Ellis 9400 User manual

Ellis Drill Press
Model 9400
Instruction Manual
M f g . C o M p a n y , I n C .

1
POWER FEED DRILL PRESS
Innitely Variable Speed
Model 9400
Operation Manual
July 16, 2010
Contents Page Number
Preface 2
Installation Instruction 2
Safety Warnings 3
Machine Parameters 4
Speed Change 4
Variable Speed Control 4-5
Power Train 5
Depth of Drilled Hole 6
Drill Chuck and Taper Shank Drill Attachment 7
Removing Drill Chuck or Drill from Spindle 7
Drill Speed and Usage 7
Elevating, Rotating and Clamping the Table 7-8
Lubrication 8-9
Maintenance 9
Parts List 10-12
Trouble Shooting 13
Variable Speed Change, Hi-Lo Pulley 14-15
PATENTED
P.O. Box 930219
Verona, WI 53593-0219
Phone: [phone]
Toll Free: 800-383-5547
Fax [phone]
www.ellissaw.com
M f g . C o M p a n y , I n C .

2
PREFACE
IMPORTANT: READ LUBRICATION INSTRUCTIONS ON PAGE 8
BEFORE USING THIS MACHINE
This machine is suitable for drilling, reaming or thread cutting in metal, wood or plastic. The reversing
feature allows the removal of a thread cutting tap. It is widely used for short part runs or high production.
Read the instruction manual carefully for the operation and maintenance of this machine. Keep the
machine in a good operational condition and keep it clean. The machine is powered by a 110-Volt single-
phase line voltage but the control box (4830) powers a 3-phase, 220-Volt electrical motor at innitely
variable speeds. Some machines are furnished with a control box (4831) for 220 Volt, single phase in
and 220 Volt 3-phase out. The control box was programmed at the factory. The program should not be
changed by the operator.
INSTALLATION INSTRUCTION
The Ellis Variable Speed Drill Press is crated and shipped completely assembled. Check for any transit
damage at the time you accept delivery. Surfaces that are not painted are protected with a lm of heavy
oil during shipment. Remove this oil after uncrating. It is VERY important to remove this oil from the
inside taper bore using mineral spirits or paint thinner by twisting a rag up into the bore.
1. After uncrating, place the drill press on a at, solid oor and within reach of the power cord to a 110-
Volt, 60 HZ Single Phase grounded power outlet. (Some machines are built for 220-Volt single phase.)
Make certain that the supply Voltage is 110 Volt (220-Volt). A long extension cord or a low supply
Voltage can cause serious problems. The wire connections at the terminals have to be reliably tight.
Do not plug into a power receptacle until the rest of the installation is nished.
Warning:
Adapters, extension cords and surge protectors should not be used with this product. Also a GFCI (Ground
Fault Circuit Interrupter) protected receptacle cannot be used. It is recommended to use a 20 amp, 115-
Volt, AC dedicated circuit.
2. If the oor is uneven and the drill press rocks, place shims under the base to remove any motion. For
light work the machine can stand on the oor by itself. It is advisable to bolt the machine to the oor
when large work pieces are drilled. Four openings are provided in the column base for foundation bolts.
3. For optimum performance the Variable Speed Control assembly is preset at the factory. The circuit is
protected by two fast blow ceramic fuses.
Do not tamper with the wiring or settings inside the Variable Speed Control Box.

SAFETY
DISCONNECT THE POWER CORD FROM THE WALL OUTLET BEFORE ANY MAINTENANCE.
CONTROL BOX AND MOTOR
1. Do not open the Control Box. Tampering with the wiring or setting will void the warranty. The circuit
board is not eld repairable. Do not touch or adjust anything without calling Ellis Manufacturing Co. for
instructions. The circuits in the control box are not isolated. Elements of the circuit board are at 230 Volt.
Direct contact with these circuits can cause serious injury.
2. The control circuit is not fail-safe. A disconnect at the wall outlet is the only way to reliably disable the control.
3. While power is ON or for some time after power-OFF, do not touch the inverter since the inverter will be
extremely hot. Doing so can cause burns.
WARNING
• While power is ON or when the inverter is running, do not open the front cover. Otherwise you may get an
electric shock.
• Do not run the inverter with the front cover or wiring cover removed. Otherwise you may access the exposed
high voltage terminals or the charging part of the circuitry and get an electric shock.
• Even if power is OFF, do not remove the front cover except for wiring or periodic inspection. You may access
the charged inverter circuits and get an electric shock.
• Before wiring or inspection, power must be switched OFF. To conrm that, LED indication of the operation
panel must be checked. (It must be OFF.) Any person who is involved in wiring or inspection shall wait for at
least 10 minutes after the power supply has been switched OFF and check that there are no residual voltage
using a tester or the like. The capacitor is charged with high voltage for some time after power OFF, and it is
dangerous.
• This inverter must be earthed (grounded). Earthing (grounding) must conform to the requirements of national
and local safety regulations and electrical code (NEC section 250, IEC 536 class 1 and other applicable
standards). A neutral-point earthed (grounded) power supply for 400V class inverter in compliance with EN
standard must be used.
• Any person who is involved in wiring or inspection of this equipment shall be fully competent to do the work.
• The inverter must be installed before wiring. Otherwise you may get an electric shock or be injured.
• Setting dial and key operations must be performed with dry hands to prevent an electric shock. Otherwise
you may get an electric shock.
• Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Otherwise you may get an
electric shock.
• Do not change the cooling fan while power is ON. It is dangerous to change the cooling fan while power is ON.
• Do not touch the printed circuit board with wet hands. Otherwise you may get an electric shock.
• When measuring the main circuit capacitor capacity, the DC voltage is applied to the motor for 1s at powering
OFF. Never touch the motor terminal, etc. right after powering OFF to prevent an electric shock.
3

OPERATING SAFETY
1. Always wear safety glasses
2. Do not wear gloves, necktie, loose clothing, jewelry or other items that may get caught in moving parts. Long
hair should be tied up and under a cap.
3. Do not hold the part to be drilled by hand. Clamp the work or brace it against the drill press column to prevent
rotation or use the Safety Drill Press Vise; see the enclosed installation sheet about the Safety Drill Press
Vise. Two T-Slots are provided in the table and column base to aid clamping.
4. Use recommended speeds that are proper for the drill, the material being drilled and accessories used.
5. Make a habit of removing the chuck key, drift key and other wrenches after their use.
6. Keep hands and ngers clear of the drill bit or cutter.
7. Shut off the power before removing the drill bit or cutting tool.
8. Do not try cutting or similar operations by moving the table or the head stock with respect to each other. Be
sure that the head stock and table are securely clamped to the column.
9. Be sure the drill bit or cutting tool is securely clamped in the chuck.
10. Keep belt guard in place and closed.
11. Do not operate the machine beyond its capacity and possibly overload the power train.
12. Maintain the machine regularly, keep it clean and keep a maintenance and lubrication log.
MACHINE PARAMETERS
Maximum drill diameter 1.062" steel; 1.25" cast iron
Tapping capacity 3/4"-10 NC
Maximum spindle travel 5.38"
Spindle inner taper Morse #3
Spindle speed Variable, 0-1200 rpm
Size of table 15.88" x 17.88" or 16.50" Dia.
Size of base 16.38" x 26.62"
Power feed rate per spindle revolution .004"
Diameter of column 4.0"
Diameter of quill 3.0"
Spindle travel 5.75"
Spindle to table 27.25"
Maximum distance spindle nose to base surface 46.25"
Drills to center 18.12"
Motor 2 HP
Net weight 675 LB
Overall size 20" W x 29"D x 69.5"H
SPEED CHANGE
A quick Speed (Torque) Range change can
be accomplished with the Ellis HI-Lo Handle
on the right side of the machine. (See the
enclosed instruction sheet.) Note: The motor
must rotate at a moderate speed to change the
operating speed range selection. The variable
speed control can vary the speed innitely
within each speed (Torque) range setting
which is explained in the next paragraph.
LOW SPEED HIGH TORQUE OPERATION
It is highlly recommended to shift into low using
the “Ellis High/Low Shift” For big drills, tapping
and hole saws see pages 14 and 15 for more information.
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5
ELECTRICAL CONTROL BOX
Set up
DO NOT PLUG INTO A GFI CIRCUIT.
Start Turn the BIG RED EMERGENCY button clockwise (in the direction of the arrows) so that the button will
pop out and the read out window will light up. Turn the Forward/Reverse switch to the reset position then to the
desired direction of forward or reverse.
Set Button The small (middle) white SET button changes the read-out display in the number window. When
the letter “A” lights up beside the window it shows the ampere draw of the motor. The voltage is shown when
there is no letter on display.
Speed Push the small white SET button until you see the letters “HZ”. Now the read-out window displays the
frequency in cycles/seconds. That feature controls the speed of the motor. This is NOT the RPM of the spindle
but represents a reference that is relative to the spindle speed. (120 HZ = 100% of the spindle speed)
Speed Change The BLACK button in the upper left hand corner regulates the spindle speed. It works in both
the forward and reverse mode. Spinning the black knob in the the upper left corner regulates the spindle speed.
A clockwise rotation of the knob increases spindle speed in both the forward and reverse directions.
Forward Switch Position Use the Forward Switch Position for standard drilling, tapping and hole saw cutting.
Reverse Switch Position Use the Reverse Switch Position to retract a tap or to tap a left hand thread. Keep
downward pressure on the feed handle when backing a tap out of the work piece.
Stop/Reset Switch Position This setting stops the motor from either forward or reverse rotation. Use this as
the STOP switch while operating the drill press during the day. Reset to the position after a power outage or
after hitting the BIG RED EMERGENCY BUTTON.
Stop The BIG RED button stops the machine and automatically disconnects the machine from electrical
power after a time delay of about twenty seconds. Use this as the Power Off switch at the end of the day.
Note: Avoid stalling the spindle and stopping the motor under
power; the resulting current surge can damage the electronic
components in the control box. Turn Power off immediately
in a stalled motor condition. Clear the jam mechanically.
Repeated stalling abuse is detectable and can lead to voiding
the warranty.
4767 4819

6
POWER TRAIN
Spindle Speed
The motor drives the middle pulley and the spindle pulley by a V-Belt. The spindle pulley drives the
spindle and the taper sleeve. The spindle speed is variable by means of the variable speed control box
or with Ellis Hi-Lo handle. Forward and reverse rotation of the spindle is selected on the control box
panel. If you have any problems with this, call the factory.
Power Feed and Manual Feed
Spindle feed can be accomplished in two modes: manual and by power. Manual Feed is accomplished
by turning the turn style (8474) at the right side of the head stock. Pulling any of the two turn styles
to the right engages the power feed and returning it to the left stops the power feed. The thumbscrew
(7027) must be loosened to engage the power feed, and tightening this thumbscrew prevents the
machine from actually engaging in the power mode. Use the power feed only when the spindle
rotates in the CW (clockwise) rotation. Do not use power feed in the tapping mode.
DEPTH OF DRILLED HOLE
Do not use the depth dial for through holes: unlock the locking clamp on the face of the depth dial.
Proceed as described in the following for drilling holes to preset depth:
1. Stop the spindle rotation. Loosen the locking handle on the depth scale hub. Lower the drill end to
the desired drill depth by turning the turn style. Turn the dial CCW (counter clockwise) as you face
the end of the turn style hub. Lock the locking clamp when the dial comes to a stop.
2. Note: When drilling through holes, place a block of wood or scrap piece of metal under the work
piece to prevent drilling into the table or use an Ellis Safety Drill Press Vise.
3. The machine is equipped with a power feed overload clutch. The overload clutch protects the feed
power train from damage if too high a feed rate or too high a spindle speed is used. The overload clutch
disengages when you hear a clicking noise. Reduce the feed rate or spindle speed when this occurs.
The overload torque at which the clutch disengages can be increased by turning the adjustment
screws clockwise and can be decreased by turning the adjustments screw counterclockwise. There
are two adjustment screws in the pulley groove at 180 degree from one another.
Note: Do not tighten the screws too far because
a solid spring cannot let the ball escape from
the groove in the shaft. In this case the overload
clutch would be rendered useless and damage
can occur. To set the maximum torque: turn each
set screw until tight and then back them out by two.

DRILL CHUCK AND TAPER SHANK DRILL ATTACHMENT
The size of the taper to be used with this machine is a Morse # 3 Taper. It is important to wipe the inside
taper in the spindle and the outside of the chuck taper or drill taper clean of oil or dirt. Insert the arbor
into the spindle and twist to align the tang with the slot in the spindle then thrust upward sharply to seat
the chuck. Follow the same procedure for a taper shank drill or accessory. A wood hammer can assist in
doing this.
REMOVING DRILL CHUCK OR DRILL FROM SPINDLE
Loosen the locking handle on the depth scale collar. Lower the quill until the slot is completely uncovered.
Grasp the locking handle and turn the collar CW (clockwise) as you face the end of the style handle body.
Lock the handle securely when the collar comes against a stop. Turn the spindle until its slot lines up with
the one in the quill. Insert the drift key into the slot. Hold the chuck or drill with one hand while tapping on
the drift key with a hammer.
DRILL SPEEDS AND USAGE
The speed at which the drill has to rotate for efcient cutting depends on the type of material being
worked and the diameter of the drill. Use a squirt bottle to add cutting oil (uid) to the drill. Retract the drill
often when deep holes are drilled; this removes chips. Use a low Spindle Speed (Torque) for tapping a
threaded hole. Use a heavy oil or thread cutting uid to lubricate the tap. Reverse the spindle rotation with
the reverse switch on the variable speed control panel to retract the tap.
ELEVATING, ROTATING AND CLAMPING THE TABLE
The table can rotate 360 degrees and move up and down on the column. Loosen both clamp screws,
rotate the table in the required position, elevate the table by means of the elevation handle and tighten
both clamp screws again.
7

LUBRICATION
The power feed gear box at the right side of the head stock has a grease tting. Another grease tting is
at the left side near the sight window, see next page.
LUBRICATION SCHEDULE
Location Suggested Lubricant Frequency
Grease Nipple Lithium Grease N.L.G.I. # 2 Daily or twice daily under heavy use
Under light use, grease at least every other day. It is much more important that you grease the
machine frequently than to worry about the type of lubricant used. Do not mix synthetic and
mineral base oils.
8

Maintenance
Keep table and sliding parts clean of dirt and chips. Every 3 months lower the quill, wipe clean and oil
lightly. If raising the table becomes difcult, clean and wipe the column with light machine oil. The ball
bearings in the motor, quill and V-Belt pulleys are lubricated for life. Keep the cooling ns of the speed
control box and the motor clean and free of dirt and dust.
The chart below identies the bearings in the various locations. The Ellis Part Number is required for
replacement orders.
No. Bearing Type Location Part No. Size Qty.
1 Deep Grove Spline-Taper Sleeve 4490 45 x 75 x 16 2
2 Deep Grove Quill 4491 30 x 55 x 13 1
3 Ball Thrust Quill 4492 35 x 52 x 12 1
4 Deep Grove Quill 4493 35 x 72 x 17 1
5 Deep Grove Middle Sheave 4494 17 x 40 x 12 2
6 Deep Grove Single Thread Worm 4495 20 x 42 x 12 1
7 Deep Grove Single Thread Worm 4495 20 x 42 x 12 1
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10

4058 Hex Head Cap Screw
4144 Set Screw
4146 Socket Set Screw
4260 Hex Nut
4346 Lock Washer
4487 Ball Bearing (15 x 32 x 9)
4530 Knob
4831 Control Box, 230 Volt
4646 Hilo Pulley
4647 Motor
4830 Control Box, 115 Volt
4938 V-Belt-Upper, Power Feed
4939 V-Belt-Lower, Front Drive
4943 V-Belt, Rear Drive
5059 Label
7027 Thumb Screw
8077 Ring
8081 Set Screw
8104 Range Position Bolt
8107 Range Position Tube
8115 Shift Handle
8127 Control Box Mount Plate
8401 Base
8402 Column Collar
8403 Rack
8404 Column
8405 Gear
8406 Elevating Handle
8407 Clamp Screw
8409 Worm
8410 Square Table
8411 Spindle
8412 Nut
8413 Thrust Plate
8414 Worm Cover
8415 Quill
8416 Counter Block
8417 Worm, single thread
8418 Shaft
8419 Head Stock
8423 Spring Cap
8429 Spiral Spring and Cover Assembly
8430 Spacer
8431 Cover
8432 Spindle Shaft
8433 Worm Base
8434 Spindle Pulley
8435 Overload Compression Spring
8436 Nut
8437 Feed Pulley
8438 Overload Cover
8439 Handle Hub
8440 Dial
8441 Key
8442 Table Bracket
8443 Clamp Screw
8445 Pin, Spring
8446 Pin, Pawl
8447 Middle Sheave
8449 Middle Sheave Spacer
8452 Worm Cover
8453 Worm, Double Thread
8454 Shim Plate
8455 Gear
8457 Transmission Shaft
8458 Gear
8459 Base
8460 Hub
8461 Bevel Gear
8462 Pawl
8464 Spring
8465 Plate
8466 Feed Box
8467 Block
8468 Feed Label, Power
8469 Feed Label, Manual
8470 Worm Housing
8471 Lock Screw
8472 Lock Handle
8473 Washer
8474 Turn Style
8476 Swivel Base
Number Name Number Name
Parts List, 9400 Drill Press
11

12

Problem Probable Cause Remedy
Motor Does Not Run Power cord not plugged into source Plug into receptacle
Power not “ON” at Speed Control Box Push “RUN” Button
Speed knob in “0” position Turn knob CW for more speed
Main switch fuse blown Replace fuse
Motor too hot, heat switch tripped Wait for motor to cool off
Power cord plugged into GFCI protected
outlet
Plug into an unprotected outlet preferably a
dedicated circuit of 20 amp, 115 VAC
Power cord not plugged into correct outlet Power cord of a 115 V single phase machine
has to be plugged into a 115 V outlet. A cord
of a 230 single phase machine has to be
plugged into a 230V outlet.
Noisy Operation Incorrect belt tension Adjust tension
Loose spindle or motor pulley Tighten set screw
Belt is too tight Reduce belt tension
Spindle bearing worn Replace spindle ball bearing
Spindle Not Moving Up Return spring may be broken Replace spiral spring
Drill Bit Smokes Or Is Burnt Incorrect speed Change speed
Chips are not coming out of hole Retract bit frequently to clear out chips
Dull drill bit Sharpen or replace drill bit
Feed too slow Increase feed to allow bit to cut
Needs lubrication Lubricate with cutting uid
Drill is running in reverse Change motor rotation
Excessive Drill Run Out Bent drill Replace drill
Chuck jaws not clamping evenly Install drill correctly
Worn spindle bearings Replace ball bearings
No Power Feed Worm gear worn Replace worm gear
Overload protection device not working Tighten springs with set screws
Pawl clutch is worn Replace pawls
Feed belt is sliding Tighten belt
Turn style does not move sideways Loosen thumb screw #7027
Hole Depth Not Correct Depth dial not clamped Tighten dial lock
Worm gear or quill worn Replace gear
Drill Not Rotating Taper on chuck slips in spindle Remove grease and oil from inside taper
bore in spindle and outside of taper on
chuck. Use mineral spirits.
Spindle Not Rotating In
Correct Rotation
Switch on control box may not be in
correct position
Use forward switch for standard drilling and
cutting. Use reverse switch to retract a tap
or tapping for left-hand threads.
13
TROUBLESHOOTING

MODEL 9400
ELLIS VARIABLE SPEED DRILL PRESS
WITH QUICK SPEED RANGE CHANGE
Ellis Mfg. Company, Inc. • PO Box 930219 • Verona, WI 53593-0219 • 1-800-383-5547
14

Operating Instructions
Note: The motor must be moving at a moderate speed to change the spindle speed
and the operating speed range selection.
• Stand next to the drill press facing toward the motor end of the drill press. Grasp the Motor Handle that is
attached to the Motor Mounting Plate and raise it to a horizontal position with your right hand. See sketch
above.
• Push forward on the handle just enough to relieve the pressure on the Range Position Bolt. Refer to the
sketch above. Raise the Bolt Lever out of the position locking slot if the bolt is not in the High Speed position.
• Push the motor and the Range Position Bolt forward to reduce the spindle speed and increase the torque.
Moving the Range Position Bolt and the motor in the opposite direction will increase the spindle speed.
Make sure that the Bolt Lever is fully seated in the locking slot when in the MID RANGE or HIGH TORQUE
positions.
MACHINE SPEED CONTROL CAPABILITY
Note: The speed range changes on the Ellis Variable Speed Drill Press are made conveniently. Each Speed
range position provides a maximum speed limit. The complete speed variation from zero to the maximum
of each range is made electronically using the speed control knob on the Ellis Variable Speed Control box.
• High Speed, 0 to approximately 1200 RPM range. This is the range best suited for small drills.
• Mid range, 0 to approximately 800 RPM speed. This is the general purpose drilling range. Most would want
to leave the selector in this position.
• High Torque or Low Speed, 0 to approximately 450 RPM. This range provides the highest torque. Use it for
larger drills and taps and for cutting large holes using Hole Saws.
Ellis Mfg. Company, Inc. • PO Box 930219 • Verona, WI 53593-0219 • 1-800-383-5547
15