Grizzly G0453 owner's manual: Section 6: maintenance

SECTION 6: MAINTENANCE

WARNING Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious personal injury.

Schedule

For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.

Note: This maintenance schedule is based on average daily usage. Adjust the maintenance schedule to match your usage to keep your planer running smoothly and to protect your investment.

Every 8 Hours of Operation:

• Clean machine and protect unpainted cast iron.
• Lubricate feed rollers bushings (Page 31).
• Tighten loose mounting bolts.
• Check/sharpen/replace damaged or worn knives (Page 36).
• Check/repair/replace worn or damaged wires.
• Resolve any other unsafe condition.

Every 40 Hours of Operation:

• Clean cutterhead and check knife height (Page 36).
• Lubricate table columns and leadscrews (Page 31).

Every 160 Hours of Operation:

• Check/tension/replace V-belts (Page 37).
• Clean/vacuum dust buildup from inside cabinet and off motor.
• Lubricate table height worm gear (Page 31).
• Lubricate table height chain and sprockets (Page 32).
• Lubricate drive chain and sprockets (Page 32).

Yearly:

• Change gearbox oil (Page 32).

Cleaning & Protecting

Vacuum excess wood chips and sawdust from the outside of the machine, inside the cabinet, and off the motor. Protect the unpainted cast iron surfaces on the table by wiping the table clean after every use—this ensures moisture from wood dust does not remain on bare metal surfaces.

Keep tables rust-free with regular applications of products like G96® Gun Treatment, SLIPIT®, or Boeshield® T-9 (see Section 5: Accessories on Page 29 for more details)..

-30- G0453/G0454 (Mfg. Since 3/08)

Lubrication

NOTICE

Failure to followed reasonable lubrication practices as instructed in this manual for your machine could lead to premature failure of components and void the warranty.

Your planer features bearings that are lubricated and sealed at the factory. These bearing do not require any further attention unless they need to be replaced. If a bearing fails, your planer will probably develop a noticeable rumble or vibration, which will increase when the machine is under a load. The bearings are standard sizes and can be replaced through Grizzly (refer to the Parts Breakdowns beginning on Page 49 for bearing identification).

Follow the maintenance schedule on Page 30 and the procedures listed below to properly lubricate the other planer components, which are essential for long life and trouble-free operation of your planer.

Feed Roller Bushings

The infeed and outfeed rollers rotate inside bushing blocks on both ends of the rollers. Add 2–3 drops of SAE 30W oil to the center hole of the four feed roller tension adjustment bolts on top of the head casting, as shown in Figure 27.

Figure 27. Lubrication locations for the feed roller bushings.

Columns and Leadscrews

The table rides on the columns and is moved by the rotation of the leadscrews inside the columns. For Model G0454, loosen the dust sleeve (see Figure 28) to access the columns and leadscrews. Apply a thin coat of SAE 30W oil to the outside surface of the columns and brush on a light application of multi-purpose grease to the leadscrew threads. Move the table up and down to distribute the lubricant.

Column Dust Sleeve Figure 28. Model G0454 column dust sleeve.

Table Height Worm Gear

Remove the three cap screws that secure the worm gear housing (see Figure 29), then lift the housing and handwheel assembly off the machine. Clean away any debris from the housing and gears, then brush on a moderate amount of multi-purpose grease to the gear teeth.

Worm Gear Housing Figure 29. Location of the table height worm gear housing.

Table Height Chain & Sprockets

The table leadscrews are synchronized by the table height chain and sprockets located underneath the base of the planer. Remove the front and rear cabinet panels to access these parts (see Figure 30). Use shop rags and mineral spirits to clean away debris and grime, then brush on a light coat of multi-purpose grease to the chain and sprockets.

Figure 30. Table height chain and sprockets as viewed from underneath the base.

Drive Chain & Sprockets

The infeed and outfeed rollers receive the transferred power from the cutterhead through the drive chain system on the right side of the machine, as shown in Figure 31.

Remove the table height handwheel and the safety covers attached to the inside of the drive chain cover, then remove the cover to access these parts.

Use shop rags and mineral spirits to clean away any debris and grime, then brush on a light coat of multi-purpose grease to the chain and sprockets.

Figure 31. Drive chain and sprockets.

Gearbox Oil

The gearbox oil should be changed after the first 20 hours of operation to clear away any debris inside the gearbox, then changed annually thereafter.

Although it is not necessary to remove the drive chain cover to access the fill and drain plugs, it is more convenient to do so (see Figures 32–33). Replace the gearbox oil with 80W–90W gear oil until it just reaches the fill plug.

Drain Plug

Figure 32. Gearbox drain plug.

Fill Plug

Figure 33. Gearbox fill plug.

SECTION 7: SERVICE

Review the troubleshooting procedures in this section if a problem develops with your machine. If you need replacement parts or additional help with a procedure, call our Technical Support. Note: Please gather the serial number and manufacture date of your machine before calling.

Troubleshooting

Motor & Electrical

Motor & Electrical (continued)

Machine Operation

Machine Operation (continued)

Setting/Replacing Knives

CAUTION Planer knives are extremely sharp and can quickly cause a serious injury to your hands or fingers. Always wear heavy leather gloves when handling these knives to reduce the risk of cutting injuries.

Setting the height of the knives correctly is crucial to the proper operation of your planer and is very important in keeping the knives sharp. If one knife protrudes higher than the others, it will do the majority of the work, dull much faster, and produce poor cutting results.

The knife gauge that is included with the Model G0453/G0454 is designed to set the knives 0.059" higher than the cutterhead surface.

Note: If you need to replace or sharpen a knife, you can remove the knife from the cutterhead during Step 4 of the following procedure. Thoroughly clean out any debris from the knife slots before replacing the knives.

Replacement knives are available through Grizzly (refer to Page 28 for options).

Tools Needed

• Hex Wrench 2.5mm (G0453) ........ 1
• Wrench 10mm (G0453) ........ 1
• Hex Wrench 3mm (G0454) ........ 1
• Wrench 12mm (G0454) ........ 1
• Knife Gauge ........ 1

To adjust the height of the knives:

1. DISCONNECT PLANER FROM POWER!
2. Remove the dust hood and the top cover to expose the cutterhead.
3. Remove the belt cover, then rotate the cutterhead pulley to give you good access to one of the knives.

Note for G0454 Only: The cutterhead for the Model G0454 ships with both springs and jack screws to adjust the knife height (see Figure 34)—which one you use is up to your personal preference. However, you should remove the components that you will not use from the cutterhead before proceeding.

Loosen Tighten Knife Jack Screw (G0454 Only) Gib Spring Gib Bolt Figure 34. Cutterhead components (G0454 cutterhead shown).

4. If you have not already done so, loosen the cutterhead gib bolts until the knife is completely loose, then position the knife gauge over the knife so that the knife edge is directly under the center pad, as shown in Figure 35.

Center Pad Knife Gauge Figure 35. Knife gauge correctly positioned over the knife (G0453 cutterhead shown).

-36- G0453/G0454 (Mfg. Since 3/08)

5. Jack Screws (G0453 & G0454): Insert the hex wrench into the jack screws through the access holes in the cutterhead (see Figure 36). Rotate the jack screws to raise or lower the knife until it barely touches the center pad of the knife gauge with all legs of the gauge still firmly on the cutterhead, then snug the gib bolts enough to hold the knife in place.

Figure 36. Jack screw access hole in the cutterhead.

Springs (G0454 Only): Push down on the knife gauge until all legs of the gauge are firmly on the cutterhead and the knife just touches the center pad of the gauge, then tighten the gib bolts enough to hold the knife in place.

6. Slightly tighten the gib bolts, starting at the middle and working your way to the ends by alternating left and right, as illustrated in Figure 37.

Figure 37. Gib bolt tightening sequence.

7. Repeat Step 6.

8. Repeat Step 6, but final tighten the gib bolts.

9. Repeat Steps 4–8 for the rest of the knives.

V-Belt Tensioning/ Replacement

NOTICE

After the first 16 hours of use, the V-belts will stretch and seat into the pulley grooves. The V-belts must be properly re-tensioned after this period to avoid severely reducing their useful life.

Three cogged V-belts transfer power from the motor to the cutterhead, and then to the infeed and outfeed rollers with the use of the drive chain system. To ensure efficient transfer of power to these systems, make sure the V-belts are always properly tensioned and in good condition.

If the V-belts are worn, cracked, or damaged, replace them. Always replace the V-belts with a matched set of three, or belt tension may not be even among the belts, causing premature belt failure.

Tools Needed Qty

• Phillips Screwdriver ........ 1
• Wrench 19mm ........ 1

To tension/replace the V-belts:

1. DISCONNECT PLANER FROM POWER!

CAUTION

V-belts and pulleys will be hot after operation. Allow them to cool before handling them.

2. Remove the V-belt cover from the left side of the machine to expose the belts, as shown in Figure 38.

Note: A collection of black belt dust at the bottom of the belt cover is normal during the life of the belts.

Cutterhead Pulley Motor Pulley V-Belts G0453 Figure 38. Belt cover removed to expose the V-belts and pulleys.

3. Remove the front cabinet panel to access the motor, as shown in Figure 39.

Motor Mount Hex Nuts Figure 39. Front cabinet cover removed to expose the motor.

4. If the V-belts need to be replaced, raise the motor to release the belt tension (refer to the next step for instructions), roll them off the pulleys, then replace them as a matched set of 3.

5. To adjust the V-belt tension, loosen the top motor mount hex nuts (see Figure 39), then adjust the bottom hex nuts to raise or lower the motor.

Note: The V-belts are correctly tensioned when there is approximately 3/4" deflection when moderate pressure is applied to them midway between the pulleys, as illustrated in Figure 40.

Approximately 3/4" Deflection Cutterhead Pulley Motor Pulley Figure 40. Belt deflection when V-belts are correctly tensioned.

6. When the V-belts are correctly tensioned, make sure the motor mount hex nuts are tight, then replace the cabinet cover and the belt cover.

Table Height Chain Tension

The table height chain transfers movement from the elevation handwheel to the columns that control table height. The chain drive can be adjusted to remove slack if the chain stretches over time or is loosened during table leveling procedures.

Tools Needed

• Phillips Screwdriver #2 ........ 1
• Wrench or Socket 12mm ........ 1

To adjust the table height chain tension:

1. DISCONNECT PLANER FROM POWER!
2. Remove the front and rear cabinet panels to gain access to the chain system, as shown in Figure 41.

Idler Sprocket Lock Bolts ON OFF

Figure 41. Table height idler sprocket and lock bolts (viewed from underneath the planer base).

NOTICE

During the next step, DO NOT let the chain fall off the sprockets. It can be very difficult to return the chain to its proper location on the sprockets without changing the table adjustments.

3. Loosen the lock bolts shown in Figure 41, and push the idler sprocket against the chain with moderate hand pressure, then while maintaining the pressure on the idler sprocket, re-tighten both lock bolts.
4. Clean and lubricate the chain and sprockets (refer to Table Height Chain & Sprockets on Page 32 for detailed instructions).

Feed Rollers, Chip Breaker & Pressure Bar Heights

It is essential that the feed rollers, chip breaker, and pressure bar are set at the correct distance below the cutterhead to ensure that the workpiece moves through the planer evenly and the correct distance from the cutterhead knives.

To ensure accurate results and make the adjustment process quicker and easier, we recommend using a Rotacator for these adjustments (refer to Page 28).

If a Rotacator is not available, a 6' 2x4 cut into two even sized pieces and a feeler gauge set can be used, but care must be taken when jointing the wood to achieve accurate results.

Dist. Below Knife Edge at BDC (Figure 42)

• A. Infeed Roller ........ 0.040"
• B. Chip Breaker ........ 0.040"
• C. Pressure Bar ........ 0.008"
• D. Outfeed Roller ........ 0.020"

Figure 42. Planer component recommended clearances (illustration is not to scale).

Using a Rotacator

Tools Needed

• Hex Wrenches 3, 5mm ........ 1 Each
• Wrench or Socket 10mm ........ 1
• Rotacator (see Page 28) ........ 1

1. DISCONNECT PLANER FROM POWER!
2. Make sure the knives are set to the correct height (refer to Setting/Replacing Knives on Page 36 for detailed instructions).
3. Lower the table at least 4" below the head casting, then lock it in place.
4. Remove the dust hood, top cover, and belt cover.
5. Using your Rotacator, find the BDC of any knife edge by slowly rocking the cutterhead pulley back and forth, then set the Rotacator dial to zero (see Figure 43).

Figure 43. Using a Rotacator to find BDC.

-40- G0453/G0454 (Mfg. Since 3/08)

6. Move the feed speed knob to the neutral position to allow the infeed roller to freely rotate.

7. Keeping the Rotacator dial at zero, position it under the right-hand side of the infeed roller and find the BDC of a serrated edge by rocking the infeed roller back and forth.

8. Loosen the jam nut and use the set screw shown in Figure 44 to adjust the height of the infeed roller bushing block until the Rotacator dial shows 0.040", which is the recommended distance for the infeed roller below the cutterhead.

Figure 44. Infeed roller bushing block and height adjustment controls.

9. Repeat Steps 7–8 on the left-hand side of the infeed roller.

10. Re-check both sides of the infeed roller and, if necessary, make further adjustments until the infeed roller height from side-to-side is 0.040" below the BDC of the cutterhead knife, then re-tighten both jam nuts.

11. Keeping the same zero reference on the Rotacator dial from Step 5, repeat Steps 7–10 for the outfeed roller, but adjust it until it is 0.020" below the BDC of the cutterhead knife.

12. Use the same zero reference on the Rotacator dial from Step 5, perform similar steps as described above to adjust the height of the chip breaker to its recommended specification given at the beginning of this subsection. The adjustment controls are shown in Figure 45.

Figure 45. Adjusting the chip breaker height.

13. Model G0454 Only: Repeat Step 12 for the pressure bar height adjustment. The adjustment controls are shown in Figure 46.

Figure 46. Adjusting the pressure bar height.

14. Re-install the belt cover, top cover, and the dust hood.

Using Wood Blocks

Tools Needed

1. Build the wood blocks by cutting a straight 6' foot long 2x4 in half.

Note: Having the wood blocks at an even height is critical to the accuracy of your overall adjustments. For best results, make the 2x4 square with a jointer and table saw before cutting it in half.

2. Make sure the knives are set to the correct height (refer to Setting/Replacing Knives on Page 36 for detailed instructions).

3. DISCONNECT PLANER FROM POWER!

4. Lower the bed rollers below the table surface (refer to Bed Roller Height on Page 26 for detailed instructions).

5. Place the wood blocks along the sides of the table, as illustrated in Figure 47.

Figure 47. Wood blocks properly positioned on the planer table.

6. Remove the dust hood, top cover, and belt cover.

7. Use a feeler gauge to adjust the table until there is a 0.040" gap between the wood blocks and a cutterhead knife at BDC, which is the recommended distance for the infeed roller below the cutterhead knife.

8. Lock the table in place, as the wood blocks will now be your reference point.

9. Using the feeler gauges and the wood blocks instead of the Rotacator, perform Steps 8–14 in the previous Using a Rotacator procedure to set the feed rollers, chip breaker, and the pressure bar to the correct distance below the cutterhead knives.

Note: Keep in mind that you will have to repeat Steps 7–8 above for each change in distance as specified on Page 40.

-42- G0453/G0454 (Mfg. Since □/□□)

Roller Spring Tension

The infeed and outfeed rollers keep the workpiece moving through the planer. There are springs that exert downward pressure on the rollers while still allowing them to raise with an uneven workpiece surface. Properly roller spring tension is crucial to keep the workpiece moving through the planer during operation.

Roller spring tension will vary depending upon the type of wood you are planing. When adjusting the roller spring tension keep the following in mind:

• If you are planing milled lumber with a relatively consistent surface, use less spring tension.
• If you are planing rough lumber with inconsistent surfaces, use greater spring tension to keep the stock moving through the planer.
• If the workpiece consistently stops feeding during operation, the roller spring tension may need to be increased.

Tools Needed Qty

• Hex Wrench 6mm ........ 1

To adjust the roller spring tension to factory recommendations:

1. DISCONNECT PLANER FROM POWER!
2. Adjust tension cap screws #1–#3 so that they protrude $1/8"$ above the head casting, and adjust cap screw #4 so that it protrudes $5/16"$ above the head casting (see Figure 48).

Figure 48. Roller spring tension adjustment cap screws.

G0453/G0454 (Mfg. Since 3/08)

Positioning Chip Deflector

• Chip Deflector Gap Setting ........ $1/4"$

When properly distanced from the cutterhead, direct the chips into the dust hood, and keeps them from falling onto the outfeed roller and being pressed into the workpiece.

Tools Needed Qty

• Wrench or Socket 10mm ........ 1
• Fine Ruler or Calipers ........ 1

To adjust the chip deflector gap:

1. DISCONNECT PLANER FROM POWER!
2. Remove the dust port, top cover, and belt cover.
3. Use the cutterhead pulley to rotate the cutterhead until a knife reaches the closest distance to the chip deflector (see Figure 49), then measure the distance between the knife and the chip deflector.

Figure 49. Chip deflector and securing hex bolts.

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4. If the distance measured in Step 3 is not equal to 1/4", then loosen the four hex bolts that secure the chip deflector and adjust the gap to 1/4".

5. Re-tighten the hex bolts, then replace the belt cover, top cover, and dust hood.

Scale Calibration

Although correctly set at the factory, the scale can be adjusted for accuracy if it becomes necessary.

Tools Needed

To re-position the scale:

1. Plane the scrap piece of stock until it is flat and of even thickness along its length.

   Note: Turn the board over between each pass.

2. Use calipers to measure the board thickness.

3. If there is a discrepancy between the board thickness and the reading on the table height scale, loosen the two screws shown in Figure 50, adjust the scale in relation to the pointer, then re-tighten the screws.

Figure 50. Table height scale.

Anti-Kickback Fingers

The anti-kickback fingers are an important safety feature of your planer. The fingers hang from a rod suspended across the head casting and in front of the infeed roller, as shown in Figure 51. This design allows the workpiece to easily enter the planer but reduces the risk of kickback by digging into the workpiece if it moves backward.

Figure 51. Anti-kickback fingers.

Check the anti-kickback fingers regularly to ensure they swing freely and easily. If the fingers do not swing freely and easily, first clean them with a wood resin solvent, then inspect them for damage. If any of the fingers are damaged, the device must be replaced before using the machine.

Do not apply oil or other lubricants to the anti-kickback fingers that will attract dust, and restrict the free movement of the fingers.

WARNING

Proper operation of the anti-kickback fingers is critical for the safe operation of this planer. DO NOT operate the planer if the anti-kickback fingers are not operating correctly. Failure to heed this warning could result in serious personal injury.

-44- G0453/G0454 (Mfg. Since □/□□)

Pulley Alignment

Proper pulley alignment prevents premature V-belt wear and unnecessary load on the motor. The pulleys are properly aligned when they are parallel and in the same plane as each other.

Tools Needed

• Straightedge 3' ........ 1
• Hex Wrench 6mm ........ 1
• Wrenches or Sockets 14mm ........ 1

To check/re-align pulleys:

1. DISCONNECT PLANER FROM POWER!
2. Remove both cabinet covers and the belt cover, then use the straightedge to check pulley alignment, as shown in Figure 52.

Figure 52. Checking pulley alignment.

—If the pulleys are not in the same plane, loosen the cap screw or hex bolt securing the pulley to the shaft, then adjust the pulleys in or out until they are aligned.

—If the pulleys are not parallel, loosen the four motor mount hex nuts, then rotate the motor on its mount until the pulleys are parallel.

3. Re-check the pulleys and repeat Step 2 if necessary.
4. When your are satisfied with the pulley alignment, re-tighten all fasteners, then replace the belt cover and cabinet covers.