Continued...
It should be noted at this point that the installation manual is particularly vague regarding the installation of the Y-Axis Powerfeed. Essentially the instructions consist of a miniaturized vertical cross-section drawing of the installed Powerfeed and directions to - in so many words -
"follow the instructions for the X-Axis Powerfeed; except where it's different."
This looks like one of the different places.
Sure enough, in one of the parts bags was this Extension.
I threaded the Extension onto the existing shaft.
A black arrow in the first picture of the Extension (above) points to a keyway that led me on a wild goose chase for most of the day.
Obviously the keyway in the original shaft and the keyway in the Extension didn't line up. Since I assumed "There can be only one!", I proceeded to try to figure out how that would work for quite a while.
Reference the above picture to see all the players in this adventure.
The Extension is on the left. The parts from top to bottom on the right are:
1. A Roll Pin.
2. A short (12mm) 3mm x 3mm Feather Key that was in the parts bag.
3. A long (25mm) 3mm x 3mm Feather Key that was original to the Mill.
Let's start with the Roll Pin...
The instructions effectively just say to "drill and fit roll pin". No indication as to what the size of the hole should be. The X-Axis installation did not have a roll pin (I'm supposed to refer to the X-Axis instructions for the Y-Axis installation). The Z-Axis installation DID have a roll pin installed in a drilled 5mm hole.
I assumed that is what I needed to do here... drill a 5mm hole. Fortunately I decided to check the diameter of the provided roll pin with my calipers. The calipers indicated the roll pin was .169" or 4.29mm in diameter.
Hmmm... a 5mm hole seems excessive for a 4.29mm roll pin. Time spent on the internet didn't really seem to provide a suitable hole size for this roll pin. The closest I came across was 5/32" hole size and this pin was a little above max size for that.
Plus I measured this Roll Pin at .694" and the shaft it is supposed to be in is 5/8" (.625"). So I've been struggling to figure out what I'm doing wrong with determining the right hole size for this Roll Pin. I may check out the hardware store for a 5/8" long pin of an appropriate diameter and use that.
Now we move on to the two Feather Keys. As I mentioned I assumed the original long key would not be used and only the shorter key would be used. Both the Bevel Gear and the Handle are broached for a key so I assumed the short key needed to engage both of them.
The length of the keyway in the Extension is bit over 20mm and the short key was only 12mm. While the short key COULD be positioned in the middle of this keyway to catch both the Bevel Gear and the Handle, it didn't seem right.
My assumption was I needed a 20mm long 3mm x 3mm Feather Key to fit into the Extension's keyway.
My local Hardware Store didn't have any Feather Keys let alone metric ones.
I spent quite a bit of Google time trying to find a 3mm x 3mm x 20mm Feather Key. From the time I spent on the computer, it seems my best bet for this item would be to drop by a hardware store next time I had a London layover.
Giving up on finding a longer Feather Key, I decided to check JET Machines web site to see if they had updated the installation manual for the Powerfeed. I went to the manuals section of their site and located an Acrobat file of the manual. I was hoping the manual might have been updated to include a hole size for the Roll Pin.
Hey! This is cool! The manual is a high enough resolution that I can actually enlarge and properly see the cutaway drawing of the Y-Axis Powerfeed...
...and the cutaway is showing BOTH Feather Keys on the shaft.
As Homer Simpson would say, "Doahh!!"
I placed the long key in the keyway of the original shaft and slide the Bevel Gear on. Then I could see how keyway in the Extension could receive the short key and, despite the "too long" keyway, be trapped in place and engage the Handle.
So a lot of wasted mental energy today but I think I can move forward on the installation now.
Scott