.25
X
20 XM1099014 BALL
BEARING
(45
X
75
X
20) XPSB02M CAP
SCREW
M6-1
X
20 XM1099019 SPACER XM1099020 GEAR XPVM27A V-BELT
M-27.5
3L275 XM1099022 PULLEY XPVM33 V-BELT
M-33
3L330 XM1099024 SPANNER
NUT
M30
X
1.5

XM1099025 BRACKET
PLATE XPLW06M LOCK
WASHER
10MM XPN02M HEX
NUT
M10-1.5

XPW04M FLAT
WASHER
10MM

REF PART
#

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 51 52 53

DESCRIPTION

XPSB50M CAP
SCREW
M5-.8
X
10 XPW02M FLAT
WASHER
5MM XM1099031 SPINDLE
SHAFT XM1099032 COGGED
BELT
263L XP6001 BALL
BEARING
6001 XM1099034 COGGED
PULLEY XPR03M EXT
RETAINING
RING
12MM XM1099036 SPACER XM1099037 COGGED
PULLEY XPK11M KEY
6
X
6
X
40 XM1099039 SPACER XM1099040 STUD XM1099041 PLATE XPW04M XPN02M FLAT
WASHER
10MM HEX
NUT
M10-1.5

XM1099044 SPINDLE
SHAFT XM1099045 BALL
BEARING
(12
X
28
X
8) XM1099046 ROLLER XPR20M XPR03M INT
RETAINING
RING
28MM EXT
RETAINING
RING
12MM XM1099049 COVER XPN06M HEX
NUT
M5-.8

XM1099052 COVER XPS08M PHLP
HD
SCR
M5-.8
X
12 -41-

115 116 117 125 126 127 128 129 118 119 120 121 122 123 124 130 131

Model M1099 (Mfg Since 8/07)

114

Apron

113 112 111 110 109 108 107 106 105 104 132 133 134 136 135 137 138 139 140 141 142 103 102 101 -42-

Model M1099 (Mfg Since 8/07)

REF PART
# DESCRIPTION

101 XPRP19M ROLL
PIN
4
X
14 102 XM1099102 HALF
NUT 103 XPRP59M ROLL
PIN
5
X
12 104 XM1099104 GEAR
SHAFT 105 XM1099105 GEAR 106 XPRP73M ROLL
PIN
4
X
30 107 XM1099107 APRON
CASTING 108 XPSB23M CAP
SCREW
M4-.7
X
12 109 XM1099109 GIB 110 XPRP76M 111 XPSS34M 112 XPSS12M ROLL
PIN
4
X
16 SET
SCREW
M5-.8
X
16 SET
SCREW
M6-1
X
25 113 XPN06M 114 XPSS04M HEX
NUT
M5-.8

SET
SCREW
M6-1
X
12 115 XM1099115 LEVER
HUB 116 XM1099116 LEVER 117 XM1099117 LEVER
HANDLE 118 XM1099118 STEEL
BALL 119 XPSB85M CAP
SCREW
M6-1
X
6 120 XM1099120 DIAL 121 XM1099121 RIVET
2
X
5

Apron Parts

REF PART
# DESCRIPTION

122 XM1099122 POINTER 123 XM1099123 SHAFT 124 XPK39M KEY
3
X
3
X
10 125 XPSB83M CAP
SCREW
M6-1
X
55 126 XM1099126 THREAD
DIAL
BODY 127 XM1099127 SIDE
GEAR 128 XPW01M FLAT
WASHER
8MM 129 XPN03M 130 XPSS02M HEX
NUT
M8-1.25

SET
SCREW
M6-1
X
6 131 XM1099131 COMPRESSION
SPRING 132 XM1099132 HANDLE 133 XM1099133 HANDWHEEL 134 XPRP04M ROLL
PIN
4
X
24 135 XM1099135 POINTED
SET
SCR
M6-1
X
12 136 XM1099136 GEAR
SHAFT 137 XPFH43M 138 XPW03M FLAT
HD
SCR
M6-1
X
10 FLAT
WASHER
6MM 139 XM1099139 INDICATOR
PLATE 140 XM1099140 SHAFT 141 XM1099141 THREADED
DIAL
PLATE 142 XM1099142 LOCKING
CAM -43-

REF

210 211 212 213 214 215 216 201 202 203 204 205 206 207 208 209

PART
#

XM1099201 XM1099202 XM1099203 XM1099204 XM1099205 XM1099206 XM1099207 XM1099208 XPW01M XM1099210 XM1099211 XM1099212 XPSB31M XPSB26M XPSS34M XPN06M 222 207 211 201 210 215 216

Tool Holder and Compound Rest

218 219 212 221 220 208 208 203 206 202 217A 217A-1 209 204 228 224 229 226 227 205 214 223

Model M1099 (Mfg Since 8/07)

213 225 230 231

DESCRIPTION

COMPOUND
REST SWIVEL
BASE GIB CLAMPING
RING GRADUATED
DIAL BARREL
NUT DOWEL
PIN TOOL
POST
STUD FLAT
WASHER
8MM DOWEL
PIN COMPRESSION
SPRING BULLNOSE
CAP
SCR
M8-1.25
X
30 CAP
SCREW
M8-1.25
X
25 CAP
SCREW
M6-1
X
12 SET
SCREW
M5-.8
X
16 HEX
NUT
M5-.8

-44-

REF PART
#

225 226 227 228 229 230 231 217A XPSS19M 217A-1 XPN03M 218 219 XM1099218 XM1099219 220 221 222 223 224 XM1099220 XM1099221 XM1099222 XM1099223 XM1099224 XM1099225 XM1099226 XM1099227 XPK03M XM1099229 XM1099230 XPSS17M

DESCRIPTION

SET
SCREW
M8-1.25
X
30 HEX
NUT
M8-1.25

HANDLE HANDLE
HUB TOOL
REST RUB
SPACER SLIDE
PLATE LEAD
SCREW LEAD
SCREW
MOUNT GRADUATED
DIAL HANDWHEEL HANDLE KEY
3
X
3
X
8 POINTER THREADED
COLLAR SET
SCREW
M8-1.25
X
6

Model M1099 (Mfg Since 8/07)

Tailstock

301 302 303 312 322 313 324 321 314 323 325 316 306 307 308 320 319 304 317 309 310 305 311 318 319 315 314 326

REF PART
# DESCRIPTION

301 XM1099301 TAILSTOCK
QUILL 302 XM1099302 LEAD
SCREW 303 XM1099303 BUSHING 304 XM1099304 HANDWHEEL
SCALE
PLATE 305 XM1099305 HANDWHEEL 306 XM1099306 LEVER
BOLT
M12-1.75
X
50 307 XM1099307 BARREL
NUT 308 XPSS04M SET
SCREW
M6-1
X
12 309 XM1099309 GRADUATED
DIAL 310 XM1099310 POINTER 311 XM1099311 SPACER 312 XM1099312 TAILSTOCK
BODY 313 XM1099313 TAILSTOCK
BASE

REF PART
# DESCRIPTION

314 XPSS21M SET
SCREW
M8-1.25
X
25 315 XM1099315 HANDLE 316 XM1099316 OFFSET
SCALE
PLATE 317 XM1099317 LEADSCREW
KEY 318 XPLN05M LOCK
NUT
M10-1.5

319 XM1099319 RIVET
2
X
5 320 XM1099320 BALL
OILER 321 XM1099321 CLAMPING
PLATE 322 XPN09M HEX
NUT
M12-1.75

323 XPB158M HEX
BOLT
M12-1.75
X
90 324 XPW06M 325 XPSS26M FLAT
WASHER
12MM SET
SCREW
M5-.8
X
6 326 XM1099326 PLATE -45-

411 410 401 402 403

Bed and Leadscew

414 413 412

Model M1099 (Mfg Since 8/07)

409 415

REF PART
# DESCRIPTION

401 XM1099401 BED 402 XM1099402 RACK 403 XPSB33M CAP
SCREW
M5-.8
X
12 404 XM1099404 LEAD
SCREW 405 XM1099405 BRACKET 406 XM1099406 BALL
OILER 407 XPSB02M 408 XPLN05M CAP
SCREW
M6-1
X
20 LOCK
NUT
M10-1.5

404 407 406 405 408

REF PART
# DESCRIPTION

409 XM1099409 SPLASH
GUARD 410 XM1099410 STUD
M10-1.5
X
35 411 XPN02M HEX
NUT
M10-1.5

412 XPSS44M 413 XPW01M 414 XPN03M SET
SCREW
M8-1.25
X
40 FLAT
WASHER
8MM HEX
NUT
M8-1.25

415 XM1099415 CHIP
PAN -46-

Model M1099 (Mfg Since 8/07)

Steady Rest and Follow Rest

506 503 501 502 504 505 510 509 507 508 513

REF PART
# DESCRIPTION

501 XM1099501 STEADY
REST
CASTING 502 XM1099502 FINGER 503 XM1099503 T-BOLT
M6-1 504 XPLW03M LOCK
WASHER
6MM 505 XPN01M HEX
NUT
M6-1 506 XM1099506 ADJUSTING
SCREW 507 XM1099507 CLAMPING
PLATE 508 XPB125M 509 XPW04M HEX
BOLT
M12-1.75
X
65 FLAT
WASHER
10MM -47-

REF PART
#

510 511 512 513 514 515 516 517 518

DESCRIPTION

XPN02M HEX
NUT
M10-1.5

XM1099511 FOLLOW
REST
CASTING XM1099512 FINGER XM1099503 T-BOLT
M6-1 XM1099514 ADJUSTING
SCREW XPN01M HEX
NUT
M6-1 XPLW03M LOCK
WASHER
6MM XPSB40M XPW01M CAP
SCREW
M8-1.25
X
35 FLAT
WASHER
8MM 514 512 516 511 515 517 518

Motor and Electrical

Model M1099 (Mfg Since 8/07)

611-5 604 610 611-3 611-4 612 611 611-6 617 611-1 611-2 616 615 602 603 601 607 608

REF PART
# DESCRIPTION

601 XM1099601 602 XPSB06M 603 XPLW03M 604 XM1099604 607 XM1099607 608 XM1099608 CABINET CAP
SCREW
M6-1
X
25 LOCK
WASHER
6MM COVER STRAIN
RELIEF
NUT STRAIN
RELIEF 610 XPS09M 611 XM1099611 PHLP
HD
SCR
M5-.8
X
10 REVERSIBLE
MOTOR
110V 611-1 XM1099611-1 FAN

REF PART
# DESCRIPTION

611-2 XM1099611-2 FAN
COVER 611-3 XM1099611-3 START
CAPACITOR
150MFD/125VAC 611-4 XM1099611-4 RUN
CAPACITOR
20MFD/400VAC 611-5 XM1099611-5 CAPACITOR
COVER
W/CAP 611-6 XM1099611-6 POWER
CORD 612 XPLW03M LOCK
WASHER
6MM 615 616 617 XM1099615 XM1099616 XM1099617 STRAIN
RELIEF STRAIN
RELIEF
NUT CONTACTOR
3TB41
22E
110V -48-

Model M1099 (Mfg Since 8/07)

Gearbox Diagram A

701 708 707 706 704 703 702 735 736 737 739 740 741 719 718 714 717 716 715 713 712 711 728 729 730 731 732 733 734 725 724 723 722 721 720 727 726 -49-

Model M1099 (Mfg Since 8/07)

REF PART #

701 XPSS01M 702 XM1099702 703 XM1099703 704 XM1099704 706 XM1099706 707 XM1099707 708 XM1099708 711 XM1099711 712 XM1099712 713 XM1099713 714 XM1099714 715 XM1099715 716 XM1099716 717 XM1099717 718 XM1099707 719 XM1099719 720 XM1099720 721 XPK97M 722 XM1099722

Gearbox Diagram A Parts

DESCRIPTION

SET SCREW M6-1 X 10 BUSHING PLASTIC DRIVE GEAR (60-TOOTH) CAST-IRON GEAR 27T SHAFT KNURELD KEEPER BALL OILER BRACKET T-NUT SPACER WASHER SHAFT BUSHING GEAR 127T GEAR 56T KNURELD KEEPER BALL OILER BUSHING KEY 4 X 4 X 14 SPACING RING

REF PART #

723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 739 740 741 XM1099723 XPW03M XPSB85M XPLW04M XPSB12M XM1099728 XM1099729 XM1099730 XM1099731 XM1099732 XM1099733 XM1099734 XM1099735 XM1099736 XM1099737 XM1099739 XM1099740 XM1099741

DESCRIPTION

GEAR 104T FLAT WASHER 6MM CAP SCREW M6-1 X 6 LOCK WASHER 8MM CAP SCREW M8-1.25 X 40 CHANGE GEAR (36-TOOTH) CHANGE GEAR (36-TOOTH) CHANGE GEAR (40-TOOTH) CHANGE GEAR (44-TOOTH) CHANGE GEAR (46-TOOTH) CHANGE GEAR (48-TOOTH) CHANGE GEAR (52-TOOTH) CHANGE GEAR (45-TOOTH) CHANGE GEAR (56-TOOTH) CHANGE GEAR (60-TOOTH) CHANGE GEAR (104-TOOTH) CHANGE GEAR (120-TOOTH) CHANGE GEAR (127-TOOTH) -50-

Model M1099 (Mfg Since 8/07)

Gearbox Diagram B

854 801 802 803 804 805 806 813 812 805 807 808 802 809 811 814 833 832 826 825 822 823 820 831 822 823 824 830 822 820 819 818 817 815 821 822 829 828 827 816 835 810 834 851 853 852 836 837 839 838 840 841 842 843 844 845 846 847 848 849 850 -51-

Model M1099 (Mfg Since 8/07)

Gearbox Diagram B Parts

REF PART
#

801 802 803 804 805 806 807 808 809 810 811 812 813 814 815 816 817 818 819 820 821 822 823 824 825 826 827

DESCRIPTION

XM1099801 PLUG XM1099802 O-RING XM1099803 BUSHING XM1099804 CLUSTER
GEAR
30-36-33T XPK133M KEY
4
X
4
X
50 XM1099806 SHAFT XM1099807 BUSHING XM1099808 CLUSTER
GEAR
22-44-33T XM1099809 PLUG XPSB50M CAP
SCREW
M5-.8
X
10 XM1099811 COVER XM1099812 PLUG XM1099813 GEAR
BOX
CASE XM1099814 DRAIN
PLUG XM1099815 SHEAR
PIN
5
X
20 XM1099816 COLLAR XM1099815 SHEAR
PIN
5
X
20 XPSB26M CAP
SCREW
M6-1
X
12 XM1099819 FLANGE XP6202 BALL
BEARING
6202 XM1099821 GEAR
33T XPR03M XPK29M EXT
RETAINING
RING
12MM KEY
4
X
4
X
8 XM1099824 GEAR
SHAFT
22T XM1099825 GEAR
44T XM1099826 COLLAR XPK05M KEY
4
X
4
X
10

REF PART
#

828 829 830 831 832 833 834 835 836 837 838 839 840 841 842 843 844 845 846 847 848 849 850 851 852 853 854 XM1099828 XM1099829 XM1099830 XM1099831 XM1099832 XPSB01M XM1099834 XM1099835 XPRP05M XM1099837 XM1099838 XM1099839 XPSS01M XM1099841 XM1099842 XPSS01M XPSB37M XPSB02M XM1099846 XM1099847 XPRP03M XM1099849 XM1099850 XM1099851 XM1099852 XM1099853 XP0602854

DESCRIPTION

SHAFT GEAR
33T GEAR
30T GEAR
35T FLANGE CAP
SCREW
M6-1
X
16 SHIFT
FORK COVER ROLL
PIN
5
X
30 COMPRESSION
SPRING SIGHT
GLASS POINTER
DISK SET
SCREW
M6-1
X
10 STEEL
BALL SHIFT
HUB SET
SCREW
M6-1
X
10 CAP
SCREW
M6-1
X
50 CAP
SCREW
M6-1
X
20 O-RING SHAFT ROLL
PIN
5
X
20 SHIFT
LEVER SHIFT
FORK EMERGENCY
OFF
SWITCH ON
PUSH
BUTTON
SWITCH MOTOR
ROTATION
SWITCH CONTROL
PANEL -52-

Model M1099 (Mfg Since 8/07)

Cross Feed and Carriage

915 910 907 908 909 906 903 920V2 919 902 921 922 923 904 905 918 924 925 926 934 935 933 939 916 914 913 912 911 917 938 936 937 901 929 928 927 930 931 932 -53-

Model M1099 (Mfg Since 8/07)

REF PART #

912 913 914 915 916 917 918 919 920 901 XM1099901 902V2 XM1099902V2 903 XM1099903 904 905 XM1099904 XM1099905 906 907 908 909 910 911 XM1099906 XPSB31M XM1099908 XM1099909 XM1099910 XPK105M XM1099912 XM1099913 XM1099914 XPSS17M XM1099916 XM1099917 XM1099918 XPSB26M XPSS11M

Cross Feed and Carriage Parts

DESCRIPTION

SADDLE CROSS SLIDE V2.08.07

GIB CROSS SLIDE NUT LEAD SCREW HOUSING CAP SCREW M8-1.25 X 25 PLATE RIVET 2 X 5 GRADUATED DIAL KEY 3 X 3 X 6 LEAF SPRING HANDWHEEL SPECIAL HEX NUT SET SCREW M8-1.25 X 6 HANDLE SLIDE BLOCK CHIP GUARD CAP SCREW M6-1 X 12 SET SCREW M6-1 X 16

REF PART # DESCRIPTION

921 XM1099921 DOWEL PIN 922 XPSS34M SET SCREW M5-.8 X 16 923 XPN06M HEX NUT M5-.8

924 XM1099924 APRON TENSION BAR 925 XPW03M FLAT WASHER 6MM 926 XPSB01M CAP SCREW M6-1 X 16 927 XM1099927 CLIP 928 XPSS25M SET SCREW M6-1 X 20 929 XPN01M 930 XPSB48M HEX NUT M6-1 CAP SCREW M6-1 X 35 931 XM1099931 WIPER 932 XM1099932 WIPER CLAMP 933 XPS07M PHLP HD SCR M4-.7 X 8 934 XM1099934 WAY COVER 935 XM1099935 COVER MOUNT 936 XM1099936 OIL PORT 937 XPSB40M CAP SCREW M8-1.25 X 35 938 XPSB48M CAP SCREW M6-1 X 35 939 XM1099939 SPECIAL SHOULDER BOLT -54-

Model M1099 (Mfg Since 8/07)

WARRANTY WARRANTY

Woodstock International, Inc. warrants all Shop Fox machinery to be free of defects from workmanship and materials for a period of two years from the date of original purchase by the original owner. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence or accidents, lack of maintenance, or reimbursement of third party expenses incurred. Woodstock International, Inc. will repair or replace, at its expense and at its option, the Shop Fox machine or machine part, which in normal use has proven to be defective, provided that the original owner returns the product prepaid to a Shop Fox factory service center with proof of their purchase of the product within two years, and provides Woodstock International, Inc. reasonable opportunity to verify the alleged defect through inspection. If it is determined there is no defect, or that the defect resulted from causes not within the scope of Woodstock International Inc.'s warranty, then the original owner must bear the cost of storing and returning the product. This is Woodstock International, Inc.'s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant that Shop Fox machinery complies with the provisions of any law or acts. In no event shall Woodstock International, Inc.'s liability under this warranty exceed the purchase price paid for the product, and any legal actions brought against Woodstock International, Inc. shall be tried in the State of Washington, County of Whatcom. We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special or consequential damages arising from the use of our products. Every effort has been made to ensure that all Shop Fox machinery meets high quality and durability standards. We reserve the right to change specifications at any time because of our commitment to continuously improve the quality of our products.

Model M1099 (Mfg Since 8/07)

Fold along dotted lIne Fold along dotted lIne

Woodstock international inc. p.o. box 2309 bellingham, Wa 98227-2309

place stamp Here tape along edges--please do not staple

High Quality Machines and Tools

Woodstock International, Inc. carries thousands of products designed to meet the needs of today's woodworkers and metalworkers. Ask your dealer about these fine products:

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