1.KEEP GUARDS IN PLACE and in working order.

2.REMOVE ADJUSTING KEYS AND WRENCHES. Form a habit of checking to see that keys and adjusting wrenches are removed from tool before turning on.

3.KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

4.NEVER USE IN DANGEROUS ENVI- RONMENT. DO NOT use power tools in damp or wet locations, or where any flam- mable or noxious fumes may exist. Keep work area well lighted.

-2-

5.KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept at a safe distance from work area.

6.MAKE WORKSHOP CHILD PROOF with padlocks, master switches, or by removing starter keys.

7.NEVER FORCE TOOL. It will do the job better and safer at the rate for which it was designed.

8.USE RIGHT TOOL. DO NOT force tool or attachment to do a job for which it was not designed.

Ultimate Series Jointers

9.USE PROPER EXTENSION CORD. Make sure your extension cord is in good condi- tion. Conductor size should be in accor- dance with the chart below. The amperage rating should be listed on the motor or tool nameplate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Your extension cord must also contain a ground wire and plug pin. Always repair or replace extension cords if they become damaged.

Minimum Gauge for Extension Cords

10.WEAR PROPER APPAREL. DO NOT wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair cover- ing to contain long hair.

11.ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resis- tant lenses, they are NOT safety glasses.

12.SECURE WORK. Use clamps or a vise to hold work when practical. It???s safer than using your hand and frees both hands to operate tool.

13.DO NOT OVER-REACH. Keep proper foot- ing and balance at all times.

14.MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubri- cating and changing accessories.

15.USE RECOMMENDED ACCESSORIES.

Consult the owner???s manual for recom- mended accessories. The use of improper accessories may cause risk of injury.

16.REDUCE THE RISK OF UNINTENTION- AL STARTING. On machines with magnet- ic contact starting switches there is a risk of starting if the machine is bumped or jarred. Always disconnect from power source before adjusting or servicing. Make sure switch is in OFF position before reconnecting.

17.CHECK DAMAGED PARTS. Before fur- ther use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, bind- ing of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

18.NEVER LEAVE TOOL RUNNING UNAT-

TENDED. TURN POWER OFF. DO NOT leave tool until it comes to a complete stop.

19.NEVER OPERATE A MACHINE WHEN

TIRED, OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL. Full mental alert- ness is required at all times when running a machine.

20.NEVER ALLOW UNSUPERVISED OR

UNTRAINED PERSONNEL TO OPER- ATE THE MACHINE. Make sure any instructions you give in regards to machine operation are approved, correct, safe, and clearly understood.

21.IF AT ANY TIME YOU ARE EXPERIENC- ING DIFFICULTIES performing the intend- ed operation, stop using the machine! Then contact our service department or ask a qualified expert how the operation should be performed.

1.JOINTING SAFETY BEGINS with your lumber. Inspect your stock carefully before you feed it over the cutterhead. If you have any doubts about the stability or structural integrity of your stock, DO NOT JOINT IT!

2.MAINTAIN PROPER RELATIONSHIPS of infeed and outfeed table surfaces and cut- terhead knife path.

3.ALWAYS USE A PUSH BLOCK when jointing. Never place your hands directly over the cutterhead.

4.SUPPORT THE WORKPIECE adequately at all times during operation, and maintain control over the work at all times.

5.WHEN JOINTING, DO NOT stand directly at the end of either table. Position yourself just to the side of the infeed table to protect yourself from possible kickbacks.

6.NEVER MAKE JOINTING CUTS deeper than 1???8".

7.NEVER JOINT A BOARD that has loose knots. All defects should be cut out of the board before it is planed or jointed.

8.NEVER JOINT end grain.

9.JOINT WITH THE GRAIN. Jointing against the grain is dangerous and could produce chatter or excessive chip out , which could lead to loss of control over the workpiece.

10.WITH THE EXCEPTION OF RABBETING, all operations must be performed with the guard in place. After rabbeting, be sure to replace the guard.

11.NEVER BACK THE WORK toward the infeed table. If a cut must be interrupted, lift the workpiece clear of the cutterhead.

12.HABITS ??? GOOD AND BAD ??? are hard to break. Develop good habits in your shop and safety will become second-nature to you.

13.???KICKBACK??? is when the workpiece is thrown off the jointer table by the force of the cutterheads. Always use pushblocks and safety glasses to reduce the likelihood of injury from ???kickback.??? If you do not understand what kickback is, or how it occurs, DO NOT operate this machine.

14.PROLONGED EXPOSURE TO WOOD

DUST IS KNOWN TO CAUSE CANCER IN HUMANS. Always wear an OSHA- approved respirator when working in an environment that could contain wood dust.

No list of safety guidelines can be complete. Every shop environment is different. Always consider safety first, as it applies to your individual working conditions. Use this and other machinery with caution and respect. Failure to do so could result in serious per- sonal injury, damage to equipment or poor work results.

Like all power tools, there is danger asso- ciated with the jointers. Accidents are fre- quently caused by lack of familiarity or fail- ure to pay attention. Use this tool with respect and caution to lessen the possibil- ity of operator injury. If normal safety pre- cautions are overlooked or ignored, seri- ous personal injury may occur.

Lack of familiarity with this manual could cause serious person- al injury. Become familiar with the con- tents of this manual, including all the safety warnings.

We are proud to offer the Model G9953 16" Ultimate Series Jointers and the Model G4815 20" Ultimate Series Jointer. These jointers are part of a growing Grizzly family of fine woodwork- ing machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation and proof of Grizzly???s commitment to customer satisfaction.

The main differences in the models are shown in the chart below. All three machines are built to withstand the rigors of heavy-duty production use. For more complete information about each machine, see Section 9: Reference Info.

We are pleased to provide this manual with the Model G9953 16" Ultimate Series Jointers and the Model G4815 20" Ultimate Series Jointer. It was written to guide you through assembly, review safety considerations, and cover general operating procedures. It represents our effort to produce the best documentation possible.

If you have any comments regarding this manual, please write to us at the address below:

Grizzly Industrial, Inc.

C/O Technical Documentation

P.O. Box 2069

Bellingham, WA 98227-2069

Most importantly, we stand behind our machines. If you have any service questions or parts requests, please call or write us at the location listed below:

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901 E-Mail: techsupport@grizzly.com Web Site: http://www.grizzly.com

The specifications, drawings, and photographs illustrated in this manual represent the Model G9953 16" Ultimate Series Jointers and the Model G4815 20" Ultimate Series Jointer as sup- plied when the manual was prepared. However, owing to Grizzly???s policy of continuous improve- ment, changes may be made at any time with no obligation on the part of Grizzly. Current Grizzly machine manuals can be viewed and printed at: www.grizzly.com.

Model

G9953/G9953ZX

Voltage & Amperage Draw

The Model G9953/G9953ZX features a 5 HP motor and is wired to operate on a single-phase, 220V circuit. The motor will draw the following load:

Plug Type

The cord set enclosed does not have a plug as the style of plug you require will depend on the type of service you currently have or plan to install. We recommend using the following plugs for your machine on a dedicated circuit only (see Figure 1 for an example).

Figure 1. NEMA-style L6-20 plug and outlet.

Circuit Breaker Requirements

Use the following guidelines when choosing a cir- cuit breaker (circuit breakers rated any higher are not adequate to protect the circuit):

Your Circuit Capacity

Always check to see if the wires in your circuit are capable of handling the amperage draw from your machine, as well as any other machines that could be operating on the same circuit. If you are unsure, consult a qualified electrician.

If the circuit breaker trips or the fuse blows regu- larly, your machine may be operating on a circuit that is close to its amperage draw capacity. However, if an unusual amperage draw does not exist and a power failure still occurs, contact a qualified electrician or our service department at (570) 546-9663.

Serious personal injury could occur if you connect your machine to the power source before you have completed the assembly process. DO NOT connect the machine to the power source until instructed to do so.

Model G9953ZXF

Voltage & Amperage Draw

The Model G9953ZXF features a 5 HP motor and is wired to operate on a 3-phase, 220V circuit. The motor will draw the following load:

Plug Type

The cord set enclosed does not have a plug as the style of plug you require will depend on the type of service you currently have or plan to install. We recommend using the following plugs for your machine on a dedicated circuit only (see Figure 2 for an example).

Figure 2. NEMA-style L15-20 plug and outlet.

Circuit Breaker Requirements

Use the following guidelines when choosing a cir- cuit breaker (circuit breakers rated any higher are not adequate to protect the circuit):

Your Circuit Capacity

Always check to see if the wires in your circuit are capable of handling the amperage draw from your machine, as well as any other machines that could be operating on the same circuit. If you are unsure, consult a qualified electrician.

If the circuit breaker trips or the fuse blows regu- larly, your machine may be operating on a circuit that is close to its amperage draw capacity. However, if an unusual amperage draw does not exist and a power failure still occurs, contact a qualified electrician or our service department (570) 546-9663.

Serious personal injury could occur if you connect your machine to the power source before you have completed the assembly process. DO NOT connect the machine to the power source until instructed to do so.

Model G4815

Voltage & Amperage Draw

The Model G4815 features a 71???2 HP motor and is wired to operate on a 3-phase, 220V circuit. The motor will draw the following load:

Plug Type

The cord set enclosed does not have a plug as the style of plug you require will depend on the type of service you currently have or plan to install. We recommend using the following plugs for your machine on a dedicated circuit only (see Figure 3 for an example).

Figure 3. NEMA-style L15-30 plug and outlet.

Circuit Breaker Requirements

Use the following guidelines when choosing a cir- cuit breaker (circuit breakers rated any higher are not adequate to protect the circuit):

Recommended Circuit Breaker ..25 Amp, 3 Pole

Your Circuit Capacity

Always check to see if the wires in your circuit are capable of handling the amperage draw from your machine, as well as any other machines that could be operating on the same circuit. If you are unsure, consult a qualified electrician.

If the circuit breaker trips or the fuse blows regu- larly, your machine may be operating on a circuit that is close to its amperage draw capacity. However, if an unusual amperage draw does not exist and a power failure still occurs, contact a qualified electrician or our service department (570) 546-9663.

Serious personal injury could occur if you connect your machine to the power source before you have completed the assembly process. DO NOT connect the machine to the power source until instructed to do so.

Minimum Cord Size

For 220V single-phase operation, use the follow- ing power cord:

For 220V 3-phase operation, use the following power cord:

Grounding

Electrocution or a fire can result if the machine is not grounded correct- ly. Make sure all electri- cal circuits are ground- ed. DO NOT use the machine if it is not grounded.

In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric cur- rent. This machine is equipped with a power cord that has an equipment-grounding prong. The out- let must be properly installed and grounded in accordance with all local codes and ordinances.

Extension Cords

We do not recommend the use of extension cords with 220V single or 3-phase equipment. Instead, arrange the placement of your equip- ment and the installed wiring to eliminate the need for extension cords.

No single list of electrical guidelines can be comprehensive for all shop environ- ments. Operating this machinery may require additional electrical upgrades spe- cific to your machine and shop environ- ment. It is your responsibility to make sure your electrical systems comply with all local electrical codes and ordinances.

Rewire To 440V

(G9953ZXF Only)

To rewire the Model G9953ZXF to 440V:

1.Disconnect the sander from the power source!

2.Replace the power indicator light in the pedestal switch to one suitable for 440V operation

3.Remove the RHN-18 overload relay and replace it with a RHN-10 (5.5-8.5A) type, with the dial set to 7A (Figure 4).

RHN-10

Overload Relay

Figure 4. Overload relays.

4.Remove the CN-18 magnetic contact over- load relay and replace it with a CN-11 type (Figure 5).

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Figure 5. Overload relays.

5.Wire the motor as shown on the diagram on the inside of the motor wire cover. Note???

The circled references on the diagrams rep- resent labels on the wires. Also, Figure 6 below has been provided for your reference and are current at the time that this manual is being written. However, always use the dia- gram on the wire cover that comes with your motor!

G9953ZXF

Motor Wiring

Figure 6. 440V motor wiring.

Ultimate Series Jointers

Rewire To 440V

(G4815 Only)

To rewire the Model G4815 to 440V:

1.Disconnect the sander from the power source!

2.Replace the power indicator light in the pedestal switch to one suitable for 440V operation

3.Remove the RHN-18 overload relay and replace it with a RHN-10 (8.5-12.5A) type, set to 10A (Figure 7).

Figure 7. Overload relay.

4.Remove the CN-18 magnetic contact over- load relay and replace it with a CN-16 type (Figure 8).

Figure 8. Overload relay.

5.Wire the motor as shown on the diagram on the inside of the motor wire cover. Note???

The circled references on the diagrams rep- resent labels on the wires. Also, Figure 9 below has been provided for your reference and are current at the time that this manual is being written. However, always use the dia- gram on the wire cover that comes with your motor!

G4815

Motor Wiring

Figure 9. 440V motor wiring.

1.Infeed Table: Facing the front of the jointer, the infeed table is located to the right of the cutterhead. The infeed table is where the workpiece is placed at the beginning of the cutting operation. The wood travels right to left; from the infeed table, across the cutter- head, and onto the outfeed table.

2.Pedestal Switch: Location of the power indi- cator light, the START button, and the

EMERGENCY STOP button.

3.Fence Adjustment Handwheel: Controls the back-and-forth location of the fence across the top of the tables.

4.Cutterhead Guard: Orange, spring-loaded safety cover that retracts over the cutterhead when the workpiece is NOT passing over the jointer.

5.Fence: Surface the workpiece guides along when jointing or surface planing. The fence can be positioned 45?? and 90?? to the surface of the tables to accommodate either bevel or right-angle jointing operations.

6.Outfeed Table: Facing the front of the joint- er, the outfeed table is located to the left of the cutterhead. The outfeed table is where

5 4

6

the workpiece is lifted from the jointer after the cutting operation is complete. The wood travels right to left; from the infeed table, across the cutterhead, and onto the outfeed table.

7.Cutterhead: The cutterhead is the cylindri- cal assembly that holds each of the three jointer knives or indexable carbide cutters. It spins on a horizontal axis between the infeed and outfeed table, and is covered by the cutterhead guard when the jointer is not in use.

8.Table Height Handwheels: Controls the height positioning of the infeed and outfeed tables in relation to the cutterhead.

9.Table Height Lock Knobs: Knobs that tighten to prevent accidental rotation of the table height handwheels.

10.Stop Lever: Shuts off the power source to the jointer and slows the cutterhead to a stop.

11.Cam Adjustment (Behind Cover): The infeed table is fully adjustable with 4 cams to allow perfect alignment with the outfeed table.

1

Unpacking

NOTICE

The photos shown in this manual are of the Model G4815 unless otherwise noted.

The Model G9953 16" Ultimate Series Jointers and the Model G4815 20" Ultimate Series Jointer are shipped from the manufacturer in a carefully packaged crate. If there are any signs of crate damage after you have signed for delivery, imme- diately call our customer service for advice.

The Ultimate Series Jointers are heavy machines. DO NOT over-exert yourself while unpacking or moving your machine

??? you will need assis- tance and power equip- ment. Serious personal injury may occur if safe moving methods are not followed.

Sharp edges on metal parts may cause person- al injury. Examine the edges of all metal parts before handling.

Parts Inventory

Figure 10. Spiral Cutterhead Accessories.

USE THIS CHART TO MATCH UP

HARDWARE DURING THE ASSEMBLY

PROCESS!

Thumb

Screw Phillips

Head

Screw

Hex

Head

Bolt

Setscrew

Lock

Washer Washer

#10

Clean Up

Unpainted surfaces may be coated with a waxy oil to protect them from corrosion during ship- ment. Remove this waxy oil with a solvent clean- er or citrus-based degreaser such as Grizzly???s G7895 Degreaser. To clean thoroughly, some parts may need to be removed. The machine will operate best when the waxy oil is removed from all moving and sliding parts.

Chlorine-based cleaners and solvents will dam- age the painted surfaces of the machine. Follow the manufacturer???s instructions when using any type of cleaning product.

Gasoline and petroleum products have low flash points and could explode if used to clean machin- ery. DO NOT use gaso- line or petroleum prod- ucts to clean the machin- ery.

Smoking near solvents could ignite an explosion or fire and cause serious injury. DO NOT smoke while using solvents.

Lack of ventilation while using solvents could cause serious personal health risks, fire, or environmental hazards. Always work in a well ventilated area to pre- vent the accumulation of dangerous fumes. Supply the work area with a constant source of fresh air.

Ultimate Series Jointers

Site Considerations

Weight Load

The Model G9953 16" Ultimate Series Jointers and the Model G4815 20" Ultimate Series Jointer represent a large weight load. Most shop floors should be sufficient to carry the weight of the machine. Reinforce the floor if you question its ability to support the weight.

Working Clearance

Working clearances can be thought of as the dis- tances between machines and obstacles that allow safe operation of every machine without lim- itation. Consider existing and anticipated machine needs, size of material to be processed through each machine, and space for auxiliary stands and/or work tables. Also consider the relative position of each machine to one another for effi- cient material handling.

Lighting And Outlets

Lighting should be bright enough to eliminate shadow and prevent eye strain. Electrical circuits should be dedicated or large enough to handle the amperage draw. Outlets should be located near each machine so power or extension cords are clear of high-traffic areas. Observe local elec- trical codes for proper installation of new lighting, outlets, or circuits.

Unsupervised children and visitors inside your shop could receive seri- ous personal injury. Ensure child and visitor safety by keeping all entrances to the shop locked at all times. DO NOT allow unsupervised children or visitors in the shop at any time.

-15-

Beginning Assembly

This section will cover the basic assembly and adjustment instructions needed to begin opera- tion. Complete the assembly in the order provid- ed in this manual and then read the remaining portion of the manual before attempting any type of operation.

Your safety is important! Please follow the warnings below during this entire section:

Loose hair and clothing could get caught in machinery and cause serious personal injury. Keep loose clothing rolled up and long hair tied up and away from machinery.

Serious personal injury could occur if you con- nect your machine to the power source before you have completed the assembly process. DO NOT connect the machine to the power source until instructed to do so.

Sharp edges on metal parts may cause person- al injury. Examine the edges of all metal parts before handling.

Fence

The fence assembly is a heavy part. Seek assis- tance when lifting it onto the fence base support.

NOTICE

The fence can easily scratch the table sur- face of the jointer. Use extreme care when making adjustments to the fence assembly

To install the fence assembly:

1.Carefully lift the fence assembly onto the fence base support. Note???Avoid letting the fence slide across the jointer tables as scratching will occur.

2.Attach the fence assembly to the jointer assembly with (6) M8-1.25 x 45 cap screws and (6) M8 lock washers (Figure 12).

Fence Assembly

Cap Screws and Lock Washers

(Also 3 On The Opposite Side)

Fence Base

Support

Figure 12. Fence assembly installed.

Pedestal Switch

To mount the pedestal switch:

Attach the pedestal switch (Figure 13) to the back of the base with (4) M10-1.5 x 25 cap screws and

(4) M10 flat washers.

Pedestal Switch

Figure 13. Attaching pedestal switch.

Dust Collection

To attach dust collection hose to the dust port:

Attach a 5" hose from your dust collection system to the dust port (Figure 14).

Dust Port

Figure 14. Dust collection hook-up.

NOTICE

The remaining instructions in this section cover factory settings which should already be adjusted correctly; however, we recommend checking the settings to be sure they were not bumped out of adjust- ment during the shipping process. If it is determined that a setting is out of correct adjustment, please refer to Section 8: Service Adjustments.

Knife To Outfeed

Table Alignment

(Model G9953 Only)

The outfeed table must be perfectly level with the full length of each cutterhead knife.

To verify the factory setting:

1.Unplug the machine from the power source!

2.Open the access door (Figure 15) on the back of the machine, just below the fence adjustments.

Access Door

Cutterhead Pulley

Figure 15. Accessing the cutterhead pulley.

3.Position the knife setting gauge on the out- feed table so that it extends over the cutter- head (Figure 16).

Figure 16. Checking knife height with the knife setting gauge.

4.Rotate the cutterhead by turning the cutter- head pulley (Figure 15).

5.Watch as each knife passes under the knife setting gauge. The full length of each knife should just touch the knife setting gauge WITHOUT lifting the gauge off the outfeed table. If this condition is not present, refer to

Section 8: Service Adjustments.

Carbide Cutter

To Outfeed

Table Alignment

(Models G9953ZX, G9953ZXF and G4815)

The outfeed table must be perfectly level with the carbide cutters. Note???You only need to verify the outfeed table height with one of the carbide cutters.

To verify the factory setting:

1.Unplug the machine from the power source!

2.Open the access door (Figure 17) on the back of the machine, just below the fence adjustments .

Access Door

Cutterhead Pulley

Figure 17. Accessing the cutterhead pulley.

3.Position the edge of a straightedge on the outfeed table so that it extends over the cut- terhead (Figure 18).

Figure 18. Verifying outfeed table height with straightedge.

4.Rotate the cutterhead by turning the cutter- head pulley (Figure 17).

5.Watch as one of the carbide cutters passes under the straightedge. The carbide cutter should just touch the straightedge WITHOUT lifting the it off the outfeed table. If this condi- tion is not present, refer to Section 8: Service Adjustments.

Infeed Table To

Outfeed Table

Alignment

NOTICE

Review the "Knife To Outfeed Table Alignment" and the "Carbide Cutter To Outfeed Table Alignment" sub-sections on the previous pages before continuing.

The surface of the infeed table must be perfectly level with the surface of the outfeed table.

To verify the factory setting:

1.Position the edge of a steel straightedge on the outfeed table so that it extends over the cutterhead and onto the infeed table (Figure 19).

Infeed Table Just Touching

The Straightedge

Figure 19. Verifying that the infeed table is even with the outfeed table.

2.Loosen the infeed table height lock knob (page 10, #9).

3.Turn the infeed table height handwheel (page 10, #8) to raise the infeed table until it just touches the straightedge WITHOUT lifting it off the outfeed table.

4.Tighten the infeed table lock knob.

5.Check the alignment of the tables with the straightedge at the various points shown in Figure 20. Again, the straightedge should sit perfectly flat across both the infeed and out- feed tables with no gaps.

Figure 20. Positions for straightedge.

6.If all the table adjustments are set correctly, the depth-of-cut scale should read "0" as shown in Figure 21. If these conditions are not present, refer to Section 8: Service Adjustments.

Figure 21. Depth of cut scale.

Fence Stops

There is a 90?? and a 45?? fence stop designed to allow the fence to quickly and accurately be moved to the 90?? and 45?? position.

Figure 22. 90?? and 45?? fence stops.

To verify the 90?? fence stop:

1.Loosen the angle setting lock handle (Figure 22) while holding the fence adjustment han- dle with your other hand.

2.Move the fence to the 90?? position. Note???

The 90?? fence stop should engage against the fence bracket to assist in correctly posi- tioning the fence in the 90?? position.

3.Tighten the angle setting lock handle.

4Place a square against the fence face and the outfeed table as shown in Figure 23. There should be no gaps between the square and the fence or the outfeed table. If this condition is not present, refer to Section 8: Service Adjustments.

Fence Face

Outfeed Table

Figure 23. Using a square to align fence.

To verify the 45?? fence stop:

1.Loosen the angle setting lock handle (Figure 22) while holding the fence adjustment han- dle with your other hand.

2.Move the fence to the 45?? position. Note???

The 45?? fence stop should engage against the fence bracket to assist in correctly posi- tioning the fence in the 45?? position.

3.Tighten the angle setting lock handle.

4Place a bevel gauge against the fence face and the outfeed table as shown in Figure 24. There should be no gaps between the square and the fence or the outfeed table. If this condition is not present, refer to Section 8: Service Adjustments.

Fence Face

Outfeed Table

Figure 24. Using a bevel gauge to align fence.

Start Up

Serious personal injury could result if the machine is connected to the power source during assembly or adjustment. Wait until the machine is turned off, unplugged and all working parts have come to a complete stop before attempting to assemble or adjust the machine!

Loose hair and clothing could get caught in machinery and cause serious personal injury. Keep loose clothing rolled up and long hair tied up and away from machinery.

Projectiles from the machine could cause serious eye injury. Wear safety glasses at all times.

Before starting the machine:

1.Read this manual and make sure you follow all safety precautions before operating this machine.

2.Make sure the cutterhead guard is installed.

3.Make sure all tools and foreign objects have been removed from the machine.

4.Review and understand Section 3: Circuit Requirements beginning on page 6.

Starting the machine:

1.Wear safety glasses at all times while the jointer is running!

2.Plug the jointer into the power source.

-22-

3.Push the ON button shown in Figure 25.

Note???Make sure the cutterhead moves in a clockwise direction as viewed with the infeed table to the left. If the cutterhead moves in a counter-clockwise direction, then the power needs to be disconnected and any two power wires need to be switched at the cir- cuit breaker in the electrical box.

Figure 25. Pedestal switch.

Main STOP lever

Routine stops on the jointer should be performed using the STOP lever shown in Figure 26. Power is disconnected when the lever is activated, and with continued activation, the lever triggers a brake that slows the cutterhead to a stop.

STOP Lever

Figure 26. STOP lever.

Ultimate Series Jointers

Operation Safety

Your safety is important! Please follow the warnings below during this entire section:

To avoid serious personal injury, read and become familiar with the entire instruction manual before using the jointer.

Damage to your eyes, lungs, and ears could result from failure to wear safety glasses, a dust mask, and hearing protec- tion while using with this machine.

Loose hair and clothing could get caught in machinery and cause serious personal injury. Keep loose clothing rolled up and long hair tied up and away from machinery.

Ultimate Series Jointers

Stock Inspection

& Requirements

Here are some rules to follow when choosing and cutting stock:

???DO NOT joint or surface plane stock that contains knots. Injury to the operator or damage to the workpiece can occur if the knots become dislodged during the cutting operation.

???DO NOT joint or surface plane ???against??? the grain direction. Cutting ???against??? the grain increases the likelihood of stock kick- back (See Warning #13 on page 4), as well as tear-out on the workpiece.

???Jointing and surface planing ???with??? the grain produces a better finish and is safer for the operator. Cutting ???with??? the grain is best described as feeding the stock on the jointer so the grain points down and toward you as viewed on the edge of the stock (Figure 27). Note???If the grain changes direction along the edge of the board, your best bet for improving cut quality is to decrease the cutting depth and make addi- tional passes.

Figure 27. Correct and incorrect grain align- ment to cutterhead.

-23-

???Remove foreign objects from the stock.

Make sure that any stock you process with the jointer is clean and free of any dirt, nails, staples, tiny rocks or any other foreign objects that may damage the jointer blades.

???Only process natural wood fiber through your jointer. Never joint MDF, particle board, plywood, laminates or other syntheti- cally made materials.

???Make sure all stock is sufficiently dried before jointing. Wood with a moisture con- tent over 20% will cause unnecessary wear on the knives and will produce undesirable results.

???Make sure the stock meets the minimum dimension requirement (Figure 28 and 29) before edge jointing or surface planing.

10" Min.

1" Min.

1???2" Min.

Figure 28. Minimum dimensions for edge jointing.

10" Min.

1???2" Min.

1" Min.

Figure 29. Minimum dimensions for surface planing.

Squaring Stock

Squaring stock involves four steps that should be performed in the order below. The following pages will go into more detail.

1. Surface Plane On The Jointer???The concave face of the workpiece is surface planed flat with the jointer.

2. Surface Plane On A Thickness Planer???The opposite face of the workpiece is surface planed flat with a thickness planer.

3. Edge Joint On The Jointer???The concave edge (viewed from end-to-end) of the workpiece is edge jointed flat with the jointer.

4. Rip Cut On A Table Saw???Place the jointed edge of the workpiece against a table saw fence and rip the opposite edge off.

Surface Planing

The purpose of surface planing on the jointer is to make one flat face on a piece of stock (Figure 30) to prepare it for surface planing on a thick- ness planer.

Figure 30. Illustration of surface planing results.

NOTICE

If you are not experienced with a jointer, set the depth of cut to 0", and practice feeding the workpiece across the tables as described below. This procedure will better prepare you for the actual operation.

To surface plane on the jointer:

1.Read and understand Section 1: Safety beginning on page 2.

2.Make sure your stock has been inspected for dangerous conditions as described in the ???Stock Inspection??? instructions beginning on page 23.

3.Set the cutting depth for your operation. (We suggest 1???32" for surface planing, using a more shallow depth for harder wood species or for wider stock.)

4.Make sure your fence is set to 90??

5.If your workpiece is cupped (warped), place it so the concave side is face down on the surface of the infeed table.

6.Start the jointer.

7.With a push block in each hand, press the workpiece against the table and fence with firm pressure.

8.Feed the workpiece over the cutterhead. Note???When your leading hand (with push block) gets within 4" of the cutterhead, lift it up and over the cutterhead, and place the push block on the portion of the workpiece that is over the outfeed table. At this point, focus your pressure on the outfeed end of the workpiece while feeding, and repeat the same action with your trailing hand when it gets within 4" of the cutterhead. To keep your hands safe, DO NOT let them get clos- er than 4" from the cutterhead when it is moving!

9.Repeat steps 7-8 until the entire surface is flat.

Edge Jointing

The purpose of edge jointing is to produce a fin- ished, flat-edged surface (Figure 31) that is suit- able for joinery or finishing. It is also a necessary step in the squaring process of rough or warped stock.

Figure 31. Illustration of edge jointing results.

NOTICE

If you are not experienced with a jointer, set the depth of cut to 0", and practice feeding the workpiece across the tables as described below. This procedure will better prepare you for the actual operation.

To edge joint on the jointer:

1.Read and understand Section 1: Safety beginning on page 2.

2.Make sure your stock has been inspected for dangerous conditions as described in the ???Stock Inspection??? instructions beginning on page 23.

3.Set the cutting depth for your operation. (We suggest between 1???16" and 1???8" for edge joint- ing, using a more shallow depth for harder wood species or for wider stock.)

4.Make sure the fence is set to 90??.

5.If your workpiece is cupped (warped), place it so the concave side is face down on the surface of the infeed table.

6.Start the jointer.

7.Press the workpiece against the table and fence with firm pressure. Use your trailing hand to guide the workpiece through the cut.

8.Feed the workpiece over the cutterhead. Note???If your leading hand gets within 4" of the cutterhead, lift it up and over the cutter- head, and place it on the portion of the work- piece that is over the outfeed table. At this point, focus your pressure on the outfeed end of the workpiece while feeding, and repeat the same action with your trailing hand when it gets within 4" of the cutterhead. To keep your hands safe, DO NOT let them get closer than 4" from the cutterhead when it is moving!

9.Repeat steps 7-8 until the entire edge is flat.

Bevel Cutting

The purpose of bevel cutting is to cut a specific angle into the edge of a workpiece (Figure 32).

The Ultimate Series Jointers have preset fence stops at 45?? to the left and 45?? to the right. If your situation requires a different angle, the preset fence stops can be easily adjusted for your needs.

Figure 32. Illustration of bevel cutting results.

NOTICE

If you are not experienced with a jointer, set the depth of cut to 0", and practice feeding the workpiece across the tables as described below. This procedure will better prepare you for the actual operation.

To bevel cut on the jointer:

1.Read and understand Section 1: Safety beginning on page 2.

2.Make sure your stock has been inspected for dangerous conditions as described in the ???Stock Inspection??? instructions beginning on page 23.

3.Set the cutting depth for your operation. (We suggest between 1???16" and 1???8" for bevel cut- ting, using a more shallow depth for harder wood species or for wider stock.)

4.Make sure your fence is set to the angle of your desired cut.

5.If your workpiece is cupped (warped), place it so the concave side is face down on the surface of the infeed table.

6.Start the jointer.

7.With a push block in your leading hand, press the workpiece against the table and fence with firm pressure.

8.Feed the workpiece over the cutterhead. Note???If your leading hand gets within 4" of the cutterhead, lift it up and over the cutter- head, and place the push block on the por- tion of the workpiece that is over the outfeed table. At this point, focus your pressure on the outfeed end of the workpiece while feed- ing, and repeat the same action with your trailing hand when it gets within 4" of the cut- terhead. To keep your hands safe, DO NOT let them get closer than 4" from the cutter- head when it is moving!

9.Repeat steps 7-8 until the angled cut is sat- isfactory to your needs.

Maintenance Safety

Your safety is important! Please follow the warnings below during this entire section:

Disconnect power to the machine when perform- ing any maintenance, assembly or adjust- ments. Failure to do this may result in serious per- sonal injury.

Loose hair and clothing could get caught in machinery and cause serious personal injury. Keep loose clothing rolled up and long hair tied up and away from machinery.

Projectiles from the machine could cause serious eye injury. Wear safety glasses at all times.

General

Regular periodic maintenance on your Ultimate Series Jointers will ensure optimum performance. Make a habit of inspecting your machine each time you use it.

Before each use, perform the following checks:

1.Loose mounting bolts.

2.Worn switch.

3.Worn or damaged cords and plugs.

4.Damaged V-belt.

5.Any other condition that could hamper the safe operation of this machine.

Table

The table and other non-painted surfaces on your machine should be protected against rust and pit- ting. Wiping the table clean after every use ensures that moisture from wood dust does not remain on bare metal surfaces.

Tables can be kept rust-free with regular applica- tions of products like SLIPIT?? or Boeshield?? T-9. For long term storage you may want to consider products like Kleen Bore's Rust Guardit???.

Knives

(Model G9953 Only)

Using sharp knives is one of the most important factors involved with the operation of the jointer. A good maintenance procedure is to hone the knives to keep them in top shape. A knife hone will polish and finely sharpen jointer knives quick- ly and easily without removing them.

For damaged or extra dull knives, have them resharpened by a professional grinder. To avoid downtime from resharpening, we recommend having an extra set of knives on hand.

Carbide Cutters

(Models G9953ZX, G9953ZXF and G4815)

The carbide cutters are typically rotated at the same time when they become dull; however, the cutters can also be rotated individually when one becomes nicked or damaged. Refer to Section 8: Service Adjustments for instructions on rotating or replacing the carbide cutters.

Lubrication

Most of the ball bearings are permanently sealed and lubricated so they will require no attention until they need to be replaced. The following loca- tions should be lubricated after approximately 80 hours of continuous use.

Cutterhead

The cutterhead has two bearings that require grease. There are white stickers with arrows pointing to their general location. There are two grease fittings???one located at each end of the cutterhead, on the top of the cutterhead axle col- lars. The grease fitting on the front side of the jointer is located in a small hole cut into the top of the front base housing. The grease fitting on the back side of the machine is located on the top of the jointer base, just under the bottom edge of the fence.

Handwheels

Each handwheel is lubricated via an oil cup locat- ed just behind the handwheel body, on the axle collar. Remove the handwheel lock knob and slide the handwheel off the axle. This will reveal the oil cup. Apply a small amount of light machine oil.

Table Elevation Mechanism

The table elevation screw and gear mechanism for each handwheel can be accessed by remov- ing the left and right rear base housings. Apply a generous amount of grease to the elevation screws and gears.

Adjustment Safety

Your safety is important! Please follow the warnings below during this entire section:

Disconnect power to the machine when perform- ing any maintenance, assembly or adjust- ments. Failure to do this may result in serious per- sonal injury.

Loose hair and clothing could get caught in machinery and cause serious personal injury. Keep loose clothing rolled up and long hair tied up and away from machinery.

Projectiles from the machine could cause serious eye injury. Wear safety glasses at all times.

Outfeed Table

To set the outfeed table:

1.Unplug the machine from the power source!

2.Open the access door on the back of the machine, just below the fence adjustments.

3.Turn the cutterhead pulley to position the knife or carbide cutter close to the highest point in its revolution.

4.Set a straightedge on the outfeed table so that it extends over the cutterhead (Figure 33).

Figure 33. Setting the outfeed table.

5.Rock the cutterhead back-and-forth, using the cutterhead pulley to position the cutter edge at the highest point in its revolution.

6.Loosen the outfeed table lock knob.

7.Turn the outfeed table handwheel to raise or lower the outfeed table until the carbide cut- ter or knife just touches the straightedge WITHOUT lifting it off the outfeed table.

8.Tighten the outfeed table lock knob.

Knives

(Model G9953 Only)

Setting the knives correctly is crucial to the prop- er operation of the jointer and is very important in keeping the knives sharp. If one knife is higher than the others, it will do the majority of the work, and thus, dull much faster than the others. Note???

The cutterhead knives should protrude above the cutterhead 2mm (0.079"). The knife jig included with the jointer is designed to set the knives with- in this height.

To set the knives:

1.Unplug the machine from the power source!

2.Open the access door on the back of the machine, just below the fence adjustments.

3.Turn the cutterhead pulley until the surface of the cutterhead is at top dead center.

4.Adjust the outfeed table to a height of 2mm above the surface of the cutterhead.

5.Turn the cutterhead pulley to reveal one of the knives.

6.Loosen the cutterhead gib bolts, starting in the middle, and alternating back and forth until all of the gib bolts are loose, but not falling out (Figures 34 and 35). Note???The gib bolts turn clockwise to loosen and coun- terclockwise to tighten (when facing the head of the bolt).

Figure 34. Loosening the gib bolts.

Gib Gib Bolt

Jack Screw

Knife

Figure 35. Components of the cutterhead.

7.Position the knife setting gauge on the out- feed table so that it extends over the cutter- head as shown in Figure 36, and loosen the gib bolts until the knife is completely loose.

Figure 36. Checking knife with the knife setting gauge.

8.Rock the cutterhead back-and-forth, using the cutterhead pulley to position the knife edge at the highest point in its revolution.

9.Using a 3mm allen wrench, find the jack screws through the access holes in the cut- terhead and rotate the jack screws to raise or lower the knife. When the knife is set correct- ly, it will barely touch bottom of the knife set- ting gauge WITHOUT lifting the gauge off the outfeed table. Note???The knife height should be level with the outfeed table to within .002". A dial indicator can be used to check varia- tion in thousandths of an inch; however, the knife setting gauge is an adequate setup instrument.

10.Snug the gib bolts tight enough to just hold the knife in place.

11.Repeat steps 5-10 with the rest of the knives.

12.Repeat step 10, but final tighten each gib bolt.

Ultimate Series Jointers

Carbide Cutters

(Models G9953ZX, G9953ZXF and G4815)

The dot on each cutter is used as a reference point when determining which cutter edges are used, or dull, and which are sharp. Be sure to always rotate the cutters is the same direction as shown in Figure 37. Otherwise, the dot will not be an effective reference for determining which cut- ting surfaces are sharp. The carbide cutter dimen- sions are 14mm x 14mm x 2mm, with a 6.5mm bore and 30?? relief angles.

Reference Dot

Figure 37. Always rotate carbide cutters in the same direction to keep track of the dull or damaged edges.

The models with spiral cutterheads are supplied with an air wrench for loosening and tightening the carbide cutter Torx?? screws. This tool is very valuable if you have to rotate or change many of the cutters at one time. T-20 Torx?? bits are included.

Installing or adjusting the carbide cutters:

1.Connect the air wrench to your regulated air compressor.

2.Adjust the air pressure (torque) setting dial on the side of the air wrench to the "2" position. Note???The "1, 2, 3" dial on the air wrench adjusts the torque, relative to the compressor air pressure. The "1" setting will produce the highest amount of torque possible at a given compressor air pressure, while the ???3??? setting will produce the least torque.

3.Install a T-20 Torx?? bit into the air wrench.

-33-

4.Sparingly oil the threads of the carbide cutter Torx?? screws with a light machine oil.

5.Adjust the compressor air pressure to 30 PSI. Note???The low pressure (torque) setting will reduce the chance of cross threading the Torx?? screw threads as well as seat the car- bide cutters correctly.

6.Once all the Torx?? screws have been seated, turn the compressor air pressure to 85 PSI. Further tighten the Torx?? screws to their final torque setting of 48-50 Inch-Pounds.

Removing the carbide cutters:

Torx?? screws that are difficult to remove with the air wrench can be removed with the supplied T- handle. Carefully insert a Torx?? bit into the hole on the side of the ???cheater bar.??? This should allow you enough leverage to loosen the Torx?? screws.

NOTICE

Remove sawdust from the heads of the Torx?? screws before attempting to remove them from the cutterhead. The head of the Torx?? screws could become stripped if this is not done.

Infeed Table Cam

Under each corner of the infeed table is an eccen- tric that can be turned with a wrench???lifting or lowering that corner of the table. A coordinated adjustment of all four eccentrics allows the infeed table surface to be adjusted perfectly level with the outfeed table.

To adjust the infeed table:

1.Remove the four hex bolts and flat washers (Figure 38) that secure the front eccentric cover to the jointer. Carefully remove the front eccentric cover and set it aside.

Figure 38. Hex bolts and flat washers used to secure the front eccentric cover

to the jointer base.

2.Remove the two hex bolts and flat washers that secure the back eccentric cover behind the infeed table. Carefully remove the back eccentric cover and set it aside.

3.Using a 4mm Allen wrench, loosen the set screw located on the side of each eccentric (Figure 39).

Figure 39. Front eccentric locations.

4.Using a 10mm Allen wrench, loosen the cap screw located in the center of each eccentric (Figure 39).

5.Set the edge of a straightedge across the out- feed and infeed tables (Figure 40). The goal is to eliminate any gaps between the straight- edge and the surface of the tables.

Straightedge

Outfeed Table Eccentric Location.

Figure 40. Straightedge positioning points.

6.Move the straightedge across the tables to various positions and make note of which cor- ners of the infeed table need adjustment, whether the adjustment should be up or down, and how much.

7.Using an adjustable wrench, turn the neces- sary eccentrics until the straightedge sits flush across the infeed and outfeed tables. Note???

In the unlikely event that the tables cannot be aligned by adjusting the infeed eccentrics, there is an eccentric also located on the cor- ner of the outfeed table closest to the operator and the cutterhead.

8.Secure the cams and re-attach the front and back eccentric covers by reversing steps 1-4.

Fence Stops

To set the 90?? stop:

1.Place a square on the outfeed table fairly close to the cutterhead as shown in Figure 41.

Figure 41. Use of square to align fence.

2.While holding the fence adjusting handle, loosen the check nut on the 90?? stop screw (Figure 42). Turn the stop screw against the bracket until the fence contacts the edge of the square evenly.

Angle Setting

Lock Knob 90?? Stop Bolt

And Check Nut

45?? Stop Bolt

And Check Nut

Figure 42. 90?? and 45?? fence stops.

3.Tighten the check nut on the stop bolt and tilt the fence back, then forward against the stop bolt.

4.Recheck with the square. Tightening the check nut will move the stop bolt slightly, so some trial-and-error may be necessary to perfect your settings.

To set the 90?? stop:

The process for setting the 45?? fence stop is the same as for the 90?? stop, with the exception of using a bevel gauge set to 45?? (Figure 43) and adjusting the fence mechanism against the 45?? stop (Figure 42).

Figure 43. Using a bevel square to align fence.

Depth-Of-Cut Scale

The depth-of-cut scale indicates the amount of material that will be removed with each pass over the jointer.

To set the depth-of-cut scale:

1.Unplug the machine from the power source!

2.Open the access door on the back of the machine, just below the fence adjustments.

3.Place a straightedge on the outfeed table so it hangs over the infeed table.

4.Turn the cutterhead pulley so the knives or carbide cutters are NOT directly beneath the straightedge.

5.Loosen the infeed table lock knob.

6.Turn the infeed table handwheel to raise or lower the outfeed table until it just touches the straightedge as shown in Figure 44.

Infeed table just touch- ing the straightedge

Figure 44. Properly adjusting the infeed table before setting the depth-of-cut scale.

7.Tighten the infeed table lock knob.

8.Loosen the depth-of-cut pointer screw and adjust the depth pointer to the ???0??? position as shown in Figure 45.

Figure 45. Depth-of-cut pointer adjusted to ???0??? position.

9.Tighten the depth-of-cut pointer screw.

If you need parts or help in assembling your machine, or if you need operational information, call the service department at (570) 546-9663. Trained service technicians will be glad to help you.

If you have any comments regarding this manual, please write to Grizzly at the address below:

Grizzly Industrial, Inc.

C/O Technical Documentation

P.O. Box 2069

Bellingham, WA 98227-2069

Important safety measures that are essential to the operation of this machine have been explained in Section 1: Safety. While most safety measures are generally universal, Grizzly reminds you that each workshop is different and safety rules should be considered as they apply to your specific situation.

We recommend you keep a copy of our current catalog for complete information regarding Grizzly's warranty and return policy. If you need additional technical information relating to this machine, or if you need general assistance or replacement parts, please contact the Service Department at the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901 E-Mail: techsupport@grizzly.com Web Site: http://www.grizzly.com.

Additional information sources are necessary to realize the full potential of this machine. Trade journals, woodworking magazines, and your local library are good places to start.

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