2. Align the key holes in the Spindle Shaft (B7) and the Quill Tube (B3) by turning the Chuck by hand. 3. Insert a Wedge Drift Key (not supplied) into the key holes. 4. Place a bundled cloth or basket below the Chuck to catch it when it falls. Lightly tap the Wedge Drift Key with a rubber mallet until the Spindle Shaft falls out of the Quill Tube. Installing the Chuck and Spindle Shaft 1. Using a clean cloth, wipe the tapered surfaces on the Spindle Shaft (B7). 2. Slide the Spindle Shaft and Chuck assembly up and into the Quill Tube (B3). At the same time, turn the assembly until the rectangular end of the Spindle Shaft slips into the notch on the Quill Tube. WARNING! In the previous step, if the Spindle Shaft is not properly set in the Quill Tube notch, it may fly out during operation. 3. Loosen the Lock Handle Support (C2) and raise the Table (C7) about three inches below the Chuck. 4. Turn the Chuck sleeve clockwise to open the jaws completely. 5. Pull the Feed Knob counterclockwise and force the Chuck against the Table until the Spindle Shaft is secure. Adjusting the Feed Wheel Return Tension Spring CAUTION! Wear an ANSI-approved full face shield during this procedure. 1. Move the Chuck to its uppermost position. 2. Loosen Hex Nuts (31) and move both to the lowermost position. This will keep the Chuck from falling during this adjustment. 3. Insert a screwdriver in the lower-front notch of the Spring Cap (29). Hold it in place and, using a wrench, remove the (outer) Hex Nut (30) only. 4. With the screwdriver still in place, loosen the (inner) Hex Nut (30) until the Spring Cap notch disengages from the Spring Retainer (27) -- about 1/8 inch. 5. Hex Nuts (30) Spring Cap (29) NotchHex Nuts (31) Pointer (32) Turn the screwdriver counterclockwise and engage the next Spring Cap notch. Leave the screwdriver in place. 6. Tighten the (inner) Hex Nut just enough to engage the notch. If this Hex Nut is too tight, it will restrict (up and down) Chuck-Spindle movement. 7. Loosen and screw the Hex Nuts (31) to the top of the Stop Rod (B12). 8. Pull the Feed Knob and check the spring tension, making sure the up movement is smooth and complete. From one inch down, the Chuck should return to its uppermost position. If more tension is required, repeat steps. 9. Replace the (outer) Hex Nut and tighten on top of the (inner) Hex Nut. Do not overtighten. 10. If the (up/down) movement is restricted, slightly loosen the (inner) Hex Nut, and retighten the (outer) Hex Nut. Troubleshooting Problem Possible Causes Likely Solutions Tool will not start. 1. Cord not connected. 2. No power at outlet. 3. Internal damage or wear. 1. Check that cord is plugged in. 2. Check power at outlet. If outlet is unpowered, turn off tool and check circuit breaker. If breaker is tripped, make sure circuit is right capacity for tool and circuit has no other loads. 3. Have technician service tool. Tool operates slowly. Extension cord too long or wire size too small. Eliminate use of extension cord. If an extension cord is needed, use shorter/heavier gauge cord. See Extension Cords in GROUNDING section. Performance decreases over time. 1. Accessory dull or damaged. 2. Carbon brushes worn or damaged. 1. Keep cutting accessories sharp. Replace as needed. 2. Have qualified technician replace brushes. Excessive noise or rattling. 1. Belt too loose (slipping) or too tight (bearing damage). 2. Spindle dry 3. Loose spindle pulley 4. Loose motor pulley 5. Internal damage or wear. 1. Properly tension belt. 2. Lubricate spindle 3. Check pulley nut 4. Tighten Set screws 5. Have technician service tool. Overheating. 1. Forcing machine to work too fast. 2. Accessory misaligned. 3. Accessory dull or damaged. 4. Blocked motor housing vents. 5. Motor being strained by long or small diameter extension cord. 1. Allow machine to work at its own rate. 2. Check and correct accessory to table alignment. 3. Keep cutting accessories sharp. Replace as needed. 4. Wear ANSI-approved safety goggles and NIOSH- approved dust mask/respirator while blowing dust out of motor using compressed air. 5. Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See Extension Cords in GROUNDING section. Drill bit burns or smokes 1. Incorrect spindle speed 2. Dull drill bit 3. Drilling too slowly 4. Lacking lubrication 1. Change spindle speed 2. Replace with new bit 3. Drill faster 4. Lubricate cutting area Drill bit wobbles 1. Bent bit 2. Worn Spindle Bearings 3. Drill bit not in Chuck correctly 4. Chuck not properly installed 1. Replace drill bit 2. Replace spindle bearings 3. Reinstall drill bit 4. Reinstall Chuck and Arbor assembly Feed Wheel returns slowly, or too fast Tension Spring not in adjustment Adjust Tension Spring. Drill bit binds 1. Workpiece pinching drill bit 2. Dull drill bit 3. Feed pressure too hard 4. Belts loose 1. Reposition workpiece, lubricate drill 2. Replace drill bit 3. Pull Feed Handle slowly. 4. Adj...