4/5/2015:
The Spindle Pulley Assembly
Based on the questions I've received and the posts I've seen, the spindle pulley assembly is probably the most difficult and misunderstood part of disassembly.
Attempting to remove the pulley without knowing how can result in a bad day. The picture on the left is an example of a pulley that was likely pried up from the top side in an attempt to remove it.
The picture on the right is the original pulley from my drill press #1. The bottom step was cleanly cut off, likely because it was also broken during a removal attempt.
____________________Photo courtesy of src60.
When snap rings are seen on the pulley inside the head frame, it is often assumed that one or both of those must be removed to get the pulley out. Under normal circumstances, this is not necessary.
This can be the result of removing the inner snap ring. I won't say it's wrong, but IMO, it sure seems much more difficult than it needs to be.
Photos "borrowed" from PICAH.
Spindle Pulley Removal steps:
1. Remove the head frame from the column.
2. Remove the quill assembly from the head frame.
3. Remove the two screws from the outside of the head frame on opposite sides of the pulley.
These screws are parts #58 in the exploded diagram above. These screws are the only thing securing the assembly into the head frame (besides dirt, dust, dried grease, gunk, etc.). The screws are threaded into the head frame and extend into the bearing cavity just above the lower bearing. They simply prevent the assembly from lifting out when the spindle is lowered and raised. They are not set screws pressing on the outer race of the bearing.
Below are a couple
King-Seeley patent drawings. The drawing on the left shows the spindle pulley assembly installed with the screws in place. The drawing on the right shows the pulley assembly partially removed.
These drawings show the quill/spindle assembly installed. When disassembling the drill press, the quill/spindle assembly should be removed prior to the spindle pulley assembly.
Depending on the condition of those screws, they may not back out. I've had screws break halfway out, bent screws, screw threads worn from the bearing, and the screwdriver slots strip out. If they are the original 8-32 screws, they
should snap while tapping out the pulley without damaging the pulley.
The bottom screw in the picture below is bent and has worn threads. It did back out, but took a little effort.
4. Pull the pulley assembly out from the top.
It should pull out with a little effort. Referring to patent drawing Fig 2 above, there are two bearings (blue) and two machined cylinders in the head frame (yellow). After the pulley is partially removed and the bearings are free from their installed position, the assembly will be loose within the head frame. It must be realigned correctly so the lower bearing can also pass through the upper bearing location.
4a. If the assembly does not pull out easily, insert a long wooden dowel or furring strip (12"-16") into the quill opening from the bottom and tap out the pulley with a hammer. A LFH should do the job just fine.
Again, the lower bearing must be realigned correctly to pass through the upper bearing location.
5. Remove the outer snap ring #5 from the top side with needle nose pliers.
The outer snap ring is only used so the lower spindle pulley bearing has something to bottom-out on. Some models are equipped with a split ring instead of a snap ring.
Under normal circumstances, the inner snap ring #4 stays on the pulley assembly during removal. I've never had the need to remove the pulley assembly in pieces.
10/25/2015:
Removing the spindle pulley bearings
Now that the spindle pulley assembly is safely removed from the head frame, the bearings may be removed.
When originally installed at the factory, the spindle bearings and spacer were simply slid onto the pulley shaft and held in place with the inner snap ring. The tolerance was very small, but the bearings were not pressed on.
Over time, two obstacles developed that prevent the bearings from sliding off the shaft. First, grease, oil, and dirt will harden and glue the inner race to the pulley shaft. Second, the inner snap ring will somewhat burr the snap-ring groove preventing the bearings from sliding off.
In most cases a puller of some sort is required to remove the bearings. However, most puller jaws are too large to reach into the underside of the pulley to grab the upper bearing.
I don't have a welder or lathe, but here's a simple and effective puller I made with bits and pieces I had on hand. I did buy two new 5/16" x 5" carriage bolts. Total cost was $1.16. Pictures tell the story.