Grizzly Tools G1026 User manual
2 HP SPINDLE MOULDER
INSTRUCTION MANUAL
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Clean up
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SECTION 6: SERVICE ADJUSTMENTS
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SECTION 5: MAINTENANCE
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SECTION 4: OPERATIONS
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SECTION 3: SET UP
SECTION 2: IDENTIFICATION
Table of Contents
SECTION 1: SAFETY 3
Additional Safety Instructions for Shapers
........................................................................................................
Controls & Features
...................................................................................................................
........................................................................................................................
Unpacking
..................................................................................................................................
Piece Inventory ..........................................................................................................................
Hardware Recognition Chart
Site Considerations
Beginning Assembly
Handwheel ..............................................................................................................................
Spindle .....................................................................................................................................
Table Inserts ............................................................................................................................
Extension Wing ........................................................................................................................
Fence Assembly .......................................................................................................................
...........................................................................................................
Rotation ....................................................................................................................................
Speed Changes .......................................................................................................................
........................................................................................................
General .....................................................................................................................................
Lubrication ................................................................................................................................
Table ........................................................................................................................................
V-Belt ........................................................................................................................................
Spindle Bearings ......................................................................................................................
.......................................................................................
Pulley Alignment ......................................................................................................................
V-Belt Tension ..........................................................................................................................
Truing The Fence .....................................................................................................................
Gib Adjustments
Machine Data Sheet
2
9
Test Run....................................................................................................................................14
SECTION 1: SAFETY
3
4
ated with this Spindle Moulder. Accidents are 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 machines there is danger associ-
frequently caused by lack of familiarity or
failure to pay attention. Use this machine
with respect and caution to lessen the pos-
sibility of operator injury. If normal safety
precautions are overlooked or ignored, seri-
ous personal injury may occur.
Additional Safety Instructions for Shapers
1. HAND POSITIONING. Never place hands
directly over or in front of the cutter. As one
hand approaches the cutter, move it in an
arc motion away from the cutter to the out-
feed side. Always keep hand at least 6" away
from the cutter while operating.
2. SAFETY DEVICES. Use a fixture, jig, or
hold-down device to decrease the chances
of injury.
3. SAFETY GUARDS. DO NOT remove the
retractable guard on the fence. Use a guard
or other type of protective device at all times.
Use overhead guard when the fence is
removed.
4. CUTTER HEIGHT. Keep any unused portion
of the cutter below the table surface.
5. STOCK LENGTH. Do not use stock shorter
than 6 inches without special fixtures or jigs.
Where practical, shape longer stock and cut
to size.
6. STOCK CONDITION. The danger of kick-
back is increased when the stock has knots,
holes, or foreign objects in it. Warped stock
should be run through a jointer before you
run it through a shaper.
7. BLIND CUT WHEN POSSIBLE. Blind cuts
keep the cutters on the underside of the
workpiece and provide a distance guard for
the operator.
8. TEST ROTATION. With the machine
unplugged, rotate the spindle to test any
new setup to ensure proper cutter clearance
before starting the machine.
9. DEPTH OF CUT. Never remove too much
material in one pass. Several light passes
are safer and produce a cleaner finish.
10. SHAPING CONTOURED WORK. Always
use a rub collar and a template. DO NOT
start out at a corner. See the rub collar sec-
tion further on in the manual.
11. FEEDING THE WORKPIECE. Always feed
the workpiece against the rotation of the cut-
ter. Never force materials through the shaper.
Let the cutters do the work. Excessive force
is likely to result in poor cutting results and
will cause dangerous kickback conditions.
12. SECURING NUTS AND KNOBS. Never
operate the shaper without the second lock-
ing nut in place over the spindle nut. Always
ensure that the cutters, fence, and spindle
elevator knob have been tightened properly
before beginning any operation.
5
Fence
Controls and features.1
1
SECTION 2: IDENTIFICATION
Controls & Features
To help you understand the setup and operation
instructions, we recommend that you become
familiar with the basic features of your new
shaper.
Please match up the list below with the letters
in Figure to identify the shaper controls and
features.
A.Guide
B. Vertical Bar
C. Adjustment Level
D.
E. Table
F.
G.
H.
Scale
I.
Reverse Switch
Figure .
6
J.
K.Motor Cover
Handwheel
On/Off Switch
Stand
BA
C
D
E
F
G
H
I
J
K
Hold Down ....
Instruction Manual...........................................1
............................................1
Body....................
DO NOT
The spindle moulder is a
SECTION 3: SET UP
Unpacking
Piece Inventory
Qty
Plywood 1:
Bag 1:
•
Cardboard 1:
• Miter Gauge Assembly
....................................1
• Handle.............................................................1
....................................................1
• ...................................................1
•Guide ..............................................................1
3mm Hex Wrench...........................................1
NOTICE
A full parts list and breakdown can be found
toward the end of this manual. For easier assem-
bly, or to identify missing parts, please refer to the
detailed illustrations at the end of the manual.
After all the parts have been removed from the
carton, you should have:
7
over-exert yourself
while unpacking or
moving your machine
– consider using power
equipment to move the
machine. Serious per-
sonal injury may occur
if safe moving methods
are not followed.
heavy machine.
•
4mm Hex Wrench...........................................1
•
5mm Hex Wrench...........................................1
•
8mm Hex Wrench...........................................1
•
•
•
Vertical Bar IV .................................................1
•
Special Wrench...............................................1
•
Vertical Bar I
Collet Nut........................................................1
•
Ruber Feet......................................................4
•
Hardware Recognition Chart
8
solvents, such as acetone or brake
Avoid
sure you clean all moving parts or
mum performance from your machine,
To clean
vent cleaner or citrus-based degreaser.
represents a moder
Site Considerations
FLOOR LOAD
-
ately large weight load in a small footprint. Most
commercial or home shop floors will be adequate
for the 345 lb. weight of the Model G1026. Some
floors may require additional support. Contact an
architect or structural engineer if you have any
question about the ability of your floor to handle
the weight.
WORKING CLEARANCES
Working clearances can be thought of as the
distances between machines and obstacles that
allow safe operation of every machine with-
out limitation. Consider existing and anticipated
machine needs, size of material to be processed
through each machine, and space for auxiliary
stands or work tables. Also consider the relative
position of each machine for efficient material
handling. Be sure to allow yourself sufficient room
to safely run your machines in any foreseeable
operation.
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
combined motor amp loads. Outlets should be
located near each machine so power or exten-
sion cords are not obstructing high-traffic areas.
Be sure to observe local electrical codes for prop-
er installation of new lighting, outlets or circuits.
The unpainted surfaces are coated with a waxy
oil to protect them from corrosion during ship-
ment. Remove this protective coating with a sol-
some parts may need to be removed.
For opti
contact surfaces that are coated.
parts cleaner, as they may damage painted sur-
faces should they come in contact. Always follow
the manufacturer’s instructions when using any
type of cleaning product.
Clean Up
Gasoline and petroleum
products have low flash
points and could cause
an explosion or fire if
used to clean machinery.
DO NOT use gasoline or
petroleum products to
clean the machinery.
Many of the solvents
commonly used to clean
machinery can be toxic
when inhaled or ingest-
ed. Lack of ventilation
while using these sol-
vents could cause seri-
ous personal health risks
or fire. Take precautions
from this hazard by only
using cleaning solvents
in a well ventilated area.
Make your shop “child safe.”
Ensure that your workplace
is inaccessible to children
by closing and locking all
entrances when you are
away. Never allow visitors
in your shop when assem-
bling, adjusting or operating
equipment.
9
thoroughly,
make
sliding
chlorine-based
This spindle moulder
2
2
Most of your spindle moulder has been
assembled at the factory, but some parts must
be assembled or installed after delivery. We
have organized the assembly process into steps.
Please follow along in the order presented here.
Beginning Assembly
Wear safety glasses dur-
ing the entire assembly
process. Failure to com-
ply may result in serious
personal injury.
Some metal parts
may have sharp edges
on them after they are
formed. Please examine
the edges of all metal
parts before handling
them. Failure to do so
could result in injury.
Disconnect power from
the machine when per-
forming any maintenance,
assembly or adjustments.
Failure to do this may
result in serious personal
injury.
10
To install the handwheel:
1. Insert the handwheel on the handwheel shaft
shown in Figure ,
Figure . Location of handwheel shaft.
Handwheel
Handwheel
2. Tighten the handwheel knob against the
screw part of the handwheel shaft.
3.
notes the key on shaft m-
atching to handwheel concave.
To turn the handwheel loose the handwheel
knob, turn the handwheel to adjust spindle
hight to desired position. Then, tighten the
handwheel knob, to keep the exact spindle
hight as set, always tighten the handwheel
knob.
Handwheel Shaft
5
4
5
4.
3
3
The spindles must be inserted correctly
interchangeable
The Spindle Moulder comes with
Spindle
and remain securely locked in the machine in
order to produce quality work. When installing and
changing spindles, make sure the spindle seats
snugly and that there is enough drawbar threaded
into the bottom of the spindle to safely secure it
in place.
Incorrect assembly can allow the spindle
and cutter to fly off the machine, which
could cause injury or death. Make certain
the spindle is properly assembled before
operating the Shaper. If you are uncertain of
any aspect of this assembly, please review
these instructions again or contact our
Customer Service.
To install a spindle:
1. KEEP SHAPER DISCONNECTED FROM
POWER!
2. Remove the hex nuts from the spindle and
the drawbar nut from the drawbar.
3. Thread the drawbar approximately 10-15
turns into the bottom of the spindle. The
drawbar has two threaded ends. One of them
remains exposed. See Figure .
Figure . Spindle and drawbar.
10-15 Turns
Spindle
Drawbar
11
spindles.
Figure . Inserting the spindle into place.
4. Place the spindle/drawbar into the spindle
cartridge at the top of the table. Line up the
keyway on the spindle with the locating pin at
the top of the spindle cartridge. You will feel
the spindle seat itself. See Figure
Make sure the spindle keyway and pin are
aligned and properly seated before tighten-
ing the drawbar nut. Improper assembly can
create an unsafe condition and possible
injury to the operator.
5. Thread the drawbar nut, tapered side up, onto
the bottom of the drawbar until it stops below
the spindle housing cartridge. .
Figure . Nut threaded onto drawbar.
See Figure
Raise the wing on one side and make sure it
8
The Spindle Moulder is supplied with three table
6
6
Figure .
7. Turn the spindle.
DO NOT use excessive force.
6. Place the spindle wrench on top of the
spindle, so it fits over the head of the spin-
dle. Push the spindle lock pin to hold spindle
in place. See
Figure .
Table Inserts
inserts which give you four possible opening
diameters in the shaper table surface. Use the
smallest opening that a particular cutter will allow.
This offers more support for the workpiece and
reduces the amount of chips that can fall into the
machine.
The correct spindle opening will also allow any
unused portion of the cutter to remain below the
table surface—increasing operator protection.
There are two aluminum table inserts and one
cast iron table insert. The cast iron table insert
must be flush with the top of the table.
To adjust the insert:
1. KEEP SHAPER DISCONNECTED FROM
POWER!
2. Remove the three Phillips head screws that
hold the cast iron insert in place.
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7
7
4. Replace and tighten the Phillips head screws
and inspect with a straightedge.
Figure . Leveling table insert.
3. Using a straightedge and a flathead screw-
driver, turn the barrel screws clockwise or
counterclockwise to level the cast iron insert
with the table as shown in Figure .
Cast Iron
Insert Cast
Iron
Insert
first bolt.
Extension Wing
The cast iron wing extends your work surface
area to provide support for larger workpieces.
To install the extension wing:
1. Make sure the contact surfaces are free of
dirt or grit.
2.
Insert the hex bolts with lock washers through
the wing and thread them into the holes at
the front of the shaper. Leave the bolts loose,
for now.
is flush with the table edge, then tighten the
See Figure .
Note: By raising or lowering the far end of the
wing, you can locate the center of the wing
flush with the shaper table.
3.
Tighten/Loose spindle
0
0
7.
Secure the center bolt.
5.
4.
8.
Figure 9. Adjusting to ensure flatness.
6. Adjust the wing up or down at the last bolt
(Figure 9 ). If necessary, use a clamp and
some wood blocks to make the two surfaces
flush. Tighten the final bolt when the two sur-
faces are flush.
Figure Installing extension wing.
Make sure the wing edge is flush at the first
two bolts and that the bolts are tight.
Note: The end of the wing at the last bolt
may not be flush with the surface of the table.
Don’t be alarmed.
13
Inspect your results with a good-quality
straightedge.
Fence Assembly
To install the fence assembly:
1. KEEP SHAPER DISCONNECTED FROM
POWER!
2.
shown in Figure 1
Figure 1 .
Fence assembly
3.
Secure the fence pieces with lock knob.
4.
Insert the hexason bar to socket, tighten two
set screws on socket to secure the hexagon
bar.
Insert the Hold Down and Guide.
As
Assembly Vertical Bar IV
1.
shown in
Figure 1
As
1.
Figure 1
14
increase safety and accuracy for specialized
entioned in this manual that can be built to
moulder. There are mang different jips not m-
to maximize the potential of your spindle
books,trade magazines, or get formal training
WE STRONGLY RECOMMEND that you read
SECTION 4: OPERATIONS
Test Run
To test run the machine:
1. Connect the machine to the power source.
2. Make sure you have read the safety instruc-
tions at the beginning of the manual and that
the machine is setup properly.
3. Make sure all tools and objects used during
set up are cleared away from the machine.
4. Press the START button to turn the machine
ON.
5. Check to make sure the spindle is rotating in
a counterclockwise direction when the switch
is in the FORWARD position.
6. Listen to and watch for abnormal noises or
actions. The machine should run smoothly
with little or no vibration or rubbing noises.
— Immediately turn the shaper OFF if you
suspect any problems and fix any prob-
lems before starting the shaper again.
Wear safety glasses dur-
ing the entire operation
process. Failure to com-
ply may result in serious
personal injury.
Disconnect power to the
machine when perform-
ing any maintenance or
assembly. Failure to do
this may result in serious
personal injury.
NOTICE
The following section was designed to give
instructions on the basic operations of this
shaper. However, it is in no way compre-
Always wear a dust
mask when operating
this shaper. Using this
machine produces saw-
dust that may cause short
and long-term respira-
tory illness.
Keep loose clothing out
of the way of machin-
ery and keep hair pulled
back during operations.
hensive of every spindle moulder application.
cuts.
15
Figure 12. Forward/reverse switch.
Rotation
Your shaper is equipped with a FORWARD/
REVERSE switch. See Figure 12. In many
instances, it will be necessary to flip the cutter
over and reverse cutter rotation. Whenever pos-
sible, mount the cutter so the board is milled on
the bottom side (the side away from the opera-
tor). This does a better job and it is safer for the
operator.
Always check the direction of cutter rota-
tion before any shaping operation. Cutters
rotating backwards will cause unsafe condi-
tions.
Speed Changes
This spindle moulder is equipped with a special
high speed V-belt. It is designed to withstand the
vibration and sudden shock loads associated with
the operation of a shaper.
To change spindle speeds:
1. DISCONNECT SHAPER FROM POWER
SOURCE!
2. Loosen the two motor mount bolts and slide
the motor toward the spindle assembly by tu-
DO NOT take the bolts out.
3. Move the V-belt to a sheave on the motor
and spindle pulleys to select the desired
speed (See Figure 14.)
Figure 14. Speed change belt positions.
4. Slide the motor back into position and tighten
the belt. When the belt is properly tensioned,
there should be approximately
tion in the center of the belt when you press
it with your thumb.
5. Tighten the motor mount bolts.
6. Spin the pulley to ensure proper tracking.
6mm of deflec-
rning the knob.
See Figure 13.
Figure 13.
7,000
10,000
Reverse Switch
Adjusting the V-belt tention
SECTION 5: MAINTENANCE
16
Spindle Moulder should be protected against rust
eplace when necessary.
it. Check for the following conditions and repair or r-
a habit of inspecting your shaper each time you use
oulder will ensure its optimum performance. Make
Regular periodic maintenance on your Spindle M-
V-Belt
Avoid getting grease or oil on the V-belt or pul-
leys.
Check the V-belt, as part of your monthly inspec-
tion, for proper tension and belt condition. Cracking
and glazing could result in belt failure. Replace
the belt if such conditions appear.
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.
General
Table
The table and other non-painted surfaces on the
and pitting. Wiping the table clean after every use
ensures that wood dust isn’t allowed to trap mois-
ture against bare metal surfaces.
Lubrication
The only parts on this machine that require peri-
odic lubrication are the ways where the cartridge
slide rides on the elevation housing and where the
worm gear and bushing are located. Use a light
grease or anti-seizing compound on the ways
and worm gear and give the shaft mount a shot
of light oil. The frequency of lubrication depends
on the amount you use the shaper. As a habit,
inspect the machine at least once a month.
Wear safety glasses dur-
ing the entire mainte-
nance process. Failure
to comply may result in
serious personal injury.
Spindle Moulder features factory-sealed bearings.
damage to other parts of the machine.
Spindle Bearings
The spindle bearing housing equipped with the
A sealed bearing requires no lubrication during
its lifetime.
Should a bearing fail, your shaper will probably
develop a noticeable rumble that will increase
when the machine is put under load. If allowed to
get worse, overheating of the journal containing
the bad bearing could occur. If the bad bearing
You must remove the complete bearing housing
assembly to replace the bearings.
is not replaced, it will eventually seize—doing
To remove the bearing housing assembly:
1. DISCONNECT SHAPER FROM POWER
SOURCE!
15
17
2. Remove the V-belt.
3. Loosen the locking bolt on the spindle slide
shown in Figure .
4. The bearing housing will drop down. If you
need to spread the casting more, use a
screwdriver.
Figure 15. Locking bolt on spindle slide.
Use care when spreading the casting—it will
break if too much pressure is applied. When
the casting is spread, the housing can fall
down. Watch your fingers to avoid being
pinched. Place a pad underneath to protect
the housing from being damaged if it falls.
5. Remove the spindle and replace the bear-
ings inside the bearing housing. If you need
pointers regarding bearing replacement, call
our service department.
6. To slide the housing back in, reverse the
procedure. Make sure the locking bolt is
tightened securely.
SECTION 6: SERVICE ADJUSTMENTS
Keep clothing rolled
up and out of the way
of machinery and keep
hair pulled back.
Wear safety glasses dur-
ing the entire adjustment
process. Failure to com-
ply may result in serious
personal injury.
Disconnect power to the
machine when perform-
ing any maintenance or
assembly. Failure to do
this may result in serious
personal injury.
Pulley Alignment
Improper pulley alignment sharply reduces the
effectiveness of power transmission and belt life
expectancy.
To align the pulleys:
1. DISCONNECT SHAPER FROM POWER
SOURCE!
2. Open the motor cover on the side of the
shaper cabinet.
3. Check the alignment with a straightedge. If
the pulleys are in alignment, the straightedge
should touch two sides of each pulley evenly.
See Figure 16.
18
5. Inspect for tilt on the motor pulley. If the pul-
ley is tilted, loosen the four bolts holding the
motor onto the motor plate. Wiggle the motor
into position. (Do not loosen the bolts that
hold the motor onto the motor mount; this
plate is preset with blocks that hold it in posi-
tion and it cannot be adjusted.)
6. Inspect your results. If they are satisfactory,
tighten all fasteners. Remember to tighten
the bolt in the split housing that holds the
spindle cartridge in position.
Figure 16. Inspecting pulley alignment.
4. If pulleys are parallel with each other, but
not in line, remove the belt from the spindle
assembly and slide the spindle cartridge
assembly either up or down.
Note: The side cover can be removed from
the shaper to improve access to the motor.
NOTICE
DO NOT over-tighten. Cast iron threads are
more easily stripped than steel.
7. You can also align the motor pulley by raising
or lowering it along the motor shaft. Loosen
the two setscrews and tap into the desired
position with a dead blow hammer.
moderate finger pressure. This may seem tight
compared to most other V-Belts, but since the
belt is small and runs fast, this much tension is
necessary. The V-Belt will slip if too loose and
squeal or cause vibration if too tight. Adjust the
tension if necessary.
To adjust V-Belt tension:
1. DISCONNECT SHAPER FROM POWER
SOURCE!
2. Make sure the pulleys are properly aligned.
3. Loosen the two motor mount plate bolts and
slide the motor left or right to modify the belt
tension. Keep the pulleys aligned.
4. Tighten the motor mount plate bolts, test the
tension, and check pulleys.
5. Repeat Steps 3-4 until tension is correct, and
pulleys are aligned.
Truing The Fence
To ensure that the fence is parallel with itself
and square with the table:
1. Ensure that the bolts through the wood fac-
ing on each side are tight and adequately
countersunk.
2. To align the wood facing, adjust one or both
fence halves so they are in close alignment.
Micro-adjust and check the alignment with a
straightedge.
3. If the wood fences are not coplanar with
each other,resurface as one unit. You can
perform this operation on a jointer.
Note: Make sure the screws are countersunk
deep enough so the workpiece will not come
in contact with the heads of the screws.
Or use electrical washers between the fence
and the fence bracket to shim the fence into
the correct position.
V-Belt Tension
You should be able to deflect the belt 1⁄4" with
19
5.
4.
The spindle gibs ensure there is no play in the
spindle that could cause it to wobble.
To adjust the spindle gibs:
1. DISCONNECT SHAPER FROM POWER
SOURCE!
2. Elevate the spindle to its maximum 3"
height.
3. If there is movement, adjust the gib against
the elevation housing, using the adjustment
screws at the top and bottom of the elevation
housing. Figure 17 shows the two upper gib
adjustment screws and locknuts. One of the
two lower adjustment screws is also visible in
the photo.
Loosen the four 12mm locknuts and remove
the slack between the elevation housing
and spindle cartridge slide by tightening the
four 5⁄16" setscrews with a 4mm hex wrench.
Alternate between the upper and lower
adjustments to ensure consistent tightness.
Failure to do so may cause disappointing
results. DO NOT over-tighten the gib. Over-
tightening will restrict spindle movement.
Loosen the spindle assembly lock knob and
raise or lower the spindle to check for free
movement.
Since there is an unbalanced weight distribu-
tion on the cartridge slide, you may have to
perform a number of adjustments before you
find the ideal location. Don’t get discouraged;
it may take a few tries to get it right.
Gib Adjustments
Figure 17. Gib adjustment screws.
Upper Gib
Adj.
Screws
Lower
Gib Adj.
Screw
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