Shop fox D4976 User manual

Figure 1. Model D4976 inventory.
The Model D4976 13" Spiral Cutterhead
is designed to be used only with the
DeWalt DW735 and DW735X Planers. DO
NOT install the D4976 in any other planer
model or make. Doing so could result
in property damage or serious personal
injury.
COPYRIGHT © JANUARY, 2022 BY WOODSTOCK INTERNATIONAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT
THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC. Printed in Taiwan
#22204SS
Model D4976
13" Spiral Cutterhead for
DeWalt DW735/DW735X Planer
Instruction Sheet
Phone #: [phone] • Tech Support: [e-mail] • Web: www.woodstockint.com
ABC
D
E
F
G
Recommended Tools
Specifications
Maximum Width of Cut ...........................13"
Cutterhead Diameter.............................17
⁄8 "
Number of Cutter Rows .............................3
Total Number of Indexable Cutters ............. 30
Description Qty
A. Ball Bearing 6202-2NSE ........................1
B. Ball Bearing 6204-2NSE ........................1
C. Flat Hd Torx Screws T-25 #10-32 x ½".......5
D. Carbide Inserts 15 x 15 x 2.5mm ............ 5
E. Spiral Cutterhead 13" ..........................1
F. T-Handle Torx Driver T-25 .....................1
G. Helical Pinion Gear 8T.........................1
Introduction
The D4976 13" Spiral Cutterhead is designed
to replace the straight-knife cutterhead on the
DeWalt DW735 and DW735X Planers.
The total procedure for changing the cutterhead
and reassembling the planer takes approximately
three hours. Read these instructions thoroughly
before beginning. These instructions make
reference to many procedures detailed in your
planer manual. Always consult your manual for
these procedures. We strongly recommend using
the new replacement bearings included with the
D4976, even if the existing bearings appear to
be in good condition. Call Technical Support at
[phone] if you need help.
Description Qty
Open-End Wrenches 6, 24 mm................. 1Ea
Deep Well Sockets 31, 40mm ................. 1Ea.
Retaining Ring Pliers (Internal and External) ... 1
Hex Wrench 4mm ....................................1
Torx Driver T-30 (Included with DW735/X) ......1
Phillips Screwdriver #2..............................1
Steel Hammer ........................................1
Hex Bolt 5
⁄16"-18 x 2..................................1
Pair of Heavy Leather Gloves ...................... 1
Wood Board (Minimum 12" Length) ...............1
Tape ........................................ As Needed
Scrap Cardboard ......................... As Needed
Inventory (Figure 1)

Cutterhead knives and inserts are razor
sharp! Always wear heavy leather gloves
when handling cutterheads, and avoid
contact with knives and inserts whenever
possible. Failure to comply can result in
serious personal injury.
Figure 2. Removing top cover.
Figure 3. Location of red wing nuts.
Figure 4. Alignment arrow on dust shroud.
Alignment
Arrow
Figure 5. Gearbox area components.
Chain Tensioner
Retaining Ring
Front Roller
Rear Roller
Sprocket
Spring
Chain
Depth Adjustment
Crank Handle
-2-
D4976 13" Spiral Cutterhead Instructions
Removing Existing Cutterhead
3. Remove red wing nuts holding dust shroud
and set aside (see Figure 3).
4. Rotate dust shroud away from cutterhead
so alignment arrow on fan housing
aligns with OPEN line on dust shroud
(see Figure 4).
5. Pull dust shroud away from fan housing and
remove.
CAUTION: Cutterhead knives will be
exposed at this time!
6. Remove gearbox cover located behind
turret lock on left side of planer.
7. Remove external retaining rings on front
and rear rollers (see Figure 5).
8. Remove spring from chain tensioner (see
Figure 5).
9. Remove sprockets and chain (see Figure 5).
10. Remove spacer on front roller behind
sprocket (see Figure 5).
1. DISCONNECT MACHINE FROM POWER.
2. Use T-30 Torx driver included with DW735/X
to remove screws holding top cover (see
Figure 2).

Figure 8. T-30 Torx screws on knife clamp.
Torx Screw
(1 of 8)
Figure 6. Pulley area components.
Chain Tensioner Assembly
Sprocket Chain
Cutterhead Pulley
Figure 7. Cutterhead lock lever.
Cutterhead
Lock Lever
Figure 9. Gearbox attachment screws.
-3-
D4976 13" Spiral Cutterhead Instructions
11. Remove depth adjustment crank handle on
right side of planer (see Figure 2 on Page 2).
12. Remove pulley cover.
13. Remove chain tensioner assembly (see
Figure 6).
14. Remove sprockets and chain (see Figure 6).
15. Press cutterhead lock lever down to allow
cutterhead to rotate (see Figure 7).
16. Remove drive belt by slowly rotating
cutterhead pulley counterclockwise and
pulling belt off. Use rear roller to secure
belt after removal.
17. Cover table under cutterhead carriage with
scrap cardboard to protect surface from
dropped parts/tools.
18. Press cutterhead lock lever and rotate
cutterhead until T-30 Torx screws are
visible on knife clamp (see Figure 8).
19. Remove screws securing knife clamp.
Note: T-30 Torx driver included with
DW735/X has magnets built into handle.
20. Attract knife clamp with magnet and
remove.
21. Attract knife with magnet and remove.
22. Repeat Steps 18–21 until all (3) knives have
been removed from cutterhead.
23. Remove cutterhead lock lever and spring
underneath that is hidden from view.
Note: Lock lever is not compatible with
the Model D4976, but should be kept if
planer is returned to original configuration.
24. Unfasten gearbox attachment screws (see
Figure 9).

Figure 11. Wood board between cutterhead
and carriage.
Figure 10. Supporting gearbox while turning
speed selector switch.
Speed
Selector
Switch
Figure 12. Helical pinion gear and retaining
ring.
Helical Pinion
Gear
Retaining
Ring
-4-
D4976 13" Spiral Cutterhead Instructions
25. While supporting gearbox, turn speed
selector switch on front panel clockwise to
release (see Figure 10).
Note: Gearbox will quickly separate from
planer after turning speed selector switch
to speed "2".
26. Pull gearbox out and rest it on planer
mount.
Note: Gearbox speed selection rod and
positioning pin will prevent gearbox from
being completely removed from planer.
Secure gearbox to planer with tape or
rope to prevent it from shifting during
disassembly.
27. Insert a wood board at least 12" in length
between cutterhead and cutterhead
carriage (see Figure 11). Verify cutterhead
no longer rotates.
28. Remove helical pinion gear from cutterhead
(see Figure 12).
29. Remove retaining ring (see Figure 12).
Spacer
Key 24mm
Nut
Cutterhead
Pulley
Figure 13. Cutterhead pulley assembly.
30. Remove 24mm hex nut from cutterhead
pulley (see Figure 13).
31. Remove cutterhead pulley, key, and spacer
(see Figure 13).
32. Remove retaining ring from right bearing
bore.
33. Install 5
⁄16"-18 x 2" hex bolt into helical
pinion gear threads (see Figure 14).
34. Remove wood board and gently tap hex
bolt dead center with hammer until
cutterhead is unseated from carriage (see
Figure 14).

Figure 17. Bearing impact distribution.
3
2
1
4
Figure 16. Guiding cutterhead into carriage.
Figure 14. Hex bolt in helical gear threads.
Hex Bolt
Inner Race
Outer Race
Rubber
Seal
Figure 15. Bearing outer race.
(Example)
-5-
D4976 13" Spiral Cutterhead Instructions
35. Pull cutterhead through right bearing bore.
36. Use a 32mm deep well socket or wood
block to remove left bearing from bore.
Note: Focus impact to bearing on outer
race (see Figure 15). Take care not to
damage rubber seal.
3. Lower cutterhead into carriage while
guiding threaded end through right bearing
bore (see Figure 16).
4. Install 5
⁄16"-18 x 2" hex bolt into helical
pinion gear threads.
5. Seat 6202-2NSE ball bearing into left bearing
bore using hex bolt as an alignment guide.
6. Use 32mm deep well socket or wood
block to gently tap bearing into bore until
retaining ring groove is visible. Bearing will
be flush with internal carriage wall.
Note: If using wood block to install
bearings, evenly distribute impact around
outer race to prevent bearing tilt. DO NOT
damage bearing shield (see Figure 17).
7. Re-install retaining ring into bearing bore
groove.
Installing Spiral Cutterhead
We strongly recommend using the new
replacement bearings included with the Model
D4976, even if the existing bearings appear to
be in good condition.
Tip: Wrap the new bearings and place them in
a freezer overnight. This will cause the bearing
metal to contract, making them easier to install.
To install spiral cutterhead, do these steps:
1. Remove spiral cutterhead from packaging.
2. Lightly oil left and right bearing bore
surfaces and remove any dust or dirt.

Spacer
Key 24mm
Nut
Cutterhead
Pulley
Figure 18. Cutterhead pulley assembly.
Figure 19. Drive belt cover location.
Figure 20. Gearbox locating pin alignment.
Alignment
Holes
Locating
Pins
Figure 21. Speed selector rod and "U" bracket.
"U"
Bracket
Speed
Selector Rod
Positioning
Pin
-6-
D4976 13" Spiral Cutterhead Instructions
8. Seat 6204-2NSE ball bearing into right
bearing bore using threaded cutterhead end
as an alignment guide.
9. Use 40mm deep well socket or wood
block to gently tap bearing into bore until
retaining ring groove is visible and bearing
is flush with internal carriage wall.
10. Re-install retaining ring into bearing bore.
11. Insert wood board between cutterhead and
cutterhead carriage. Verify cutterhead no
longer rotates.
12. Install spacer, key, and cutterhead pulley
onto cutterhead end (see Figure 18).
13. Re-install 24mm hex nut onto cutterhead
pulley.
14. Remove hex bolt and install helical pinion
gear.
15. Remove wood board.
16. Remove drive belt cover located on right
side (see Figure 19) and verify that drive
belt is centered on drive wheel.
17. Gently stretch drive belt over cutterhead
pulley while slowly rotating pulley
clockwise until belt is centered.
Note: Drive belt and pulley wheels have
grooves along their surface for alignment.
18. Verify drive belt is centered on cutterhead
and drive pulleys before re-installing drive
belt cover.
19. Turn speed selector switch clockwise to
speed "2".
20. Re-install gearbox by aligning both locating
pins on gearbox assembly with both
alignment holes on planer (see Figure 20).
21. While installing gearbox, confirm that "U"
bracket attached to speed selector switch
engages with positioning pin on gearbox
speed selection rod (see Figure 21).
Note: If gearbox does not fully seat during
Steps 20–21, slowly rotate cutterhead
pulley back-and-forth to re-align helical
pinion gear with gearbox.

Figure 22. Gearbox area components.
Chain Tensioner
Retaining Ring
Front Roller
Rear Roller
Sprocket
Spring
Chain
Figure 24. Cutterhead installed in planer.
(Example)
-7-
D4976 13" Spiral Cutterhead Instructions
22. Turn speed selector switch
counterclockwise to speed "1" to grasp
positioning pin with "U" bracket.
23. Re-install screws removed from gearbox in
Step 24 on Page 3 of Removing Existing
Cutterhead instructions.
24. Test for smooth operation of speed
selection assembly by cycling speed
selector switch from "1" to "2" and then
back to "1".
25. Re-install spacer on front roller, as shown in
Figure 22.
26. Re-install sprockets and chain on front and
rear rollers (see Figure 22).
27. Re-attach spring to chain tensioner. Verify
tensioner is engaged with chain, as shown
in Figure 22).
28. Re-install retaining rings on front and rear
rollers (see Figure 22).
29. Re-install gearbox cover.
31. Re-install chain tensioner and re-attach
spring. Verify tensioner is engaged with
chain (see Figure 23).
Figure 23. Pulley area components.
Chain Tensioner Assembly
Sprocket Chain
Cutterhead Pulley
32. Re-install pulley cover.
33. Re-install dust shroud into fan housing.
Note: DO NOT re-install cutterhead lock
lever! Lock lever not compatible with Model
D4976.
34. Rotate dust shroud towards cutterhead.
Verify alignment arrow on fan housing
aligns with CLOSED line on dust shroud.
35. Re-install red wing nuts on dust shroud.
36. Re-install top cover.
37. Remove any cardboard used to protect
planer table.
38. Connect power to machine and follow all
procedures outlined in your planer manual
for adjustment and calibration.
30. Re-install sprockets and chain on front and
rear rollers in pulley area (see Figure 23).

Figure 25. Rotating indexable carbide insert.
Reference Dot
-8-
D4976 13" Spiral Cutterhead Instructions
Item Needed:
Pair of Heavy Leather Gloves ...................... 1
T-Handle Torx Driver T-25 .......................... 1
T-30 Torx Driver (Included w/DW735/X) .........1
Torque Wrench 0-50in.-lb........................... 1
Clean Shop Rags.......................... As Needed
Degreaser ................................. As Needed
Light Machine Oil ........................ As Needed
The Model D4976 13" Spiral Cutterhead is
equipped with 30 indexable carbide inserts.
Each insert can be rotated to reveal any one
of its four cutting edges. If one cutting edge
becomes dull or damaged, rotate it 90˚ to reveal
a fresh cutting edge, as shown in Figure 25.
Rotating/Replacing Indexable Inserts Note: Proper cleaning is critical to
achieving a smooth finish. Contaminants
trapped between the insert and cutterhead
will slightly raise the insert, making
noticeable marks on your workpieces the
next time you plane.
5. Lubricate Torx screw threads with a light
machine oil, wipe excess oil off threads,
and torque screw to 48-50 inch/pounds.
6. Return planer to its original configuration
by performing Steps 33–38 on Page 7 of
Installing Spiral Cutterhead instructions.
Accessories
D4297—Indexable Carbide Inserts (10 pack)
Replacement indexable carbide inserts for Model
D4976 13" Spiral Cutterhead.
1
3
2
4
6
7
5
REF
PART # DESCRIPTION
1XD4976001 SPIRAL CUTTERHEAD 13"
2XD4976002 CARBIDE INSERT 15 X 15 X 2.5MM (10PK)
3XD4976003 FLAT HD TORX SCR T-25 #10-32 X 1/2
4XD4976004 BALL BEARING 6204-2NSE
5XD4976005 T-HANDLE TORX DRIVER T-25
6XD4976006 HELICAL PINION GEAR 8T
7XD4976007 BALL BEARING 6202-2NSE
Parts Breakdown & List
Each insert has a reference dot on one corner.
As the insert is rotated, the reference dot
location can be used as an indicator of which
edges are used and which are new. When the
reference dot revolves back to its starting
position, the insert should be replaced.
To rotate or replace an insert, do these steps:
1. DISCONNECT MACHINE FROM POWER!
2. Gain access to cutterhead by performing
Steps 2–6 of Removing Existing
Cutterhead instructions.
3. Remove Torx screw and carbide insert.
4. Clean all dust and dirt off insert and
cutterhead pocket from which insert was
removed, and replace insert so a fresh,
sharp edge is facing outward.