Mill-right 529 Owner's Manual

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W^VU\U,

CAUTION!

Read all

Safety

I nstructions

Careful

ly

IKONWOOD DKAND

MILL.RIGHT

ROUTER

MILLING

CENTER

Designed, Manufactured and Sold

by:

POSITIVE POSITION,INC.

SCHENECTADY. NY I2309

OWNER'S

MANTJAL

(Part

No

:1t,B3052)

Model No. 529

and

Accessories

Verli.Mill

B5018

Side.Mill

85041

Y-Posi.Mill 85032

Extend.A.Mill

B5057

Spindle.N1ill

85071

Clamping

Kit 85028

Dovetail Index 85055

Dust

Collcctor

B5045

Convenience

Switch

85063

OWNER'S MANUAL

SAFETY

PRACTICES AND

INSTRUCTIONS

I.

GET TO

KNOW YOUR MILL.RIGHT

Read

and understand

your

owner's manual

and the

CAUTION! and

WARNING!

labels

in

the manualand

affixed to

the tool

. Learn the operations and

the

limitations

of the MILL.zuGHT

as

well

as

any

potential

hazards that

may

result from its

operation.

2. ROUTER SAFETY

Follow the

safety

practices

and

instructions

recommended by

your

router manufacturer.

Ifyour router requires

grounding,

be

sure

to

use

the

proper grounded

type receptacle.

3. KEEP WORK AREA CLEAN

Avoid accidents by keeping

your

work

area clutter free. Do

not

work

on waxed floors or floors covered

with

sawdust.

4. AVOID DANGEROUS CONDITIONS

Don't use

your

Mill.Right

in

damp or wet locations. Use

adequate

lighting.

5. KEEP

CHILDREN SAFE

Do not operate

with

children

present.

Remove

starter

keys

when not

in use.

Lock work

shop

when

not in use.

6.

DON'T FORCE THE TOOL

Do thejob better

and

safer

by

operating the router at the rate

and speed for which it was designed.

Don't

force

the

machine to

do

a

job

it

was not

designed for.

7.

CLOTHING

Do not wear

loose clothing,

gloves,

neckwear or

jewelry

which

can

get

caught in moving

machinery. Use non-slip

shoes.

Contain long

hair.

Roll

long sleeves above the elbow.

8.

USE SAFETY GLASSES

As a minimum, wear

safety

glasses

with

side

shields at all

times

(comply

with

ANSI Z'18.1). Use face or dust mask if

operation

warrants

and

ear

protection

during

extended

periods

ofoperation.

9.

LNATTENDED

MACHINE

Never leave

a running machine unattended. Be

sure

the

router

has completely

stopped before

leaving.

IO.

SECURE

WORK

Use clamps to secure

work to

work

surfaces.

When

..

-.

moved for operation, use

hold-downs or featherboa::r

against table and

guide

fence. When

possible.

free r:'-:

operate the machine.

1 I. DON'T OVERREACH

Maintain

footing and

balance

at all

times.

12.

CARE AND

MAINTENANCE

Use

only

sharp and clean tools. Follou router

r:- -':,.

-

maintenance

gu

idelines.

I3. DISCONNECT TOOLS

Turn

off

router

and unplug

it

when

chaneine b

:.

operations. Turn off

your in-line con\.::en.e

:

-

When

plugging

in

router,

be

sure rt

rs :.

::.. Oi

:

:.

14.

USE ACCESSORIES

DESI(

i\F.D

i

THE MILL.RIGHT.

See owner's manual for recommende:

:- --,i:.-- i

accessories may

result in hazardous

.

-','

15. DAMAGED PARTS

Damaged

parts

should be

properly

..i...

j

-<:

.:

--:-r'-

Check

for

alignment, movemen!.

t're:r:.:

'

:',-

r

-

may have been affected.

Repair or

:i:

3-.

before continuing operation.

16.

WORK

FEED DIRECTIT

tr.

Always feed

work

against the direc:..:

'

'

fixed.

feed the router into the

uork

::r

-i.'

,': .

--

I7.

STABILITY

The MILL.RIGHT

is

construcled.:

-:i,

-!

r

';-

any

tendency

for the unit to tip dur::.;

--

,:.:

-

be bolted to the floor or a suppon

:ia- :

'-

.'

. .

:-

securing them to the legs

and exten:

-

r

''

:-

potential

tipping.

I8.

CUTTING

LINE

Neither the

operator

or observer{

s

r: -

:

.L'

- .'

-

when

the

work is being moved

int.-

:-: ' -':.-

'

--:lt
'

:

;i

ct'ii

'-

l: li

:

-iiO0llC€

-':.3One.

.

.\

ITH

'-'

?r

-

::al

'.!--

l

-

rkis

-i

Jn.

'

::e is
.'-ruld
{l

by

l

l

O

1996,

Positive Position,

Inc

..iung

l9 ROUTING

S.{FETY USING THE

CONVENTIONAL

(BIT

UP)

ROUTING

STATION

Always feed

the work

against

the direction of
rotation.
Proceed counterclockwise

around the

outside of

a
workpiece.
Proceed

clocku ise around

the

interior of

a workpiece

(such

as a

cutout

or

a recess

in

the body

ofthe
workpiece)
Never

pass

the

rvorkpiece

between the router bit and

the

guide

fence. The

work

piece

could become

trapped

and

"kickback".

Note that

this

operation

would also

violate the

"counterclockwise

around the

outside

of

the

rvorkpiece"

rule.

When

plough

cutting through a

workpiece

(such

as

a dado

cut

with

the

router bit

pointing

up)

always be

aware that

the router bit will be hidden

until

it

emerges

from the

workpiece.

DO

NOT

PLACE

YOUR HAND

BEHIND

THE

WORKPIECE

AT

ANY

TIME. Use

a

push

stick or secure the

workpiece in a miter

gauge

equipped with a clamp.

Do

not release the

workpiece

until it has

passed

completell

bevond the

router bit.

Use a

featherboard to hold the workpiece against the

main

table

rrork

surface.

The

guide

fence is

equipped

* ith

a T-slot for mounting a featherboard.

A featherboard

designed

specifically

for

this

operation

is available fronr

IRONWOOD/MILL.RIGIIT. Refer to

the

accessories

catalog.

Use

a featherboard to hold the workpiece

against

the

guide

fence. The miter

gauge

slot

is

also a

T-slot

rvhich

can be used

to

mount a featherboard. A

featherboard designed specifically

for

this operation

is available

from

IRONWOOD/MILL.RIGHT.

Refer

to

the

accessories

catalog.

Do not use

warped,

twisted

or cupped stock.

Do not

attempt to flatten

a

warped

workpiece

by

the force of
hold downs or featherboards. These devices are
meant to hold only

flat

stock against the

work
surfaces.
Use

a bit

guard

whenever

your

operation

allows

its

use.

The

bit

guard

will help keep

your

hands away

lionr

the router

bit

during operation.

Ner

er

turn

the router "ON" before clearing the work

surfaces oftools, wood scraps etc.

not intended for

use

with

the

planned

operation.

OWNER'S MANUAL

SAFETY

PRACTICES

ANDINSTRUCTIONS

(CONTINUED)

.

Wlen using the VERTI.MILL

accessory, be sure

that

the

workpiece

is

securely

clamped.

Keep both hands

on

the

fixture

when routing.

.

Do

not

attempt to

move

or

adjust any

paft,

fixture,

hold down,

machine

part

etc. while the

router bit

is

still

turning.

r

Do

not

use

this

station

for

"plunge

type" operations

by

pressing

the work

down onto

the

rotating router

bit. Use the

router

caniage station with

a

"plunge

rype"

router

for this operation.

r

Close the split fence as close as

possible

to the

router

bit

to

prevent

cocking of the work as it

passes

the

opening in

the

fence.

20. ROUTING

SAFETY

USING

THE

ROUTER CARRTAGE

(BrT

DOWN)

ROUTING

STATION

o

Always feed the work

against the

direction

of

rotation.

.

Proceed

counterclockwise around the outside of a

workpiece.

o

Proceed

clockwise

around the interior

of

a workpiece

(such

as

a cutout or

a recess in

the body of the

workpiece).

o

Always

check that

the work

is securely clamped

before turning on the

router.

.

Backrouting is not recommended.

o

Make

sure

that

no machine

parts

are

in

the

line

of

travel ofthe

router

bit for

your proposed

operation. If

machine parts

are in

the

line of travel, use

travel

stops

or other suitable means of

preventing

the

router

bit

from contacting metal

parts.

o

Do not

attempt to remove

the

work or any machine

parts

while the router bit is still

rotating.

.

Keep both hands on the router handles

or

the router

caniage

when routing.

.

Take small

cuts rather

than

large. The

MILL.RIGHT

was designed with

precision

positioners

which

allow

you

to

proceed quickly

with smaller cuts for safer

operation

and

a better finish.

o

The router carriage

router

station was designed to

enhance safery by clamping the work

in place and

moving the

router

along a

controlled

predetermined

path in

its carriage.

Do

not

let

this

controlled situation

lull

you

into carelessness. A SECOND OF

INATTENTION CAN

RESULT IN SEVERE

INJURY.

O 1996. Positive

Position.

Inc.

512-tr-96

OWNER'S

MANUAL

CONTENTS

AVAILABLE ACCESSORIES

Safety

Practices and Instructions

I

Verti'Mill

Main

Assembly Instructions

5

Assembly Instructions

Step

l, Assembling the Leg

Set

5 Adjustment Instructions

Step 2,

Assembling the Base

5 Application Instructions

Step 3,

Assembling the Main Table to the Base

6 Assembly Figure

Step

4, Assembling the X-Positioner

6

Assembled Figure

Step 5,

assembling the X-Y Caniage

7 Application

Figure

Step

6,

Assembling the Guide

Fence 8

Basic Operation. Fig.

I

Step 7,

Assembling the Auxiliary Milling Table

Support 8 Basic Operation, Fig.

2

Step

8,

Assembling the

Auxiliary

Milling

Table

(AMT)

9

Basic Operation. Fig. 3

Step 9,

Assembling the Router Carriage

9 Basic Operation,

Fig.

4

Step

10, Assembling the Carriage Lock

l0

Y-Posi.Mill

40
40
40
40
4l
42
43

44

45

46

4',7

48
48
49

50

5l

)i

53

<t

51
55
56

5'7
58
59

60
60
6l
62

63
63
64

65
65
66

o/

68

Main Assembly Figures I through

9

Fig. I Assembling the

Base and Leg

Set

Fig.2 Assembling the Main Table

to

the Base
Fig. 3 Assembling the X-Positioner
Fig.

3A

Assembled X-Positioner
Fig. 4 Assembling the X-Y Caniage
Fig. 44.

Assembled

X-Y

Carriage
Fig. 5 Assembling the Guide Fence
Fig.

5A Assembled Guide Fence
Fig. 6 Assembling the AMT Support
Fig.

6A

Assembled AMT Support
Fig. 7 Assembling the AMT
Fig.7A Assembled AMT
Fig.

8 Assembling the Router Carriage
Fig. 8A Assembled Router Carriage
Fig. 9

Assembling the

Carriage Lock

Adjustments

Adjusting

the X-Y Carriage

Adjusting

the X-Positioner Acme Nut Pre-Load

Adjusting the Auxiliary Milling

Table

(AMT)

Adjusting the

Guide

Fence

Adjustment

Figures,

Main Assembly l0 through l4
Fig. I0 Adjusting the Router Carriage
Fig. 1l Adjusting the AMT

Support
Fig. 12 Adjusting the AMT
Fig. l3

Adjusting

the AMT

Fig. l4 Adjusting the

Guide

Fence

Basic

Operations

Using the X-Positioner Scales
Using the Router Table Station
Using the Router Carriage

Station

Planing with the

Router Carriage Station

Basic Operation

Figures

Figs. l

-4

Basic Operation

Figs. 5-8

Figs.9-10

Basic

Operation

Basic

Operation

Using the

X-Positioner Scales

I I Assembly Instructions
I

I Application & Adjustments
12 Assembly Figure
l3 Assembled Figure
14 Application Figure
l5

Application Figure

(Rear

r

ie*

)

l6
17 Side.Mill
l8 Assembly lnstructions
19 Application &

Adjustments
20 Assembly Figure
2l

Assembled Figure
22 Application Figure
23

Operation

Figure
24
25 Extend.A.Mill

Assembly Instructrons
Assembly

Figure

Assembled

Figure

Dust Collector

Assembly lnstruction.
Assembly

Figure

26
26
26
27
27

28
28 Dovetailing Index Plates
29

Assembly Instructrons
30 Assembly Figure
3l Assembled Figure
32

Optional Set-ups Frgurc
33 Spindle.Mill

33

Assembly

Instructions
34 Application & Adjustments
35

Basic

Operation

Instrucrrons
36 Assembly Figure
37 Assembled

Figure

37 Application

Figure
38
39

Convenience Srvitch

39

Clamping Kit

59
69

-0

-l

-l

J

-{

'76

@

1996, Positive Position,

Inc.

5

l2-

r r-96

OWNER'S

MANUAL

ASSEMBLING

THE MILL.RIGHT

MODEL 529

PLEASE READ THESE INSTRUCTIONS

THOROUGHLY BEFORE

ASSEMBLY

TO INSURE A

TROUBLE FREE EXPERIENCE. THESE INSTRUCTIONS

HAVE BEEN

TESTED ON NOVICES

AND WE

HAVE DONE OUR BEST TO WEED

OUT

PROBLEMS

FOUND

DURING

THIS

TESTING. IF YOU

SHOULD

EXPERIENCE ANY PROBLEMS, PLEASE

CALL

TOLL

FREE

888-478-2453 AND REQUEST A SERVTCE

CALL. A SET OF HEX

[ALLEN]

WRENCHES

AND A

COUNTERSINK

HAVE BEEN

PROVIDED FOR

YOU

CONVENIENCE. YOU WILL ALSO NEED

FLAT

TIPPED AND PHILLIPS SCREWDRIVERS

AND A SET

OF

BOX OR

SOCKET WRENCHES. THE ONLY

DRILLING YOU

WILL

HAVE TO DO IS FOR

YOUR

ROUTER

MOUNTING HOLES

IN THE ROUTER

SUPPORT

PLATES

AND

FOR

THE BRASS INSERTS INTO YOUR

WOOD FENCE INSERTS.

STEP

I

ASSEMBLING THE LEG

SET

(OptionalAccessory)

(Assembly

52685017)

Refer to

Figure

I

Find

the

parts

described by

Figure l key

numbers 7 through l4 in

the

quantities

indicated. Check

that

all hardware

items

match the

description

given

in the key

list.

Match

the three

bolt

holes

in

the

upper

end of each

Leg

[7]

to

the

matching

bolt

hole pattern in

the

ends of the Stiffeners

[0] & [l

l].

The

two Long

Stiffeners

[0]

should be opposite

each other and the two Short

Stiffeners I I I ] should

be

opposite each

other.

The

Legs should be

positioned

outside the Stiffeners. Use

one

each of

Bolt

[2],

Nut

|31

and

Lock Washer

[3]

fbr each

of

the 24 holes.

Note the hardware

sequence

shown

in

Figure

l.

Do not

tighten

Bolts

until

all

Bolts

have

been inserted. Then be

sure to securelv tighten all Bolts.

Thread

one Nut

[9]

onto

each Foot

[8].

About I inch of thread should extend past

the Nut.

Insert

one of these assemblies into the

bottom

hole

of each

Leg.

Thread the remaining Nuts

[9]

onto the

Feet

[8].

Note

the

harduare sequence

shown in Figure l.

Hand tighten the top Nut and place the

assembled

Leg

Set on its Feet. Once

you

hale completed the

MILL*RIGHT assembly and

positioned

it in

your

shop,

level

the feet and securely tighten

the top Nuts

[9].

STEP 2

ASSEMBLING THE

BASE

(Assembly

52685022)

Refer

to Main Assembly

Figure I .

Find

the

parts

described by

Figure l

key numbers I through 6 in the

quantities

indicated. Check that

all

hardware items

match the

description given in

the key list.

If

you

have

purchased

Lee Set

52685017,

position

the

unit

Base

[

]

on

the

Leg Set and

align the

three 7

I 6 bolt

holes

with the

matching bolt holes

on

top of

the

Stiffeners in the Leg

Set.

Q.lote:

the

Base

is

.r nrmetrical

top to bottom so it

can't be

positioned

wrong.)

Loosely fasten the

Base

to the Leg Set

with

one

each of

Bolt

[3].

Washer

[4],

Washer

[5]

and

Nut

[6]

in each of these holes. Note the hardware

sequence

shown in

Figure l.

BoltoneAngle[2]tothetoprearoftheBaseasshowninFigure

l

usingthefwo5/l6holesandBolt[3],Washer

[-l].

\\

asher

[5]

and

Nut

[6].

Bolt the other Angle to

the

bottom

rear

holes.

Note that

the

Angles

are

positioned

inside

of

the

Base flanges. Bolt

the

bottom

Angle to

the Leg

Set

using the center hole in the

bottom

Angle

and

one

each

of Bolt

[3].

Washer

[4],

Washer

[5]

And Nut

[6].

Note the hardware sequence shown in Figurel.

When all

harduare is

in

place,

be

sure to securely tighten all bolts.

@

1996, Positive Position,

lnc

512-tt-96

OWNER'S MANUAL

STEP 3

ASSEN,IBLING

THE MAIN TABLE TO THE

BASE

Refer

to Main Assembly Figure 2.

(Main

Table

Assembly 52685021)

Find

the parts

described by

Figure 2

ke1 numbers I through 7 in the

quantities indicated. Check that all hardware items match the description

given in

the ker

lrst

Position

the

Main

Table

[1]

on the assembled Base

(step

2).

CAUTION:

The

tgble

*eishs

aporoximatelv

90 lbs

and

this sten may require assistance.

Be

sure

to position the table * rth the

"U"

shaped

end

and under side T-slot overthe

large

cut out hole

in

the

long side of the

Base.

Loosely secure

the Table

to the Base

using

the

holes in the top flange of

the Base

and

Bolt

[3]

and

Washer

[J].

When all hardrrare rs in

place.

be sure Io

securelv

tighten all bolts.
Attach two Positioner Levelers

[2]

to the underside of the

Table

as

5ho\\n in Frcurc l. usrng

Screw

[7]

and Washer

[6].

Thread

the

Thumbscrews

[5]

into the threaded

holes

oiPosrtrtne:

l.erelers

[2].

lnsert the six Locking Setscrews

[0]

into

the Router Supptrn

I)rt,n-ln

p1311'

lal

P.:;e

the Router

Suppon

Drop-ln

Plate

in

the

rabbetcd

recess in

the

Main

'l'able

and

Ir'rel tt u:rir{

thc lour.,.n:.':

I L

ir:rS Selscre$s.

Ad.lust

the side-to-side

fit

by ad.justing

the tu'o l.ocking Sr'tSCft'rrs

ltrt:ited rr: :he rtle:

Place

your

router on the Router Supporf

Drop-ln Plat.' an,l

ptr:ii.trr.

.i

lrr

i:itrrr i!,:\ 3nienl

access to the

controls.

Note

this

router position. Rernove

)our

router 5

phcn..lrc

b,ase

rr.: --:rS lt

J)

J:ern9:Jle.

scribe vour

router

base bolt

hole pattern

onto

the Router

Support

Drop-ln Pi,:ic l)rrl,

hrlr-

;.:-3-ronc::i

:.

:..

-:

:!ruter

base screns

andcountersinkthetopoftheRouterl\,lountingPlatcusrnS:hccct.rnis:.r\::.r\:ie;

'--\';i()\'Useflatheaded

scrcws of

the

fight threud und length lo

fully

engape the tupped httles

.:.

'.i-r

rt]urir

'r

: - :'.:' hare

to

buy

longer

screws

than

the

ones that come

with

)-our

router.

Anach thc frrLlir ii ::.. R-

-:.:

\tou:.:.:i

?

j:3

S'l

l:P

l

ASSENIBLI\C

tllf: Pr

ts;'

r

\i {

(Positioner

.-\::enrb." : l: 3

j

Ret-er to Main Assembly Figure

j.

Firrd the

panr

Jes.:.:;: :, i :-:r

I xcr 1-"':.-':.

. ::.:ough

24 in the

quantities

indicated. Check

that

all hardrvare itenrs nratch thc ;e:;::::..

-

i

.i:

iir ri3 ri.

.:

Placethe

Positioner Support

u]on

a

rrork

surt'ace

rllhe:::

: :::

e s-:::ce ;t :::: ,.

::::ranple.)

Insert

thetwoBall

Bearings[0] intothetwocounterbored]E'holes::i..::.e::s.-:'.i.Po::,-3-:-::.:r[].TheBall

Bearing outer diameter is designed

as a slip

fit into these brrrc: a..J,

l:i

B:..

Bea:lngs

s:..- : :3 \e::

jquare

to

the

bores

uhile

inserting to

prevent

binding.

Screu,the Fixed

End

Acrne

Nut

[3]

into the 5 l6-l8lrr:i:r.l rl::

,:,:

Cr:-:lase

?--: i .-r3: {ssembly

[2]

as

shown

in Figure

3. IMPORTANT! Tishten br hand onlr

Position

Carriage

Positioner

Assembl;

[2]

u

rth

the

r.

.e::::.: :r::

.-:'

'i'

a.:g:.e:

both ends

of Positioner Support

[1.

Insert Guide Rod

[-]

lh:..ugr.::,e :.:.

":

,::e eni l:

'

bearingboreof[2] andthenthroughtheboreattheothcrcnir,i'i.' \..;-::3.:Jitii-l

:l

surfaces of

[]then

secure

[7]

in

[]with

two

setscre\\s

[81

as

sii\\;i

:n F::-:e -:

With

the opening of

Il]

facing

y'ou.

insen Acnrc' Lerd:cre*

'91

:ni.. i:.e :!,re oi:r'.e :lshl

nanl Ball

Bearing

[10].

The

l/4-20

threaded end of

[9]

must be on

the rrghr l'hen :r'.rerJ'q

l.rn

\ra\

::io

i-.

,,rhrch

has

alreadybeenscrewedinto[2].Makesure[9] doesnotprojectrntothc.r3''\St)i -:'lirtdols.

Ih.n:.ici[9]

offuntil

thejawareaof

[3]

isclear.Alignthematingja*sof FrceEnd.{:;lerut

l;

',rr:n:retd*Sraii:i:n.trullr

engage

thc

jaws.

Holding

[4]

in

this

position,

continue scrolins

[9]

rnto

[-r]

rnj

i-l]

I'eepr:i

IJ]

as;..,:e ll

[-l]as

possible.

Whenthethreadsof[9]har,eengagedboth[3]and[1].both[-r]

andlll

'.rrll

r;:3)runir

\er:.s,rpAcmeNut

Spring

[6]

and then Acme Nut

Collar

[5]

over the

por-tion of

[9]

trhrch

ha: arreiJ\

rr>:ei

li.:'rr.gh

[-rl

and

[4].

Thread

[5]

onto

[1]

slightll'

compressing

[61.

''\

.:: ::.3

;

.

'

bores at

::.::.::.:,-;gh

the

-:i.

'\.ll

::e

outside

O 1996.

Positive

Positiorr

5ll-rl-96

OWNER'S MANUAL

STEP

4

ASSEMBLING THE POSITIONER

(CONTINUED)

Continue tuming

[9]

until it

passes

through

the

ID

of

the

BallBearing

[0]

on

the

left

and

projects

beyond

-

.

:frrut

5.5 inches.

Apply' a few

drops of light

machine oil

to the two O-Rings

fl

31 and slide

them

over the

end of Sleeve

Il I ]

"

-

;n is nearest

the

fwo

O-ring

grooves.

Position

one

O-Ring

in each

groove.

Next, slide Round

Scale

[4]

over

the

'

t-)-

Rings [ 3

].

The

scale markings of [ 4] must be

at

the end

of the

assembly

and the knurled

part

of

fl

4l must

-',

:..u

ard the center. If not, turn

il

4] around now.

Slide this assembly over

the

left

end of

[9].

Slide

the

bore

of

Crank Handle Assembly

[15]

over the end of

[9]

until

[9]

bonoms out in the bore. Secure

'

to

[9]

with Setscrew

[15-A].

Tighten

securely. Push

the

Crank Handle

and Leadscrew

Assembly all the

way to

-

i

:rsht. Thet/u20

threaded

end should

be outside the Positioner

Support Assembly

Il].

Apply two % Flat Washers

^

the Wave Washer

Il7]

and the

t/*20

Locknut

[

8]. Tighten the Locknut to remove

axial

play

of

the

::iscrew. Do not over tighten as this will make

the

Leadscrew difficult

to

turn.

Insert Setscrew

fl2]

into

Sleeve

and tighten.

Apply a few drops of light rnachine oil to Guide Rod

[7]

just

outside

of

the two linear

bearinss at both ends

'

,-

.rrriage Positioner

Assembly

[2].

Slide

the

Carriage Positioner Assemblv

[2]

back and forth

repeatedly

to work

-:

orl into

the

linear bearings. Wipe the Guide Rod

[7]

clean.

Place

Cover

[9]

on Positioner Support

[]and

secure with four

screws

[20].

Attach

Round Scale Indicator

- ' to cover

with

screw

[20].

Attach

Adjustable Positioner Indicator to Carriage Positioner

[2]

with Thumbscrew

-:; and Washer

[2a]

in

the sequence shown.

STEP

5

ASSEMBLING'THE X-Y CARRIAGE

i.cter

to Main Assembly Figure

4.

Find

the

parts

described

by

Figure

4 key numbers I through l5

in the

:uantities indicated. Check that all

hardware

items match the description

given

in the key

list.

Place the

bottom edge of the Positioner Assembly

[5268500 I ]

on top of

the Levelers.

[See

..*e lers in Main Assembly

Figure 2.1

Secure

the Positioner Assembly to the

Main

Table

[2]

with two

Capscrews

1,11.

Finger

tighten only at this time. Attach

Carriage Track

[6]

to the

Main Table using two Capscrews

[4],

three

\\

ashers I l

]

and three Disk

Springs [ 2].

Note that

the Disk Springs are near the edge

of

the

Main

Table

and

the

\\'ashers

are inboard.

Place two each

Washers

and

Disk

Springs below the table and

one each above.

[This

stack up

na1 change later when

leveling the X-Y Caniage Assembly.]

Slide the Linear Bearing Assembly

[7]

onto

the Guide

Rod

[3]. [Note:

if

you

have

purchased

the Clamp

Kit

85028,

slide the

two

Shaft

Collars

[5]onto

the Guide Rod as

.rell

placing

on

at each

end of the Linear Bearing Assembly.] Slide

one end of the Guide

Rod

into the %" bore of

:re

Carriage Positioner

IKey

No.2,

Main Assembly Figure 3.] Slide the'io" bore of the

Ball

Bearing

Caniage

\ssembly

[5]

onto the other end

of

the

Guide Rod. Screw two Capscrews

[8]

each into

both ends. Snug

tighten

only

:: this

time

with

the Allen wrench provided.

Screw

the

Support Angle

[4]

onto the ends of the

Caniage

Positioner

:nd

Ball Bearing Caniage Assembly

using four Capscrews

[9].Use

the

two Washers

[10]

on the Ball Bearing

.arriase

Assembly

end only. At this time,

go

back

and securely tighten

the two Capscrews [ 3]. Check

to

see that

:.:e

ball bearings of the Ball

Bearing Caniage Assembly are sitting on top of the

Caniage

Track. If necessary adjust

:r.e

position

of the Ball Bearing

Caniage Assembly.

Once

this is done, securely tighten the eight

Capscrews

[8]

&

.l

Turn the Positioner

Crank Handle to check that the X-Y

Carriage

Assembly

moves freely.

We will

level

the

X-

':

Carriage Assembly later.

Apply a few

drops of light machine oil to Guide Rod

[3]

just

outside of the

two linear

bearinss at both ends

: ::e

Lrnear Bearing Assembly

[7].

Slide

the

Linear Bearing Assembly

[7]

back and forth repeatedly to work

the

:nto

the linear

bearinss. Wipe the

Guide

Rod

[3]

clean.

rqq6

Posirive Position, Inc

512-tt-96

OWNER'S

MANUAL

STEP 6

ASSEMBLING THE GUIDE

FENCE

[526B5o

l o]

Refer to

Main Assembly Figure 5.

Find

the

parts

described by

Figure 5 key numbers I through 9

in the

quantities

indicated. Check

that all hardware

items match the description

given

in the

key list.

Attach the Right

Fence

Support

Bracket

[3]

and the Left

Fence

Support

Bracket

[4]

to the

Fence

Assembly

[2]

with four

Capscrews

[7].

Note that

the Left Fence Support

Bracket

[4]

has a

recess on the bottom to

provide

clearance

for the optional

Dust Collector attachment

85045.

Attach

the

resulting assembly to the X-Y

Caniage

Assembly of

Main Assembly

Figure 4 using four Capscrews

[7].

Make

two

Wooden Fence Insert halves

t4] & t5]

from scrap hardwood.

Wood Fence Inserts

should be %" thick

and 90" beveled on one end. Measure

the

distance

from the underside of

the Aluminum Fence

T-Slot to the

Main Table surface. Make the

width

of

the Wood

Fence Inserts equal

to this distance less

l/8". Make the

right Wood Fence Insert

12.5" long and the left Wood

Fence

Insert I l" long. Position the

Wood Fence Insert

halves with the bevel

in the center as shown and line up

the

beveled edge

with the center of the

Router Drop-ln Support

Plate

[Main

Assembly Figure 2 Key

No.9].

Holding the

Wood Fence

Insert against the Aluminum

Fence

[2]

and up

aqainst the Aluminum

Fence T-Slot, trace the outline of

the four

(4)

Keyholes in the

Aluminum Fence onto

the backs of the

Wood Fence lnserts. Mark

the

center of the

narrow

end of

each

Keyhole as shown. Drill a

flat bottom A318"

x 5i8" deep hole

in

the center of

each of the four

locations

marked. Thread the

four Brass Threaded

Inserts into these

holes. Insert the four Pan Head Phillips Screws

[9]

into the Brass Threaded

Inserts.

Slide

the heads of

the Pan Head

Philips

Screws

into the ke1'hole slots and

tighten

the Wood Fence

Inserts against the

Aluminum Fence in the

desired

position.

STEP

7

ASSEMBLING THE

AUXILIARY MILLING

TABLE

(AMT)

SUPPORT

Ref'er to

Main Assembly Figure 6.

Find the

parts

described

by Figure 6 key numbers

I through l8 in the

quantities

indicated. Check that all hardware

items match the description

given

in the key

list.

Bolt

the AMT Mounting Wedge

[2]

to the

AMT Support

[ ]

using two Capscreu

s

[7]

and

Locking Washers

[8].

Attach the Stop Pin Assembly

[12]

to

the AMT Support using two

Capscreu s

[13].

Pass

Capscrew

I

l]through Spacer

[0]

and

through Clamping Lever

[9]making

sure the hex

pan

of

the

Clamping

Lever hole is facing the

head of

Capscrew

[11].

Thread Capscrew

[11]

into the AMT Support clamping

flange as

shown.

Attach the Jacking Screw

Mounting Plate

[4]to

the

AMT

Support

underside using nvo

Pan Head Phillips

Screws [ 6].

Insert

Stud

[

8] into the Plastic T-Handle

Knob [ 7] and tighten using double

3

'8-

16 nuts Thread the

assembled

T-Handle/Stud into the Jacking Screw

Mounting Plate.

Drop

the

Jacking Disk [ 5] into the

top

of

the 2"

bore of the AMT Support.

Pass Capscrew

[6]through

Spacer

[5]and

through Clamping

Lever

[4]

Pass Capscreu'

[6]through

the l"

bore

of the AMT Support top

flange. through the

AMT Mounting Wedge and

loosely

screu

Capscrew

[6]

into the

AMT Mount T-Nut

[3].

Lift the entire assembly

and maneuver the

AMT llount T-Nut

[3]

into

either

end

of

the AMT Mounting T-Slot located

under the Main Table.

[See

Main Assembll Figure 2 for

location

of the AMT Mounting

T-Slotl. Slide the AMT Support

Assembly to a

position

at about

the middle of the

AMT Mounting T-Slot and lock securely into

place

using

the Clamping Lever

[5].

O 1996,

Positive Position. Inc

512-n-96

OWNER'S MANUAL

STEP 8

ASSEMBLING

THE

AUXILIARY MILLING TABLE

(AMT)

Ret-er

to

Main Assembly

Figure

7. Find

the parts

described by Figure 7 key numbers I

through l3 in the

quantities

indicated.

Check

that all hardware items match the description

given

in the

key

list.

Position the AMT

[ ]

on

a work

surface

with

the back showing as

in

Main

Assembly Figure 7.

Position

the

AMT SwivelHead

[2]

between the two 2"

bored

flanees

of

the

AMT

[]and

line up the bores of

both

parts.

The elons,ated slots

in the

2" shaft of

the AMT

Swivel

Head

[2]

should face away

from

the AMT

Il].

With

its

rhree

stop

pin

holes

to the left, slide

the

AMT Support

Pipe

[0]through

allthree 2"

bores until

it is flush

with the

rieht

face of the

right AMT

flanee. Slide the

AMT Swivel Head all the way

to the right until it contacts

the

left

rnside face of the

right AMT flanse. Loosely thread fwo

Setscrews

[3]

into the fwo

tapped holes in the top

of

the

\\1T

Swivel Head.

Inspect the

Stop

Pin Assembly

[7]

to

familiarize

yourself

with its operation.

Note the

position

irhich

detents the Stop

Pin

and

keeps it from

protruding

out

its hole. This is

thefree or detent

position.

Turning the

inurled

knob releases the Stop

Pin

and allows it to

project

from its hole. This is the

slop

position.

Attach the

Stop

Prn Assembly

[7]to

the underside of

the

left

AMT flanse using

fwo Capscrews

[8]

and

Flat

Washers

[9]

in the

.cquence

shown in Main Assemblv Figure 7. Turn the

Stop

Pin

knurled

knob

to

release it

to its.r/op

position.

Facing

lhe left end of

the AMT

Support

Pipe

[

0],

rotate

the

AMT Support Pipe so that the

Stop

Pin engages the

stop

pin

hole which is counter

clockwisefrom the middle

hole.

tNilh

the 2" shaft of the AMT

Swivel

Head

pointing

down,

)ecurely tighten the

two

Setscrews

[31.

Pass Capscrew

[6]

through Spacer

[5]

and Clamp Lever

[4].

Screw Clapscrew

l6l

into the clampine flange of the AMT. Lifi

the

entire AMT

Assembly and place

the

2"

shaft of the

AMT

Swivel

ttead into the top of the

2"

bore of the

AMT Support in

Main Assembly

Figure

6. Slide the AMT SwivelHead2"

r,haft

all

the wa1' to the bottom of the AM-f Support bore.

s fllP

9

ASSEMBLING T'HE ROUTER CARRIAGE

Refer

to

Main Assembly Figure 8. Find

the

parts

described by

Figure

8 key numbers I through 9 in the

.'1uantities

indicated.

Check

that all hardware items

rnatch

the description

given in

the key list.

Inspect

the

two

Side Brackets

[2].

Notice that

only one side of

each

is

machined

and the two Side

Brackets have opposite sides

rnachined.

Place the two

Side

Brackets

[2]

inside

the Router Mounting Plate

[ ]

with

rhe

machined

sides

facing the insides of the fbur

vertical tabs of the

Router Mounting Plate

[].

Attach the

Side

Brackets to the Router Mounting Plate using the four Plastic Knobs

[4]

and

Lock Washers

[5J

as

shown.

Position

Ball Bearing

Carriage

Assembly

[3]

under

the ends of the

Side

Brackets

as

shown.

Attach the Ball

Bearing Carriage

\ssembly

to

the Sidc Bracket

feet

using the

two

Round Head Square Neck Bolts

[7]

and Flat

Washers

[9].

Screw

the two Brass

Thumb

Scrervs

[6]

into

the U-channel ends of the Side Brackets as shown.

Refer to

Main Assembly

lrrgure

10.

Place the

completed

Router

Caniage Assembly

on the X-Y

Carriage

by

placing

the U-channel ends over

rhe Linear Bearing Assembly and tighten the Brass Thumb Screws

[6]

and

resting the

ballbearinss of

the

Ball

Bearing Carriage Assembly

[3]

on the Support Angle. Place

your

router on the

Router

Mounting Plate and position

rt to allow convenient access to the

controls.

[f

you

draw

an

imaginary line through the

router's

handles, that

line

should run

parallel

to the

Side

Brackets. Note this

router

position.

Remove

your

router's phenolic

base and

using

it

.ls a template,

scribe

),our

router

base

bolt

hole

pattern

onto

the

Router

Mounting Plate

[].

Drill holes

conesponding

to

your

router base

screws and countersink

the

bottom of

the Router

Mounting

Plate

using

the

countersink

provided.

CAUTIONI

Use

flat

heuded screws of the

right

thread and length to

fullv

enssse the

tapped

holes tn

your

router. You may have

to buy longer scrcws than the

ones

that

come with

your

router. Attach the

router

to the

Router Mounting Plate.

The

Router Carriage

is vertically

adjustable. Loosen the

Plastic Knobs

[4]

just

enough to move the Router

Carriage

up

or down

-

then

retighten.

The

Router Carriage

should be level with

respect

to the Main Table. A simple

\\ a\

to do this is to lower

the Router

Carriage onto a flat

board covering

the

"U"

shaped opening at the

right end of

the Main

Table.

With

the

Router

Caniage sitting on

the flat board, tighten the Plastic Krobs

[4].

Use

thicker or

more boards to

raise

the Router Carriase level or a thinner board to lower it.

e'

1996, Positive Position, Inc

512-11-96

OWNER'S MANUAL

STEP IO

ASSEMBLING

THE CARRIAGE LOCK

Refer

to

Main Assembly Figure 9.

Find the

parts

described by Figure 9 key numbers I

through 6 in the

quantities indicated.

Check that all hardware items match the description

given

in the ke1 list.

Pass the Stud and Handle Lock Assembly

[2]

through the Bronze Flat

S'asher

[.1]

and nro Disk

Springs

[5].

IMPORTANT! The Disk Springs are dished

which

is

what gives

them their

spring Be sure the Disk

Springs are ananged such that they are touching back to back at their center holes. Next.

pass

the

stud through the

3/8" bore at the

rear

of the Ball Bearing Caniage Assembly

[ ].

Place the Lock Clamp Angle

[3 ]

over the srud

and

thread

the Locknut

on

the

end of the stud. The Lock Clamp Angle must engage the top flange oi the

Carriage Track

[Main

Assembly Figure 4,

Key No. 6]. The Carriage Lock Assembly is unlocked

when

the *nob is vertical

and

locked when the knob

is horizontol. Adjust the Locknut

[6]

to

give

adequate Drsk Sprine force to lock

the carriage.

IMPORTANT!

Do

not

over tighten the Locknut as

excessive

locking force

rr

rll cause the

b,all L'e arings to tarl

prematurely.

With the Caniage Lock Assembly in the

unlocked

position.

the \-\

Carriase

.:.r:ld

mor.e tieelr

when the Positioner

Crank Handle is turned. CAUTION! Do not turn

lhe Pc)srliofrcr

Cra:r' ii.:.:.iie

uith

the Caniase

Lock Assembly in the lock

position

as this may damage the

Positroner.{ssemb,r

l0

e

1996. Positive

Position. Inc.

OWNER'S

MANUAL

t/

MA i \,1

ASSTIVBLY

t

I Gt,] RT

I

ASSIiVEL

I

i\G

-tFrl

EASI

&

L[G

SI-t

PART

DESCRIPTI

BASE

ASSEMBLY

(STANDARD)

CAPSCREU. Htx HEAD.

1/4-20 \

3/1

VASHER,

FLAT

I /{

INTERNAL TOOTH,

TYPE

B, I/4

NUT,

HEX

JAH, I/4-20

T ASSEHBLY

(OPTIONAL

ACfSSORY)

'ODI,

I 5

DIAH RUBBIR,

l/?-13

x ? STUD

NUT,

HEX,

I,/2_I 3

SIIFFENER,

LON6

STIFFTNER,

SHDRI

BoLT. RoUND AEAD,

I/4-2o x 5/8

NUT, HfX,

I,/4.20

VASHER,

LOCK,

INTfRNAL TOOTH,

TYPt

B,

I/4

CAPSCREv,

HEX HEAD.

3/8-16 x

3/a

IASHER,

FLAI,3/A

R,

LUCK, INTERNAL TOOTH,

T"ti.iA

NUT, HfX

JAX, 3/8

l6

53al 033

c-

4{!

l't / \ t4

O

I 996. Positive

Position.

512-l

l-96

OWNER'S

MANUAL

L-l,-l

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512-l

l-96

@1996,

Positive

Position,

Inc.