Grizzly G0453 owner's manual: Section 3: setup

SECTION 3: SETUP

Needed for Setup

The following are needed to complete the setup process, but are not included with your machine:

Unpacking

Your machine was carefully packaged for safe transportation. Remove the packaging materials from around your machine and inspect it. If you discover the machine is damaged, please immediately call Customer Service at (570) 546-9663 for advice.

Save the containers and all packing materials for possible inspection by the carrier or its agent. Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the condition of your shipment, inventory the contents.

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Inventory

The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them.

If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store.

Box Inventory: (Figure 5)

• A. Planer (Not Shown) ........ 1
• B. Dust Hood ........ 1
• C. Foot Pedal ........ 1
• D. Handwheel ........ 1
• E. Caster ........ 1
• F. Extension Wings ........ 2

G0453 Hardware and Tools (not shown)

• Set Screws M8-1.25 x 20 (Wings) ........ 4
• Hex Bolts M8-1.25 x 30 (Wings) ........ 6
• Flat Washers 8mm (Wings) ........ 6
• Lock Washers 8mm (Wings) ........ 6
• Handwheel Bushing ........ 1
• Handwheel Handle ........ 1
• Hex Nut M12-1.75 (Handwheel) ........ 1
• Flat Washer 12mm (Handwheel) ........ 1
• Hex Bolts M6-1 x 10 (Dust Hood) ........ 3
• Flat Washers 6mm (Dust Hood) ........ 6
• Hex Nuts M6-1 (Dust Hood) ........ 3
• Cap Screws M8-1.25 x 20 (Dust Hood) ........ 3
• Hex Wrenches 2.5, 3, 4, 6mm ........ 1 Each
• Wrenches 10/12, 14/17, 17/19mm ........ 1 Each
• Knife Gauge ........ 1

G0454 Hardware and Tools (not shown)

• Set Screws M8-1.25 x 20 (Wings) ........ 6
• Hex Bolts M8-1.25 x 30 (Wings) ........ 6
• Flat Washers 8mm (Wings) ........ 6
• Lock Washers 8mm (Wings) ........ 6
• Handwheel Bushing ........ 1
• Handwheel Handle ........ 1
• Hex Nut M12-1.75 (Handwheel) ........ 1
• Flat Washer 12mm (Handwheel) ........ 1
• Flange Bolts M6-1 x 12 (Dust Hood) ........ 6
• Hex Wrenches 3, 4, 5, 6mm ........ 1 Each
• Wrenches 8/10, 12/14, 17/19mm ........ 1 Each
• Knife Gauge ........ 1

Figure 5. Model G0453/G0454 inventory.

NOTICE

If you cannot find an item on this list, carefully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpacking or they are pre-installed at the factory.

Cleanup

The unpainted surfaces of your machine are coated with a heavy-duty rust preventative that prevents corrosion during shipment and storage. This rust preventative works extremely well, but it will take a little time to clean.

Be patient and do a thorough job cleaning your machine. The time you spend doing this now will give you a better appreciation for the proper care of your machine's unpainted surfaces.

There are many ways to remove this rust preventative, but the following steps work well in a wide variety of situations. Always follow the manufacturer's instructions with any cleaning product you use and make sure you work in a well-ventilated area to minimize exposure to toxic fumes.

Before cleaning, gather the following:

• Disposable rags
• Cleaner/degreaser (WD•40 works well)
• Safety glasses & disposable gloves
• Plastic paint scraper (optional)

Basic steps for removing rust preventative:

1. Put on safety glasses.
2. Coat the rust preventative with a liberal amount of cleaner/degreaser, then let it soak for 5–10 minutes.
3. Wipe off the surfaces. If your cleaner/degreaser is effective, the rust preventative will wipe off easily. If you have a plastic paint scraper, scrape off as much as you can first, then wipe off the rest with the rag.
4. Repeat Steps 2–3 as necessary until clean, then coat all unpainted surfaces with a quality metal protectant to prevent rust.

WARNING Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. Avoid using these products to clean machinery.

CAUTION Many cleaning solvents are toxic if inhaled. Only work in a well-ventilated area.

NOTICE Avoid harsh solvents like acetone or brake parts cleaner that may damage painted surfaces. Always test on a small, inconspicuous location first.

T23692—Orange Power Degreaser A great product for removing the waxy shipping grease from the non-painted parts of the machine during clean up.

Call 1-800-523-4777 To Order

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Site Considerations

Weight Load

Refer to the Machine Data Sheet for the weight of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.

Space Allocation

Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual. See below for required space allocation.

! CAUTION Children or untrained people may be seriously injured by this machine. Only install in an access restricted location.

Physical Environment

The physical environment where the machine is operated is important for safe operation and longevity of machine components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions. Extreme conditions for this type of machinery are generally those where the ambient temperature range exceeds 41°–104°F; the relative humidity range exceeds 20%–95% (non-condensing); or the environment is subject to vibration, shocks, or bumps.

Electrical Installation

Place this machine near an existing power source. Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or other hazards. Make sure to leave enough space around machine to disconnect power supply or apply a lockout/tagout device, if required.

Lighting

Lighting around the machine must be adequate enough that operations can be performed safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated.

Model G0453 X = 42" Y = 28"

Model G0454 X = 55-5/8" Y = 36-5/8"

Figure 6. Minimum working clearances.

Lifting & Moving Base Unit

WARNING The Model G0453/G0454 is a heavy machine. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use power equipment to move the shipping crate and remove the machine from the crate.

The cabinet stand on the Model G0453/G0454 planer is equipped with four lifting bars that pull out in order to lift and place the planer, as shown in Figure 7.

Figure 7. Lifting the planer with a forklift.

Tip: When positioning the lift forks, place shop rags or cardboard between the forks and the cabinet stand to avoid scratching the paint.

Assembly

To assemble your planer:

1. Install M8-1.25 x 20 set screws in the holes in the bottom of the wings (see Figure 8).

Figure 8. Front extension wing installed (Model G0454 shown).

2. Attach the table extension wings to the planer table with the M8-1.25 x 30 hex bolts, 8mm lock washers, and 8mm flat washers, as shown in Figure 8, but do not fully tighten the bolts at this time.

3. Using a straightedge as a guide and the set screws for leveling control, position the extension wings even with the table, then fully tighten the hex bolts.

Note: Be aware that the bed rollers will give you a false reading with your straightedge if they are raised above the table. Move them down or work around them when leveling the extension wings.

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4. Place the bushing on the handwheel shaft.
5. Insert the key into the shaft keyway.
6. Screw the handle into the handwheel.
7. Place the handwheel on the shaft and secure it with the M12-1.75 hex nut and 12mm flat washer, as shown in Figure 9.

Figure 9. Installing the table height handwheel.

8. Model G0453: Attach the dust hood to the top of the planer with the M6-1 x 10 hex bolts, 6mm flat washers, and M6-1 hex nuts as shown in Figure 10, then attach the bottom of the dust hood to the planer with the M8-1.25 x 20 cap screws.

Note: You will need to reach into the dust hood to get access for fastening the nuts.

Figure 10. Dust hood attached.

Model G0454: Attach the dust hood with the provided M6-1 x 12 flange bolts.

9. Remove the two cap screws already installed on the left-hand side of the head casting.
10. Attach the switch bracket with the two cap screws, as shown in Figure 11.

Figure 11. Attaching magnetic switch.

NOTICE

Before starting your machine, you must make sure the gearbox has the proper amount of oil to avoid machine damage.

11. Remove the gearbox fill plug (see Figure 12).

Figure 12. Gearbox fill plug.

12. Using the short end of a clean hex wrench, dip it inside the fill hole and remove it.

—If the end of the hex wrench is coated with oil, then the gearbox oil level is okay. Replace the fill plug and skip to the next section.

—If the end of the hex wrench is not coated with oil, then you need to add more oil. Refer to Page 32 for instructions on how to do this.

NOTICE Replace the gearbox oil after the first 20 hours of operation. This is a normal break-in procedure.

13. Remove the pin and hex bolt that are already mounted in the foot pedal bracket.

14. Align the caster assembly with the mounting holes in the foot pedal bracket.

15. Insert the hex bolt into the hole in the back side of the caster assembly, and tighten the bolt just enough for it to be snug without hampering the pivot action of the caster.

16. Install the foot pedal to the caster and secure together by inserting the pin between the two parts.

17. Lock the caster and pedal in place with the E-clip and washers, as shown in Figure 13.

Pin, E-Clip & Washers Hex Bolt & Nut Bracket Caster Foot Pedal Figure 13. Foot pedal and caster installed.

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Dust Collection

CAUTION DO NOT operate the Model G0453/G0454 without an adequate dust collection system. This planer creates substantial amounts of wood dust while operating. Failure to use a dust collection system can result in short and long-term respiratory illness.

Recommended CFM at Dust Port

• G0453 ........ 400 CFM
• G0454 ........ 625 CFM

Do not confuse this CFM recommendation with the rating of the dust collector. To determine the CFM at the dust port, you must consider these variables: (1) CFM rating of the dust collector, (2) hose type and length between the dust collector and the machine, (3) number of branches or wyes, and (4) amount of other open lines throughout the system. Explaining how to calculate these variables is beyond the scope of this manual. Consult an expert or purchase a good dust collection "how-to" book.

Check Gearbox Oil

It is critical that you make sure there is oil in the gearbox before proceeding with the test run. Refer to the Lubrication instructions for the gearbox on Page 32 for more details on which type of oil to use, how much to use, and where to put it.

Test Run

Once the assembly is complete, test run your machine to make sure it runs properly and is ready for regular operation. The test run consists of verifying the following: 1) The motor powers up and runs correctly and 2) the stop button safety feature works correctly.

If, during the test run, you cannot easily locate the source of an unusual noise or vibration, stop using the machine immediately, then review Troubleshooting on Page 33.

If you cannot find a remedy, contact our Tech Support at (570) 546-9663 for assistance.

WARNING Before starting the planer, make sure you have performed the preceding assembly and adjustment instructions, and you have read through the rest of the manual and are familiar with the various functions and safety features on this machine. Failure to follow this warning could result in serious personal injury or even death!

To test run the machine:

1. Make sure you understand the safety instructions at the beginning of the manual and that the machine is set up properly.
2. Make sure all tools and objects used during set up are cleared away from the machine.
3. Make sure the gearbox has the correct amount of oil (refer to Gearbox Oil on Page 32 for detailed instructions).

4. Push the OFF button in, then twist it clockwise so it pops out. When the OFF button pops out, the switch is reset and ready for operation (see Figure 14).

Figure 14. Resetting the switch.

5. Verify that the machine is operating correctly by pushing the ON button. —When operating correctly, the machine runs smoothly with little or no vibration or rubbing noises. —Investigate and correct strange or unusual noises or vibrations before operating the machine further. Always disconnect the machine from power when investigating or correcting potential problems.

6. Press the OFF button to stop the machine.

7. WITHOUT resetting the switch, press the ON button. The machine should not start. —If the machine does not start, the OFF button safety feature is working correctly. The Test Run is complete. —If the machine does start (with the OFF button pushed in), immediately disconnect power to the machine. The OFF button safety feature is not working correctly. This safety feature must work properly before proceeding with regular operations. Call Tech Support for help.

Re-Tension V-Belts

The final step of the setup process must be done after approximately 16 hours of operation. During this period, the V-belts will stretch and seat into the pulley grooves and need to be properly tensioned to avoid severely reducing the life of the V-belts. Refer to V-Belts on Page 37 for detailed instructions.

Recommended Adjustments

For your convenience, the adjustments listed below have been performed at the factory.

However, because of the many variables involved with shipping, we recommend that you at least verify the following adjustments to ensure the best possible results from your new machine.

Step-by-step instructions for these adjustments can be found in the SERVICE section starting on Page 33.

Factory adjustments that should be verified:

• Table height chain tension (Page 39).
• Chip breaker height (Page 40).
• Pressure bar height (Page 40).
• Infeed/outfeed roller height (Page 40).
• Roller spring tension (Page 43).
• Chip deflector positioning (Page 43).

SECTION 4: OPERATIONS

WARNING To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations.

Operation Overview

The purpose of this overview is to provide the novice machine operator with a basic understanding of how the machine is used during operation, so the machine controls/components discussed later in this manual are easier to understand.

Due to the generic nature of this overview, it is not intended to be an instructional guide. To learn more about specific operations, read this entire manual, seek additional training from experienced machine operators, and do additional research outside of this manual by reading "how-to" books, trade magazines, or websites.

To complete a typical operation, the operator does the following:

1. Examines the workpiece to make sure it is acceptable for planing.
2. Puts on safety glasses or a face shield, a respirator, and ear protection.
3. If necessary, uses a jointer to make one surface of the workpiece flat.
4. Correctly adjusts the worktable height for the operation.
5. If the workpiece is longer than can be supported by the planer table, arranges for assistance or roller accessories to support the workpiece.
6. When all safety precautions have been taken, turns the planer ON, then sets the correct feed rate for the operation.
7. Stands to one side of the planer path to reduce the risk of kickback injuries, then, with the flat surface of the workpiece facing down, feeds the workpiece into the planer until the infeed roller grabs it.
8. Once the workpiece is clear of the outfeed roller, turns the planer OFF.

WARNING Damage to your eyes, lungs, and ears could result from using this machine without proper protective gear. Always wear safety glasses, a respirator, and hearing protection when operating this machine.

WARNING Loose hair, clothing, or jewelry could get caught in machinery and cause serious personal injury. Keep these items away from moving parts at all times to reduce this risk.

NOTICE If you have never used this type of machine or equipment before, WE STRONGLY RECOMMEND that you read books, review industry trade magazines, or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.

Planing Tips

• Use the full width of the planer. Alternate between the left, the right and the middle of the table when feeding lumber into the planer. Your knives will remain sharp much longer.
• Scrape all glue off of joined boards before planing. Dried glue is extremely hard on the knives.
• Plane ONLY natural wood fiber. Do not plane wood composites or other materials that could break up in the planer and cause operator injury or property damage.
• To avoid chipping, plane the workpiece with the grain. NEVER feed end-cut or end-grained lumber into your planer.
• Keep your work area clear to help ensure safe working conditions.
• Always true any cupped or warped stock on a jointer before planing and feed the workpiece into the planer with the flat face down. This will ensure the workpiece will not rock or twist as it goes through the planer.
• When possible, plane both faces of the workpiece so that they will be parallel with one another.

Workpiece Inspection

Some workpieces are not safe to use or may require modification before they are. Before cutting, inspect all workpieces for the following:

• Material Type: This machine is only intended for workpieces of natural wood fiber Attempting to use workpieces of any other material that may break apart during operation could lead to serious personal injury and property damage.
• Foreign Objects: Inspect lumber for defects and foreign objects (nails, staples, imbedded gravel, etc.). If you have any question about the quality of your lumber, DO NOT use it. Remember, wood stacked on a concrete floor can have small pieces of stone or concrete pressed into the surface.
• Large/Loose Knots: Loose knots can become dislodged during operation. Large knots can cause kickback and machine damage. Always use workpieces that do not have large/loose knots.
• Wet or "Green" Stock: Avoid using wood with a high water content. Wood with more than 20% moisture content or wood exposed to excessive moisture (such as rain or snow), will cut poorly and cause excessive wear to the machine. Excess moisture can also hasten rust and corrosion of the machine and/or individual components.
• Excessive Warping: Workpieces with excessive cupping, bowing, or twisting are dangerous to cut because they are unstable and often unpredictable when being cut. DO NOT use workpieces with these characteristics!
• Minor Cupping: Workpieces with slight cupping can be safely supported if the cupped side is facing the table. On the contrary, a workpiece supported on the bowed side will rock during operation and could cause severe injury from kickback.

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Wood Hardness

The species of wood, as well as its condition, greatly affects the depth of cut the planer can effectively take with each pass.

The chart in the figure below shows the Janka Hardness Rating for a number of commonly used species. The larger the number, the harder the workpiece, and the less material should be removed in any one pass for good results.

Note: The Janka Hardness Rating is expressed in pounds of force required to embed a 0.444" steel ball into the surface of the wood to a depth equal to half the ball's diameter.

Figure 15. Janka Hardness Rating for some common wood species.

Feed Rate

The infeed and outfeed rollers move the workpiece through the planer while keeping it flat and providing a consistent rate of movement. The speed that these rollers move the workpiece through the planer is known as the feed rate.

Generally, low feed rates are used for dimensioning passes, while higher feed rates are used for finishing passes.

Figure 16 illustrates the three different positions of the feed rate control knob:

• Push the knob in to use the high feed rate (30 FPM for Model G0453, and 20 FPM for Model G0454).
• Pull the know out to use the low feed rate of 16 FPM.
• Move the knob to the center position to place the gearbox in neutral.

Figure 16. Feed rate control knob positions.

NOTICE

Only change the feed rate when the planer is running, but DO NOT attempt to change the feed rate during any cutting operations or damage to the gearbox will result.

G0453/G0454 (Mfg. Since □/□□) -25-

Depth of Cut

The depth of cut on a planer means the amount of material that is removed from the top of the workpiece as it passes underneath the cutterhead.

The depth of cut is set by adjusting the distance of the table below the cutterhead. This distance is the thickness of the workpiece minus the depth of cut.

Although the correct depth of cut varies according to wood hardness and workpiece width, we recommend a maximum depth of cut no more than 1/16". A series of light cuts will give better end results and put less stress on the planer than trying to take off too much material in a single pass.

The planing depth of cut is controlled by using the table height handwheel on the right side of the machine. Rotating the handwheel clockwise raises the table.

The depth of cut is read directly from the inch/millimeter scale on the front of the planer, as shown in Figure 17.

One complete turn of the handwheel raises or lowers the table approximately 1/16". The range of material thickness that can be planed is 3/16"–8".

Table Height Handwheel

Depth of Cut Indicator & Scale

Figure 17. Depth of cut indicator and scale.

Bed Roller Height

• Bed Roller Height Range ........ 0.002"–0.020"

The correct height of the bed rollers will vary, depending on the type of material you intend to plane. However, as a general rule, keep the bed roller height within 0.002"–0.020" above the table surface, as illustrated in Figure 18.

Table

0.002"–0.020"

Roller

Figure 18. Recommended bed roller height above the table surface.

When planing rough stock, set the rollers high to keep the lumber from dragging along the bed. When planing milled lumber, set the rollers low to help minimize snipe.

To ensure accurate results and make the adjustment process quicker and easier, we recommend using a Rotacator (refer to Page 28) to gauge the bed roller height from the table surface. If a Rotacator is not available, a straightedge and feeler gauges can be used, but care must be taken to achieve accurate results.

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NOTICE

Bed rollers that are not adjusted to the correct height or out of alignment with each other can cause poor finishes, inconsistent planing thickness, and other undesirable results.

Tools Needed

To adjust the bed rollers:

1. DISCONNECT PLANER FROM POWER!
2. Lower the table all the way to give yourself room to work.
3. Loosen the set screws above each of the four roller adjustment hex bolts (see Figure 19).

Figure 19. Bed roller height controls.

4. Rotate the eccentric adjustment hex bolts to raise or lower the bed rollers until they are the desired height above the table surface.
5. Verify that both sides of each roller are at the same height, then re-tighten the four set screws to secure the setting.
6. Re-check the roller heights to make sure they did not change when you secured them.

—If the roller heights are not correct, repeat this procedure until they are.

SECTION 5: ACCESSORIES

WARNING Some aftermarket accessories can be installed on this machine that could cause it to function improperly, increasing the risk of serious personal injury. To minimize this risk, only install accessories recommended for this machine by Grizzly.

NOTICE Refer to the newest copy of the Grizzly Catalog for other accessories available for this machine.

Call 1-800-523-4777 To Order

G1738—Rotacator™ Precision Planer Tool The Rotacator is a dial indicator on a magnetic base and is designed for quickly and accurately setting the critical tolerances needed when adjusting any planer, so that nasty surprises such as non-parallel and chattered cuts can be eliminated. Helps adjust infeed/outfeed rollers, pressure bars, chip breakers, and bed rollers. Also a great setup tool for other machines! Accurate to 0.001". Indicator rotates 360°

Figure 20. Rotacator™ Precision Planer Tool.

include dust collector

G6701—HSS Replacement Knives for Model G0453, Set of 3 G6702—HSS Replacement Knives for Model G0454, Set of 4

G2790—Universal Knife Grinder This dry-type Knife Grinder is ideal for sharpening planer and jointer knives. High quality cast iron construction, together with large knife holding capacity (will sharpen up to 20" planer/jointer knives) makes this grinder an excellent investment. Features a heavy-duty 1/2 HP 110V motor, knife holding angle adjustable from 20° to 70°, and adjustable-height 120 grit grinding wheel.

Figure 21. G2790 Universal Knife Grinder.

H7768—15" Byrd® Shelix Cutterhead H7768—20" Byrd® Shelix Cutterhead Made in the USA by Byrd, this indexable carbide insert cutterhead is the best money can buy—period! The inserts are not only placed in a spiral pattern, they are also positioned at an angle so the shearing action leaves a glassy smooth cut on the toughest and most figured woods. Comes with 5 extra replacement inserts. Great upgrade!

Figure 22. Byrd® Shelix Cutterhead.

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T20501—Face Shield Crown Protector 4" T20502—Face Shield Crown Protector 7" T20503—Face Shield Window T20448—Economy Clear Safety Glasses T20452—"Kirova" Anti-Reflective Glasses T20456—"Dakura" Clear Safety Glasses H0736—Shop Fox® Safety Glasses These glasses meet ANSI Z87.1-2003 specifications. Buy extras for visitors or employees. You can't be too careful with shop safety!

Figure 23. Our most popular eye protection.

G8982—Roller Table Use this versatile roller table wherever you need extra workpiece support. Features all steel welded construction and measures 19" x 65" long. Comes with 9 ball bearing rollers and has four independently adjustable legs for any leveling requirement Adjustable in height from 26-3/8" to 44-1/8".

Figure 24. SHOP FOX® Roller Table.

H9155—Dispoz-A-Blade® System 15" (Includes 3 Holders & Knife Inserts) G5858—Dispoz-A-Blade® Knife Inserts 15" HSS (Set of 3) H9156—Dispoz-A-Blade® System 20" (includes 4 Holders & Knife Inserts) G5859—Dispoz-A-Blade® Knife Inserts 20" HSS (Set of 4) Install a Dispoz-A-Blade® Knife system in your new planer and save up to 70% on knife replacements for the life of your machine. Each knife insert is double-edged, so you get two knives in one, and is indexed so that all knife inserts can be installed at the same height in just minutes. Yes, that means you can throw away the knife gauge!

Figure 25. Dispoz-A-Blade® Holder and Knife.

G5562—SLIPIT® 1 Qt. Gel G5563—SLIPIT® 12 oz Spray G2871—Boeshield® T-9 12 oz Spray G2870—Boeshield® T-9 4 oz Spray H3788—G96® Gun Treatment 12 oz Spray H3789—G96® Gun Treatment 4.5 oz Spray

Figure 26. Recommended products for protecting unpainted cast iron/steel part on machinery.