Hawk 408 User manual

MODEL 408 PLANER
OPERATORS MANUAL FOR
PLANER) MOLDER) SANDER)
READ THOROUGHLY BEFORE
OPERATING
Bushton Manufacturing
PO Box 127
319 S. Main
Bushton KS 67427
620-562-3557
Manual #: 1187

CONTENTS
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ITEM•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••PAGE NUMBER
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General Instructions ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••3
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Planing Operation Instructions •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••6
I.LliJriC:Clti()11••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1r
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Suggesti()ns for Reducing Snipe •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11
Parts Breakdown Drawing •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12
flcar1t i ElrIt2li(ci()lftIl1 I.i it •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1:s
Tr()uble Shooting •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••14
Molding Accessory Installation Instructions ••••••••••••••••••••••••••••••••.••.15
1Wi()lclillll~C:C:E S i()ry flClrt I.ist ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 111
Sanding Head Installation Instructions ••••••••••••••••••••••••••••••••••••••••••.•18
Sanding Head Operation Instructions ••••••••••••••••••••••••••••••••••••••••••••••19
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()rclerin l flCli1ts ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• : :

SPECIFICATIONS _
OVERALLDIMENSIONS:Height 34 3/4 in.
Width 19 in.
Length 16 1/4 in.
Weight 161 Ibs.
47 @4200 RPM cutterhead speed
self feeding @ 22 ft/min.
1 1/2 H.P.,a.c. brushless electric motor, single phase, 23 amp peak, overload
protected
PLANING CAPABILITIES:Max. Cutting Depth ~ 3/32 in.
Max. Width Of Cut 8 in.
Max. Thickness Of Stock 4 in.
Min. Thickness Of Stock 3/16 in.
Shortest Planable Board 9 in.
CUTSPERINCH:
FEEDSPEED:
POWER:
GENE~L INSTRUCTIONS~ ~
The Model 408 Planer is intended for both high use and hobby shop applications. It is designed for ease
and simplicity of operation, maintenance, and adjustment with the operators' safety in mind. As with any
new piece of equipment, the operator should become familiar with the Model 408 before attempting to
operate it. To do this, this operators manual should be thoroughly read and understood.
SAFETY INSTRUCTIONS _
FOR ALL POWERTOOLS
1. Readthe operators manual carefully. Be thoroughly familiar with the operation of the machine. Know
where the controls are and how to operate them.
2. Never allow children to operate equipment without proper supervision.
3. Keep work area clear of other persons.
4. Maintain a clean and uncluttered work area.
5. Never make adjustments to the machine while it is running.
6. Disconnect power supply before performing any adjustments to the machine.
7. Remove all working tools and equipment before starting machine.
8. Wear proper clothing. Avoid loose fitting clothing, long sleeves, long hair, gloves, neck ties, jewelery,
watches, rings, etc.
9. Wear safety goggles, ear protection (ear plugs or covers) and mask in dusty operation.
10. Do not operate an electrical device in a damp or wet area to avoid electrical shock.
11. Maintain all safety guards.
12. Do not operate machine under the influence of medication, alcohol or drugs.
13. Never allow machine to operate unattended.
14. Do not overload machine. Follow the instructions in the operators' manual for safe operation.
15. Maintain machine in proper working order. Follow recommended maintenance procedures in the oper-
ators' manual.
- 3 -

ADDITIONAL SAFETYINSTRUCTIONSFOR PLANING
1. Do not use lumber with loose knots or splintered surfaces.
2. Check cutterhead screwsfor tightness after 5minutes of operation when new and after changing knives.
3. Do no raise bed high enough to contact cutterhead knives.
4. Never operate planer with hood removed.
5. Do not stand directly in line with the front or rear of the machine. Always stand to one side.
ASSEMB~INSTRUCTIONS~~~~~~~~~~~~~~~~~~
The Model 408 Planer is shipped partially assembled and requires a minimum of set-up assembly. Remove
the shipping carton from the planer upon receipt and check to seethat all parts were received without dam-
age.After the carton is examined, the power switch and extension tables should be mounted to the machine.
CONTENTSOF 408 PLANERSHIPPINGCARTON:
Item Qty.
1. Planer Assembly 1
2. Extension Tables 2
3. Bed Height Adjustment Crank 1
4. Bolt Bag 1
5. Operators' Manual 1
NOTE: Damaged and/or missing parts are to be reported to the transportation carrier. Manufacturer is
not responsible for shipping damage.
MOUNTING THE RB-69POWERSWITCH AND
RB-111SWITCHLOCK
1. Removejam nut from threaded stud on power
switch.
2. Insert switch stud through the hole in the side of
the left (facing infeed) skirt. The slot in the stud
should be up.
3. Place switch lock on switch stud ("ON" side up)
and secure with the jam nut.
4. Mount switch enclosure on left skirt with the car-
riagebolts, nuts and washersprovided in the bolt
bag. The rounded head of the bolts should be
on the outside. (fig. 1)
Fig. 1
- 4 -

MOUNTING RB-75 EXTENSION TABLES
1. Install two 5/16" bolts with lock and flat washers
from the bolt bag in the threaded holes on both
ends of the bed. Do not tighten. The bolts should
extend enough from the bed to allow the mount-
ing of the extension tables. (fig. 2)
2. Mount one of the tables by sliding it over the bolts
on one end of the bed.
3. Tighten the 5/16" bolts until the tables are snug.
4. Adjust table height. The infeed extension table
should be level with to 1/32" above the working
surface of bed. The outfeed table should be lev-
el with to 1/32" below the bed surface.
5. Tighten the 5/16" bolts.
6. Check and adjust if necessary.
POWER CONNECTIONS
EXTENSION TABLE
MOUNTING BOLT~.~
Fig. 2
Power for this machine should be supplied by a separate electrical circuit utilizing #12 or larger conductor
and that is protected with a 20 amp time lag fuse. If it is necessary to use an extension cord, use only 3
wire extension cords with 3 prong grounding type plugs and 3 pole receptacles. For distances up to 100
feet, use #12 conductor cords. For distances up to 150 feet, use #10 cords. Be sure the power switch is in
the "OFF" position before connecting the machine to electric power and that the electric current is of the
same characteristics as stamped on the motor nameplate. All line connections should make good connec-
tion. Operating this machine on voltage that is lower than recommended will damage the motor:
GROUNDING INSTRUCTIONS
This tool must be grounded while in use to protect the operator from electric shock. The standard motor
supplied with this machine is wired for 120 volt single phase power, is epuipped with an approved 3 conduc-
tor cord and a 3 prong grounding plug to fit the proper grounding type receptacle. The green conductor
in the cord is the grounding wire. Never connect the green wire to a live terminal. Do not remove the grounding
prong from the power plug.
NOTE: Be sure the receptacle that is to be used is properly grounded. Have a certified electrician check
the receptacle if you are not sure.
Adjustments may be made to the electric motor that will allow it to operate on 220 volt power. Theseadjust-
ments should only be performed by a certified electrician.
- 5 -

OPERATING INSTRUCTIONS FOR PLANING _
Before the machine is turned on, be sure that all nuts and bolts are tight and all wrenches have been re-
moved. Turn the machine on and visually inspect the feed rollers for proper rotation. Remember to keep
hands away from all moving parts. After the machine has been inspected, turn it off and execute the follow-
ing procedure. ,
1. Place the board to be planed (9 in. or longer) under the infeed roller.
2. Turn the crank handle clockwise and raise the planer bed until the board contacts the roller.
3. Remove the board.
4. Turn the crank handle 3 1/2 turns up. This prepares the machine to perform a light cut on the board
that will remove any high places.
5. Turn the machine on.
WARNING: DO NOT STAND DIRECTLY IN FRONT OF OR BEHIND THE MACHINE WHEN IN USE.
Fig. 3
6. Feed the board into the machine so that it travels in a straight line. (fig. 3)
7. Allow board to pass through machine. Remove board from outfeed extension table after it has stopped
moving.
8. Adjust bed to the desired depth of cut with the crank handle and feed board through again.
1/4 Turn Of Crank Handle = 1/64 inch cut
1/2 Turn Of Crank Handle = 1/32 inch cut
1 Full Turn Of Crank Handle = 1/16 inch cut
NOTE: DO NOT PLANE MORE THAN 3/32 INCH (1 1/2 TURNS) IN ONE PASS.
NEVER OPERATE THIS MACHINE WITH THE HOOD REMOVED.
-6 -

LUBRICATION _
(figs. 4 & 5)
CORNER SCREW (RB-78) AND CRANK SCREW (RB-79)
Apply 2-4 drops of machine oil at the bed ears and bottom wear washers as required for ease of turning.
FEED ROLL BEARINCS (RS-57)
Apply 2-4 drops of machine oil on the ends of the roller shafts at the bronze bushings every 20 hours
of operation. Lubricate more often during severe or intermittant use.
ELECTRICMOTOR (RB-52) Lubricate electric motor according to insrtructions supplied with motor.
CEAR BOX (RB-87)
Grease the gearbox assembly every 100 hours of operation. Do not over-grease as excess grease that
may escape from the assembly will cause belt slippage.
BED (RB-85) AND EXTENSION TABLES(RB-75)
Apply paste or paraffin wax to prevent oxidation and to ease feeding on bed and extension tables.
Fig. 4 Fig. 5
ADJUSTMENTS AND REPAIRS _
Disconnect machine from electric power supply before performing any adjustments to it. If unsure of the
identity or location of a part, refer to the parts breakdown drawing and list for assistance.
CUTTERHEAD KNIVES: REMOVAL
1. Disconnect from electrical power supply.
2. Loosen and remove the four nuts securing hood. Remove hood.
3. Mark gibs and slots so they may be replaced in the same location when blades are installed.
4. Loosen the three set screws in one of the gibs approximately 1/4 in.
5. Using a flat piece of metal approximately 1/4 x2'; tap the gib down in the cutterhead slot.
6. Remove knife when free.
7. Repeat procedure for the other two knives in the cutterhead.
- 7 -

INSTALLATION:
1. Clean all gibs, slots and
knives by wiping them with
an oiled cloth.
2. Turn slot upward and insert
gib on opposite side of slot
from jackscrewswith curved
edge facing jackscrew.
3. Insert knife with the beveled
edge toward the jackscrews
and center the knife in cut-
terhead. (fig. 6)
GIB SET SCREWS
'\
JACKSCREWS
Fig. 6 ~#j.
NOTE: BESURETHEJACKSCREWSARESCREWEDINTO THE CUTTERHEADFARENOUGH TO ALLOW THE
KNIVESTO RECEDEBELOWTHE MAXIMUM HEIGHTLEVEL.
4. Tighten set screws in gib r
slightly so that the gib holds
the knife in place.
5. Positionknife guageover the
knife with the bottom of the
plunger on the edge of the
knife. (fig. 7)
6. Adjust knife so the plunger
is 5/32" below the top. The
allen screw locks the plung-
er guide in position.
7. Raisethe knife by turning the
jackscrew counter-clockwise
until the knife guage plung-
er islevelwith the top of the
plunger guide.
8. Check the entire length of the knife for equal height. Fig. 7
9. If uneven, check tightness of gib set screws.Ifthey are too tight, the gibs will bind the blades and restrict
their movement.
10. When blades are of even height, tighten gib set screws and recheck knife height.
11. Repeat procedure for other blades. Recheck all set screws for tightness before starting machine and
after five minutes of operation. Be sure all fasteners are tightened and all tools are removed from ma-
chine prior to starting.
GEARBOXASSEMBLYV-BELTADJUSTMENT
1. Loosen the two bolts fastening RB-87gearbox assembly to skirt.
2. Slide gearbox assembly down to tighten belt.
3. Tighten the two mounting bolts while maintaining downward pressure on assembly.
- 8 -

ADJUSTING CUTTERHEAD
DRIVE BELTTENSION
1. Loosen bottom nut on RB-47
threaded rod (#80 on parts break-
down drawing).
2. To tighten belt, tighten nut on rod
that is above RB-187 adjustment
bracket. This should lower the mo-
tor adjustment bracket. (fig. 8)
3. When drive belt is of desired ten-
sion, tighten bottom nut on rod
against the adjustment bracket.
RB-85 BED HEIGHT ADJUSTMENT
1. Place RB-84crank handle on RB-79
crank screw. (fig. 9)
2. Turning handle clockwise raises
bed. Counter-clockwise lowers
bed.
3. Bed moves 1/16" with each com-
plete turn. Maximum depth of cut
for this machine is 3/32" (1 1/2
turns).
CLEANING RB-51-Z FEED ROLLERS
During extended periods of time and
during moist wood operation, resin
may accumulate on the feed rollers.
To remove this build-up, wipe the
rollers with a rag moistened with
kerosene.
KNIFE SHARPENING
1. For major sharpening, the beveled
edge of the knife should be ground
to a 30 or 45 degree angle over the
entire length of the knife to remove
all nicks and notches.
2. For minor sharpenings between
major sharpenings, use ahone on
the flat side of the knife cutting
edge over the entire length of the
knife.
RB-85 PLANER BED LEVELING
1. Place the RB-84 crank handle on
RB-79 crank screw.
2. Turn crank until the top of the cor-
ner screw ear on the bed is five
inches from the top of the base.
3. Remove the RB-61chain connector
link and remove chain from sprock-
ets. (fig. 10)
4. Adjust the corner screws until all
ears are the same distance from the
top of the base.
THREADED
ROD Fig. 8
Fig. 9
MASTER LINK
Fig. 10
- q -

5. Testdownward movement of
bed. Adjust the proper cor-
ner screwdown until corner
screw sprockets rest evenly
on all four corners. Press
downward on all corners to
check for movement.
6. Check the distance from the
cutterhead knives and bed
on both left and right sides.
Ifone sideismore than 1/64"
lower than the other, turn
the corner or crank screws
on the lower side clockwise
to raisethe bed (1/4 turn of
screws = 1/64" rise of bed).
Bedto knifedistancesshould
be the same on both sides.
7. Replace RB-61chain when
bed islevel.Becareful not to
move corner sprocket set-
tings, as turning them will
change the level of the bed.
Fig. 11
FLANGETTE
BOLTS
RB-85PLANERBEDREMOVAL
1. Remove hood.
2. Install RB-84 crank handle
and adjust planer bed to
lowest position.
3. Removeconnector link from
RB-61 chain and remove
chain.
4. Drive roll pinsout of all RS-4
corner sprockets. (fig. 11)
5. Loosen and remove top bar mounting bolts. Remove both RB-83top bars.
6. Remove corner screws.
7. Loosen and remove RB-64drive belt from cutterhead pulley.
8. Remove RB-56cutterhead drive pulley.
9. Loosen RB-59bearing collar on drive belt side of cutterhead. Loosen and remove bolts from flangettes
holding the bearing.
10. Remove RBZ-205threaded rods and RB-113feed roller springs from ends of feed rollers.
11. Remove bolts connecting the bottom of the RB-80sides to RB-184base. (fig. 12)
12. Slide side outward until bed can be tilted and removed from planer.
13. Reverseprocedure to install.
Fig. 12
- 10 -

RB-51-Z FEEDROLLERREMOVAL
1. Remove hood.
2. Remove RB-66 feed roller
drive belt.
3. Remove dust collector as-
sembly if necessary (outfeed
roller removal only).
4. Remove RBZ-205 threaded
rods and RB-113 feed roller
springs. (fig. 13)
5. Loosen and remove RB-64
drive belt from RB-56 drive
pulley.
6. Loosen RB-59 bearing collar
on drive belt side of cutter-
head. Loosen and remove
bolts in RB-58 flangettes. Fig. 13
7. Loosen and remove RB-83 top bar mounting bolts on right side of both bars.
8. Loosen and remove RB-80 side mounting bolts from right side.
9. Slide right side outward until roller can be removed.
10. Remove roller and RS-57 bearings. Bearings may be pulled off end of shaft.
11. Reverse procedure to install.
RB-78 CORNER SCREW REMOVAL
1. Install RB-84 crank handle.
2. Lower bed to lowest position.
3. Drive RZ-59 roll pin out of RS-4 sprocket in the corner screw to be removed.
4. Loosen and remove RB-83 top bar mounting bolts on bar that the screw to be removed passes through.
Remove this top bar.
5. Grasp the corner screw with a pair of pliers or visegrips and screw out of bed ear. If crank screw, use
crank handle to remove from ear.
6. Reverse procedure to install.
HINTS~ REDUCESNIPE~~~~~~~~~~~~~~~~~~.
Snipe is a deeper cut at the ends of a board. This deeper cut usually extends 2 to 3 inches from the ends
and can range from 1/64 to 1/8 inch in depth. It occurs when a board is held down by only one feed roller;
for example, when it enters the infeed side of the planer but has not yet reached the outfeed roller. When
an end is not held down, the planer knives tend to lift the board as they cut, raising it into the cutterhead
and producing a deeper cut. This also occurs when the board exits the planer when it is held only by the
outfeed roller. All planers tend to create snipe. R.B.I. planers have been designed to produce less snipe than
most others within their price range. The following suggestions may reduce or eliminate snipe from your boards.
1. Butt boards as they are fed into machine. This routine will limit snipe to one end of first and last boards.
2. Make thinner cuts.
3. Saw the the boards at an angle and plane. Square the ends after planing is completed.
4. Support the ends of long boards by roller stand.
- 11 -

- 1') -

408 PLANER PART LIST _
Key No. Part No. Part Description Qty.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
RB-99
RB-223
RBZ-207
RBZ-208
RB-l77
RB-241
RB-109
RZ-81
RZ-74
RZ-178
RZ-179
RB-150
RZ-181
RBZ-203
RBZ-205
RB·51-Z
RS-57
RB-l13
RB-91
RB-83
RZ-83
RB-60
RB-98
RB-13
RB-81-Z
RZ-182
RB-58
RB-59
RB-56
RB-93
RB-80
RB-85
RB-78
RB-84
RZ-59
RS-4
R-549
RB-74
RZ-52
RB-75
RB-184
RB-187
RB-186
RB-240
1/4-20 x 5/8 Carriage Bolt 28
1/4-20 Lock Nut 16
1/4 Split Lock Washer 12
1/4-20 Hex Nut 12
1/4 Flat Washer 2
Hood Top. . . . . . . . . . . . . . . . . . . . 1
Drive Guard 2
5/16-18 Hex Nut 26
5/16-18 Jam Nut. . . . . . . . . . . . . . .. 8
5/16 Lock Washer 17
5/16-18 x 3/4 Carriage Bolt 14
5/16 Flat Washer 14
5/16-18 x 1" Hex Head Bolt. . . . . .. 4
5/16-18 x 2" Hex Head Bolt. 3
5/16-18 x 3" Threaded Rod. . . . . .. 4
Feed Roller . . . . . . . . . . . . . . . . . 2
Feed Roller Bearing . . . . . . . 4
Feed Roller Spring .. . . . . . . . .. 4
Feed Roller Pulley 2
TopBar 2
1/4-20 x 1/4" Set Screw. . . . . . . . .. 8
8 1/4" Aluminum Gibs . . . . . . . . . .. 3
3/8-24 x 1/2" Set Screw. . . . . . . . .. 9
Knife (Set Of 3). . . . . . . . . . . . . . . .. 1
Cutterhead . . . . . . . . . . . 1
1/4-28 x 3/4" Socket Flat Head .... 6
Flangette . . . . . . . . . . . . . . . . . . . . 4
1" Bearing With Collar. . . . . . . . . .. 2
Cutterhead Drive Pulley. . . . . . . . .. 1
Cutterhead Drive Pulley Key. 1
Side. . . . .. 2
Planer Bed. . . . . . . . . . . . . . . . . . . .. 1
Corner Screw . . . . . . . . . . . . . . . . 3
Crank Handle " 1
1/4 x 1 1/8" Roll Pin _. . . .. 5
5-4 Corner Sprocket. . . . . . . . . . . .. 4
5/8" Machine Bushing " 4
Pointer. . . . . . . . . . . . . . . . . . . . . . .. 1
Drive Screws. . . . . . . . . . . . . . .. 4
Extension Tables. . . . . . . . . . . . . . .. 2
Base .
Motor Adjustment Bracket 1
Pivot Attaching Bracket . . . . . . . . .. 1
Hinge Rod. . . . . . . . . . . . . . . . . . . .. 1
- 13 -
Key No. Part No. Qty.
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
RB-185
RB-52
RB-55
RB-188
RB-69
RB-108
RB-101
RB-120
RB-87
RB-63
RZ-58
RB-158
RB-97
RB-62
RBZ-210
RB-67
RB-73
R-369
RB-95
RB-94
RB-96
RB-68
RB-90-Y
RB-160
RB-89
RB-57
RB-88
RB-61
RB-66
RB-65
RB-246
RB-111
RZ-73
RZ-71
RZ-SO
RB-47
RB-71
PS-36
RB-189
RZ-184
RB-l00
RB-241
RB-79
Motor Pivot. . . . . . . . . . . . . . . . . . .. 1
1 1/2 H.P. Motor With Key. . . . . 1
Motor Pulley. . . . . . . . . . . . . . . . . .. 1
Right Side Skirt. . . . . . . . . . . . . . . .. 1
Power Switch . . . . . . . . . . . . . . . . .. 1
Switch Enclosure. . . . . . . . . . . . . . .. 1
Strain Relief Bushing. . . . . . . . . . . .. 2
Cotter Key 3/32 x 1" . . . . . . . . . . .. 1
Gearbox Assembly. . . . . . . 1
Idler Spring. . .
3/8-16 Hex Nut. . . . . . . . . . . 1
Idler Arm Spacer .
Idler Bracket. . . . . . . . . . . . . . . . . .. 1
2" Idler Pulley. . . . . . . . . . . . . . . . .. 1
Grease Fitting . . . . . . . . . . . . . . . . .. 1
Gearbox Face Plate .
3/8 Flanged Bronze Bushing. . . 1
1/2" Flanged Bronze Bushing. . . . 7
Internal Gear V-Sheave . . . . . .. 1
Gearbox Spacer 3
Internal Gear Shaft. . . . . . . . . . . . .. 3
Spur Gear. . . . . . . . . . . . . . . . . . . .. 3
Gearbox Drive Pinion .
Bushing Pinion '" .
Gearbox Back Plate .
Key ' 1
Gearbox Drive Pulley. . . . . . . 1
#41 Chain ' 1
1490 V-Belt, Roller Drive. . . . . . .. 1
1340 V-Belt, Reducer Drive. . . . . .. 1
2340 V-Belt, Motor Drive 1
Power Switch Lock. . . . . . . . . . . . .. 1
3/8-16 Jam Nut 4
3/8" Lock Washer. . . . . . . . . . . . . .. 1
3/8" Flat Washer. . . . . . . . . . . . . . .. 2
3/8-16 x 4" Threaded Rod. . . . . . .. 1
3/16 x 1 1/4" Roll Pin 3
Name And Serial No. Tag . . . . . . .. 1
Left Side Skirt . . . . . . . . . . . . 1
5/16-18 x 5/16" Set Screw 1
Power Switch Decal ..
1
Power Pack (Motor W/Key, Switch,
Decal, Switch Lock) . .. 1
Crank Screw. . . . . . . . . . . . . . . . . .. 1

TROUBLE-SHOOTING -- __
PROBtEM
POSSIBLE CAUSE
Reverse motor rotation
feed roller pushes board out Motor turning in wrong direction
feed. rolter turns, but board does not
~'feed'
Obstruction under feed roller bearing
Feed roller worn or damaged
Build-up of resin material on rollers
POSSIBLE SOLUTION
Remove obstruction
Replace
Remove resin with kerosene
feed roller turns with jerking motion Feed roller belt slipping
Attempting too deep of a cut
Feed roller worn or damaged
Main drive belt loose
Small single drive belt slipping
Adjust feed belt tension or replace idler
spring
Reduce depth of cut
Replace feed roller
Adjust belt tension or replace belt
Adjust or replace belt
feed roller slips on board Build-up of resin or material on roller Clean roller
Board difficult to feed into machine Attempting too deep of cut
Adjust or replace belts
feed roller inoperative Reduction drive belts loose, off, or
broken
Feed roller bearings seized
Set screws in feed roller pulleys loose
Reduce depth of cut
Replace bearings
Align pulleys and tighten screws
Revolution marks in board
Ridge or grooves
Large hunks torn from board
Stripping or peeling
Press marks in wood
ROUGH SURFACEFINISH
Knives not installed to uniform height
Nicks in knives
Cutting against grain
Lumber green
Resin and material build-up on feed
rollers
Adjust height of knives
Resharpen knives
Feed other end of board first
Allow to dry
Clean feed rollers, reduce depth of cut
Deeper cut on the ends of the boards Board ends not supported
(snipe) Board too thin
Making deep cuts
Corner screws allowing vertical
movement of bed
See snipe reduction section for further information.
Support ends of boards with roller
stand
Use thicker boards
Reduce depth of cuts
Adjust corner screws
/
Cutterhead rpm slows when in use Knives dull
Making too deep of cut
Undersized motor
low current
Cutterhead drive belt slipping
.Sharpen knives
Reduce depth of cut
Replace with more powerful motor
Have electrician check electrical circuit
Tighten or replace belt
Excessvibration Knives improperly adjusted
Knives missing or damaged
Build-up on cutterhead
Drive belt loose
Planer head bearings failing or seized
V-pulley, motor; or cutterhead loose
Adjust knives
Replace knives
Clean cutterhead
Tighten belt
Replace
Tighten
Motor does not start Burned fuse
Thermal reset tripped
Replace fuse, use 20 amp time lag type
Allow motor to cool, then push reset
button, unclog motor vents if necessary
- 14 -

MOLDING ACCESSORY INSTALLATION INSTRUCTIONS _
The 400-A Molding Head, 402 Bit Holder, 402-C Custom Knife Holder and 408-GB Guide Board Assembly
are accessories available at extra cost.
TO INSTALL 400-A MOLDING HEAD AND 402 BIT HOLDER ONLY Perform steps A, B (1 or 2), C, D and F.
TO INSTALL 400-A MOLDING HEAD WITH 402-C CUSTOM KNIFE HOLDER Perform steps A, B (1 or 2), C,
E and F.
NOTE: STEPSA, B (1 OR 2), AND C MUST BECOMPLETED BEFOREOPERATING THE 408 WITH MOLDING
EQUIPMENT.
A. TABLEPREPARATION
1. Disconnect from electrical power source. Remove hood.
2. Place a 3/4/1 x 8 1/2" X 15 board under the cutterhead to prevent accidental raising of the bed into
the bits or knives.
3. Center the board with the bed and secure using bolts or clamp to the table.
B-1. FACEMOLDING GUIDES
1. Obtain two 1" x 1/1 (or wider) x 20" boards.
2. Center the boards under the cutterhead and mark the feed roller locations under the face.
3. Cut 1/4/1 deep arc in both boards to allow clearance of the feed rollers.
4. Place guides under the cutterhead and at 90 degrees to it. Secure with clamps or bolts.
8-2. EDGE MOLDING GUIDES
1. Obtain two 1" wide boards that are at least
1/2" shorter than the board to be edge
molded.
2. Center boards under cutterhead and mark
feed roller locations on the edge.
3. Cut 1/4/1 deep arcs in both boards to allow
clearance for the feed rollers.
4. Place guides under the cutterhead and at 90
degrees to it. Secure with clamps or bolts.
(fig. 14)
NOTE: 408-CB Cuide Board Assembly is available
from your nearest dealer or from the factory.
Pricing on request.
Fig. 14
- 1 c; -

c.
400-A MOLDING HEAD INSTALLATION
1. Disconnect from electrical power supply.
2. Remove hood.
3. Loosen set screws in both bearing collars.
4. Loosen the two bolts holding the bearing
flangettes on both sides of the cutterhead.
Remove the bolts on the motor pulley side.
5. Remove motor drive belt.
6.
7.
NOTE:
Lift motor drive end of cutterhead with
bearing and flangettes out of planer side.
Remove reduction drive belt and slide cut-
terhead through bearing and flangettes on
reduction drive side. (CAUTION: KNIVES
ARE SHARP) (fig. 15)
Set planing head aside.
400-AS Cutterhead Stand is available for
holding cutterhead to prevent damage to
knives.
8. The 400-A Quick Change Molding Head As-
sembly contains one 402 bit holder. If an-
other bit holder or 402-C Custom Knife
Holder is to be installed, they must be
mounted on the molding head shaft before
assembly.
9. Slide the molding head shaft into the bear-
ing and flangettes on the reduction drive
side of planer and install reduction drive
belt.
10. Lower the drive pulley end of the molding
head shaft with bearing and flangettes in
place into the motor drive side of planer.
(fig. 16)
11. Install flangette bolts. Tighten flangette bolts
on both sides of cutterhead.
12. Align all belts and tighten collar set screws.
13. Attach motor drive belt.
D. BIT INSTALLATION IN 402 BIT HOLDER
1. Slide bit into slot in bit holder. Position bit
in holder as shown in fig. 27.
2. Secure by tightening holding screw.
3. Repeat for the remaining cutterbits. (fig. 17)
4. Check knife to hood clearance by turning
cutterhead by hand. Minimum clearance is
1/8':
BEARING
AND FlANGETTES· .... .
..... :.;~,'.;.~~<::
Fig. 15
BEARING
AND FlANGETTES
----
Fig. 17
- 16 -

E. CUSTOM KNIFE
INSTALLATION IN 402-(
CUSTOM KNIFE HOLDER
1. Place proper weighted
gib in the knife holder
slot with the radius facing
away from the centerline
of the molding head.
2 . Slide knife into slot on
the radius side of the gib.
Position so that knife is as
shown in fig. 18.
3. Tighten gib set screws. Be
sure the knife is as far
down in slot as possible.
4. Turn cutterhead by hand
to check knife to hood
clearance. Minimum Fig. 18
clearance is 1/8'~(fig. 18)
NOTE: R.B.1.custom knives are balanced to fit in the 402-( Custom Knife Holder. If the knife is to be used
in a holder other than the 402-C, additional balance weights, gibs, or other equipment may be re-
quired and must be specified when ordering.
F. POSITIONINC BOARDS UNDER CUTTERBIT OR CUSTOM KNIFE
1. Disconnect from electrical power source.
2. Adjust guide boards to the thickness of the board to be molded and secure. Be sure the guide
boards are square with (at 90 degrees to) the cutterhead.
3. Slide the board to be molded under the infeed roller until the leading edge of the board is at the
point where the bit or knife is at its deepest cutting depth.
4. Raise the bed until knife or bit is close to the board to be planed. Rotate the molding head until
the edge of the knife or bit is at its lowest possible position. With the back of the knife or bit touch-
ing the leading end of the board to be planed, adjust the bed height to attain the desired depth
of cut. Use the end of the board as a guage. Slide the bit or knife holder on shaft to adjust cutter
alignment if necessary. Be sure all keys are in place and all set screws are tight before operating
machine.
NOTE: Depth of cut must be great enough so that the board to be molded is held securely by pressure
applied to it by the feed rollers.
S. Crank the bed down until the boards can be removed from under the feed rollers. Count the num-
ber or turns that are required.
6. Be sure all nuts, bolts and set screws are tight and all tools are removed.
7. Replace hood and connect to electrical power source.
8. Turn power switch on.
9. Raise bed to correct level by turning crank handle the same number of turns as in step 5.
10. Feed the board into machine.
11. Perform minor adjustments after first pass if necessary. Be sure to turn machine off and unplug it
from electrical power before performing adjustments to it.
- 17 -

PART LIST FOR MODEL 408 MOLDING ACCESSORIES _
When ordering parts, always state model number, part number, and part name as given in part lists. Do not
use key numbers when ordering parts. See Odering Parts section.
BIT HOLDER ASSEMBLY
Key. . . .
Bit Holder. . . . . .. . .
Set Screw. .. . .
Set Screw With Cone Point
Extra Bit Holders may be purchased.
Key No. Part No.
15 RB-400-A
1
RZ-185
2RB-56
3RB-93
4RB-58
5RB-59
6RB-401
7RB-406
8RZ-83
9RB-403
10 BIT
14 RB-402
3RB-93
7RB-406
8 RZ-83
9RB-403
Description Qty. Key No. Part No. Description Qty.
QUICK CHANGE MOLDING HEAD
tm ASSEMBLY
Set Screw. . . . . . . . . . . . . . . . . . . .. 1
V-Pulley. . . . . . . . . . . . . . . . . . . 1
Key 2
Flangette. . . . . . . . . . . . . . . . . . . . .. 2
Bearing And Collar . . . . . . . . . . . .. 1
Shaft. . . . . . . . . . . . . . . . . . . . . . . .. 1
Bit Holder. . . . . . . . . . . . . . . . . . . .. 1
Set Screw. . . . . . . . . . . . . . . . . . . .. 1
Set Screw With Cone Point 3
Random Set (3 Pieces) 1 set
20
16
17
18
RB-402-C
RB-93
RB-404
RZ-83
CUSTOM KNIFE HOLDER ASSEMBLY
Key.... . .. . .. .... . . . . 2
Custom Knife Holder. . . . . . 1
Set Screw. . . . . . . . . . . 2
14
Fig.19
RB-402-C Custom Knife Holders are not included in RB-400-A Molding Head Assembly and must be pur-
chased separately. R.B.I. Custom Knives are balanced at the factory and are shipped with gibs included.
SANDING ACCESSORIES INSTALLATION INSTRUCTIONS _
This RB-400-Ssanding head is shipped without felt or sandpaper installed. Correct lengths of felt material
and sandpaper are included in the sanding kit. Install the felt material first, then install the sandpaper over
the felt.
FELTMATERIAL INSTALLATION
1. Unwind the felt material.
2. Wrap the material around the head and mark the point at which the end of the strip meets the rest of
the strip. This distance marked should be the circumference of the sanding head.
3. Remove the material from the head and draw a diagonal line from the end of the strip to the wrap around
point. Cut on the line.
- 18 -

4. Apply the material to the head, wrapping it in a
spiral, starting with the diagonally cut edge. Rea-
lign the material after each complete wrap. After
afew revolutions havebeen completed, tape the
starting end of the material with masking tape.
Wrap the end twice with the tape. Continue wrap-
ping the material until the entire head iscovered.
5. Trim the other end of the material to the edge
of the head and tape with two turns of masking
tape. (fig. 20)
SANDPAPERINSTALLATIONINSTRUCTIONS
Sandpaper installation instructions are basically the
same asfelt installation instrucitons. Beginwrapping
sandpaper 180degreesfrom where felt wrap begins.
Use half the width of the masking tape when taping
ends of sandpaper.
Fig. 20
1. With the machine turned off, place the board to be sanded (at least 9" long) under the infeed 'roller.
2. Raisethe bed until the board makes contact with the roller.
3. Remove the board.
4. Raisethe bed 5/16" (5 turns of the crank handle). This will position the sanding head close to the board.
5. Turn the machine on.
6. Feed the board into the machine so that it travels in a straight path:
7. As the board passesunder the sanding head, slowly raisethe bed until the board contacts the head (ap-
prox. 1 to 3 turns).
8. Continue feeding board into machine until desired finish is attained. Do not raise bed more than .0075"
(1/8 turn) per pass.
HELPFULHINTSFOR SANDING
1. Boards to be sanded should be devoid of nails and other metal objects.
2. Some woods such as pine have large amounts of gum or resin that accumulates on the sandpaper very
quickly. Becauseof this, sanding these types of wood will yield poor results and is not recommended.
3. Use the abrasive cleaner stick that is provided to remove material build-up from sandpaper.
4. Removing more than 1116 of material with the sanding head will significantly shorten sandpaper life.
S. Do not make heavy passeswith the sanding head. Light passeswill result in smoother surface finishes.
- 19 -

RB-408-S SANDING KIT PART LIST _
Key No. Part No. Description Qty.
Fig. 21
1
2
3
4
5
6
7
8
9
RB-93
5-8-02
RB-56
RB-58
RB-59
RZ-83
5-8-03
5-8-12
RB-408-sFR
Key 1
Head 1
Pulley. . . . . . . . . . . . . . . . .. 1
Flangette . . . . . . . . . . . . . . .. 2
1" Bearing With Collar. . . .. 1
Set Screw .. . . . . . . . . . . . .. 1
Sandpaper 2
Abrasive Cleaner Stick. . . .. 1
Felt Material . . . . . . . . . . . .. 1
*Available in 80, 100, 150, 180, and 220 grit.
Specify desired grit when ordering.
WOODS AND THEIR CHARACTERISTICS _
The following is a listing of the hardness, workability, and uses of some of the more popular woods.
SOFT WOODS
Basswood
Light, straight-grained, and of fine texture. Easy to work. Suitable for both turning and carving. Applications
include picture frames, molding, furniture, and toys.
Cedar
Light, fine texture, and beautifully grained. Works and finishes easily. Popular material for moth resistant chests
and closets. Also utilized in toys, furniture, and other uses.
Cypress
Soft and easily worked. Possesses rich, reddish-brown color which makes it particularly suitable for furniture.
Extremely weather-resistant and often used in outdoor applications.
fir
Stiff, strong, and of even texture. Has an orange-brown color. Suitable for toys and other articles of heavy
construction.
Gum
Heavy, strong, and fine textured. Usually cross-grained and brown or yellow in color. Often twists or warps
when exposed to weather. Mainly used for interior finish and small objects.
Poplar
Fine textured, light, and very soft. Gray to yellow in color. Easy to work but not durable. Often used in furni-
ture that will not be subjected to rugged use.
Redwood
Light, fairly strong, and finishes well. Sapwood is whitish; hardwood is light red that turns brown when ex-
posed. Very durable and often used in cabinet work.
White Pine
Very light and soft. Although quality varies greatly, it is usually quite durable. Resists boring insects if sea-
soned properly. Exceptionally easy to work with almost unlimited applications.
- 20 -