Grizzly G0900 User guide

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MODEL G0900

5 HP DELUXE SPINDLE SHAPER

OWNER'S MANUAL

(For models manufactured since 11/23)

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#CS20545 PRINTED IN TAIWA N

***Keep for Future Reference***

V3 .11. 23

This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators.

Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.

The owner of this machine/tool is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and comprehension, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal protective equipment.

The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Table of Contents

INTRODUCTION ............................................... 2

Contact Info.................................................... 2

Manual Accuracy Identification Controls & Components Machine Data Sheet

SECTION 1: SAFETY

Safety Instructions for Machinery Additional Safety for Shapers

SECTION 2: POWER SUPPLY

SECTION 3: SETUP

Needed for Setup Unpacking Inventory Cleanup Site Considerations Lifting & Placing Shaper Anchoring to Floor Assembly Adjusting Table Inserts Preparing Spindle for Test Run Dust Collection Test Run

SECTION 4: OPERATIONS

Operation Overview

Workpiece Inspection................................... 23

Using Featherboards Changing Cutter Rotation Changing Spindle Speed Installing Cutters Adjusting Spindle Height Adjusting Cutterhead Guard Adjusting Fence Straight Shaping Digital Readout Operation Using Rub Collars Irregular Shaping Pattern Work Shaping Small Stock

.................................................... 13

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SECTION 5: SHOP-MADE SAFETY ACCESSORIES

Making a Zero-Clearance Fence Making Featherboards Making Push Sticks Making Box Guards

SECTION 6: ACCESSORIES

SECTION 7: MAINTENANCE

Schedule Cleaning & Protecting Lubrication Replacing Spindle Bearings

V-Belt Tension & Replacement.................... 45

SECTION 8: SERVICE

Troubleshooting Adjusting Table Inserts Zeroing Out Fence Aligning Fence Faces Truing Wooden Fence

Aligning Pulleys............................................ 52

Adjusting Spindle Gib

SECTION 9: WIRING

Wiring Safety Instructions Wiring Diagram Electrical Components

SECTION 10: PARTS

Guard, Fence & Table Cabinet, Controls & Tools Motor, Handwheel & Spindles Labels & Cosmetics

WARRANTY & RETURNS

.............................................. 35

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We stand behind our machines! If you have questions or need help, contact us with the information below. Before contacting, make sure you get the

serial number

machine ID label. This will help us help you faster.

We want your feedback on this manual. What did you like about it? Where could it be improved? Please take a few minutes to give us feedback.

Email: manuals@grizzly.com

We are proud to provide a high-quality owner’s manual with your new machine!

instructions, specifications, drawings, and photographs in this manual. Sometimes we make mistakes, but our policy of continuous improvement also means that

you receive is

slightly different than shown in the manual

If you find this to be the case, and the difference between the manual and machine leaves you confused or unsure about something

check our

website for an updated version. W

current

manuals and

on our web-

site at

Alternatively, you can call our Technical Support for help. Before calling, make sure you write down the

serial number

from the machine ID label (see below). This information is required for us to provide proper tech support, and it helps us determine if updated documentation is available for your machine.

INTRODUCTION

Contact Info

and manufacture date from the

Grizzly Technical Support

1815 W. Battlefield Springfield, MO 65807 Phone: (570) 546-9663

Email: techsupport@grizzly.com

Grizzly Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Manual Accuracy

made every effort to be exact with the

sometimes the machine

e post

manual updates for free

www.grizzly.com.

manufacture date and

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 personal injury, damage to equipment, or poor work results.

Manufacture Date

Serial Number

-2-

Model G0900 (Mfd. Since 11/23)

Identification

Become familiar with the names and locations of the controls and features shown below to better understand the instructions in this manual.

A. Work Table B. Table Featherboard (1 of 2) C. Fence (1 of 2)

Fence Featherboard (1 of 2)

D. E. Guard Lock Knobs F. Cutterhead Guard G. Guard Adjustment Knobs H. Spindle Assembly I. Control Panel

J. Fence Lock Knobs K. Fence Assembly Adjustment Knob L. Fence Micro-Adjustment Knobs M. Dust Ports N. Cabinet Access Door O. Miter Gauge P. Spindle Elevation Handwheel Q. Motor Access Panel

For Your Own Safety Read Instruction Manual Before Operating Shaper

a) Wear eye protection. b) Be sure two-piece keyed washer is installed directly under cap screw and cap screw is tight. c) Feed workpiece against rotation of cutter. d) Do not use awkward hand positions. e) Keep fingers away from revolving cutter–use fixtures when necessary. f ) Use overhead guard when adjustable fence is not in place.

Model G0900 (Mfd. Since 11/23)

-3-

Controls &

To reduce your risk of serious injury, read this entire manual BEFORE

Components

Inside Cabinet Controls

using machine.

Refer to the following figures and descriptions to become familiar with the basic controls and components of this machine. Understanding these items and how they work will help you understand the rest of the manual and minimize your risk of injury when operating this machine.

Control Panel

FWD/REV

Switch

DRO Screen

ON Button

Motor Bracket

Handle

Figure 2. Cabinet control functions.

Spindle Assembly Lock Handle: Locks/unlocks

spindle seat to change spindle size.

Motor Bracket Handle: Engages and releases V-belt tension.

Spindle Assembly

Lock Handle

Work Area Controls

Zeroing Button

Emergency

mm/in. Button

Figure 1. Control panel functions.

ON Button: Turns machine ON.

Emergency STOP Button: Turns machine OFF

and prevents it from starting.

Forward/Reverse (FWD/REV) Switch: Starts, stops, and reverses spindle rotation.

Digital Readout (DRO) Screen: Displays height of the spindle in either inches or millimeters.

Zeroing Button: Adjusts height to 0 in./mm.

mm/in. Button: Displays cutter height in either

inches or millimeters.

-4-

STOP Button

Spindle

Elevation

Handwheel

Cabinet Access

Door

Figure 3. Cabinet components.

Spindle Elevation Handwheel: Raises and low-

ers spindle and cutter to desired height.

Cabinet Access Door: Allows access to inside cabinet to change spindle speed and size.

Model G0900 (Mfd. Since 11/23)

Guard Adjustment

Cutterhead

Guard

Knobs

Featherboard

Miter Gauge

Location

Starting Pin

Location

Fence Assembly

Adjustment Knob

Micro-Adjustment

Knobs

Featherboard

Adjustment

Handles

Lock Knob

(1 of 2)

Fence

Figure 4. Guard and table components.

Featherboards: Guide and support workpiece as

it moves past cutterhead.

Cutterhead Guard: Adjusts to protect user from accidental cutter contact or chips thrown by cutterhead.

Guard Adjustment Knobs: Adjust guard position/height.

Miter Gauge (not shown): Supports workpiece for controlled straight or angled cuts as it slides along the work table miter slot.

Starting Pin (not shown): Supports workpiece during beginning of freehand cuts until workpiece contacts rub collar (refer to Page 31).

Figure 5. Fence components.

Fence: Each fence is independently adjustable

side to side and front to back. Also removable for easy replacement with a zero-clearance or other custom-made fence.

Fence Lock Knobs: Tighten to lock fence position on table.

Fence Micro-Adjustment Knobs: Move each fence independently relative to cutterhead. One

turn moves each fence approximately

/64" (.015").

Fence Assembly Adjustment Knob: Moves entire fence and guard assembly on table using

rack and pinion. One turn is approximately 1

/8" of

movement across table.

Featherboard Adjustment Handles: Adjusts featherboard position.

Model G0900 (Mfd. Since 11/23)

-5-

Machine Data Sheet

MACHINE DATA

SHEET

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901

MODEL G0900 5 HP DELUXE SPINDLE SHAPER

Product Dimensions:

Weight.............................................................................................................................................................. 657 lbs.

Width (side-to-side) x Depth (front-to-back) x Height........................................................ 39-1/2 x 35-1/2 x 50-1/2 in.

Footprint (Length x Width)............................................................................................................... 23-1/2 x 25-1/2 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate

Content........................................................................................................................................................... Machine

Weight.............................................................................................................................................................. 812 lbs.

Length x Width x Height....................................................................................................................... 44 x 39 x 61 in.

Electrical:

Power Requirement........................................................................................................... 220V, Single-Phase, 60 Hz

Full-Load Current Rating........................................................................................................................................ 18A

Minimum Circuit Size.............................................................................................................................................. 30A

Connection Type....................................................................................................................................... Cord & Plug

Power Cord Included.............................................................................................................................................. Yes

Power Cord Length............................................................................................................................................... 10 ft.

Power Cord Gauge......................................................................................................................................... 12 AWG

Plug Included.......................................................................................................................................................... Yes

Included Plug Type.............................................................................................................................................. L6-30

Switch Type............................................................................................ Control Panel w/Magnetic Switch Protection

Motors:

Main

Horsepower................................................................................................................................................ 5 HP

Phase............................................................................................................................................ Single-Phase

Amps............................................................................................................................................................ 18A

Speed................................................................................................................................................ 3450 RPM

Type.......................................................................................................................... TEFC Capacitor Start/Run

Power Transfer ............................................................................................................................................ Belt

Bearings..................................................................................................... Shielded & Permanently Lubricated

Centrifugal Switch/Contacts Type......................................................................................................... External

Main Specifications:

Operation Info

Max. Cutter Height....................................................................................................................................... 5 in.

Max. Cutter Diameter................................................................................................................................... 7 in.

Spindle Sizes.................................................................................................................................. 3/4, 1-1/4 in.

Spindle Lengths........................................................................................................................... 3-7/8, 5-7/8 in.

Exposed Spindle Length............................................................................................................. 3-7/8, 5-7/8 in.

Spindle Cap. Under the Nut........................................................................................................ 3-1/2, 5-1/8 in.

Spindle Speeds........................................................................................................ 5,000, 7,000, 10,000 RPM

Spindle Travel.............................................................................................................................................. 4 in.

Spindle Openings.......................................................................................................... 2-1/2, 4-1/8, 5-1/4, 7 in.

-6-

Model G0900 (Mfd. Since 11/23)

Table Info

Accessories Included:

Number of Table Inserts................................................................................................................................... 3

Table Insert Sizes I.D........................................................................................................ 2-1/2, 4-1/8, 5-3/4 in.

Table Insert Sizes O.D...................................................................................................... 4-5/8, 6-1/4, 8-3/8 in.

Table Counterbore Diameter................................................................................................................. 5-3/4 in.

Table Counterbore Depth......................................................................................................................... 5/8 in.

Table Size Length................................................................................................................................ 39-1/4 in.

Table Size Width................................................................................................................................. 31-1/2 in.

Table Size Thickness............................................................................................................................ 3-1/4 in.

Floor to Table Height........................................................................................................................... 35-1/4 in.

Table Fence Length............................................................................................................................. 44-1/2 in.

Table Fence Width................................................................................................................................ 1-1/4 in.

Table Fence Height............................................................................................................................... 4-3/4 in.

Miter Gauge Info

Miter Angle.................................................................................................................................. 0 - 60 deg. L/R

Miter Gauge Slot Type.............................................................................................................................. T-Slot

Miter Gauge Slot Width............................................................................................................................. 3/4 in.

Miter Gauge Slot Height........................................................................................................................... 3/8 in.

Construction

Table....................................................................................................................... Precision-Ground Cast Iron

Cabinet.......................................................................................................................................... Formed Steel

Fence.................................................................................................................................................. Aluminum

Miter Gauge........................................................................................................................................ Aluminum

Guard........................................................................................................................................... Polycarbonate

Spindle Bearings................................................................................................................ Sealed & Lubricated

Paint Type/Finish....................................................................................................................... Powder Coated

Other

Other Specifications:

Country of Origin .............................................................................................................................................. Taiwan

Warranty ........................................................................................................................................................... 1 Year

Approximate Assembly & Setup Time ........................................................................................................ 30 Minutes

Serial Number Location .................................................................................................................................. ID Label

Sound Rating ..................................................................................................................................................... 85 dB

ISO 9001 Factory .................................................................................................................................................. Yes

Certified by a Nationally Recognized Testing Laboratory (NRTL) ......................................................................... Yes

Features:

Dual 4" Dust Ports DRO for Height Positioning Rack & Pinion Fence Adjustment 4-3/4" Aluminum Fence w/Featherboard Attachments Various Power Feeder Attachment Locations 3 Speeds: 5000, 7000, 10,000 RPM Fence Micro-Adjustment Knobs Quick-Release Belt Tensioner Poly-V Belt Drive 4" of Fence Travel 7" Maximum Cutter Diameter 3/4", 1-1/4" Spindles Included Fully Adjustable Clear Guard

Number of Dust Ports....................................................................................................................................... 2

Dust Port Size.............................................................................................................................................. 4 in.

Open-End Wrenches 14 x 17mm, 22 x 24mm Spindle Wrench 50mm Hex Wrenches 3, 6mm Combo Screwdriver #1 Starting Pin Featherboards for Table and Fence

Model G0900 (Mfd. Since 11/23)

-7-

SECTION 1: SAFETY

For Your Own Safety, Read Instruction

Manual Before Operating This Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures. Always use common sense and good judgment.

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe practices.

Alerts the user to useful information about proper operation of the

NOTICE

machine to avoid machine damage.

Safety Instructions for Machinery

OWNER’S MANUAL. Read and understand this

owner’s manual BEFORE using machine.

TRAINED OPERATORS ONLY. Untrained operators have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine. When machine is not being used, disconnect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make your workshop kid proof!

DANGEROUS ENVIRONMENTS. Do not use machinery in areas that are wet, cluttered, or have poor lighting. Operating machinery in these areas greatly increases the risk of accidents and injury.

MENTAL ALERTNESS REQUIRED. Full mental alertness is required for safe operation of machinery. Never operate under the influence of drugs or alcohol, when tired, or when distracted.

ELECTRICAL EQUIPMENT INJURY RISKS. You can be shocked, burned, or killed by touching live electrical components or improperly grounded machinery. To reduce this risk, only allow qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment.

DISCONNECT POWER FIRST. nect machine from power supply BEFORE making adjustments, changing tooling, or servicing machine. This prevents an injury risk from unintended startup or contact with live electrical components.

EYE PROTECTION. Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are NOT approved safety glasses.

Always discon-

-8-

Model G0900 (Mfd. Since 11/23)

may damage the wires inside. Do not handle

WEARING PROPER APPAREL. Do not wear loose clothing, gloves, neckties, or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to reduce risk of slipping and losing control or accidentally contacting cutting tool or moving parts.

HAZARDOUS DUST. Dust created by machinery operations may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece material. Always wear a NIOSH-approved respirator to reduce your risk.

HEARING PROTECTION. Always wear hearing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.

REMOVE ADJUSTING TOOLS. Tools left on machinery can become dangerous projectiles upon startup. Never leave chuck keys, wrenches, or any other tools on machine. Always verify removal before starting!

USE CORRECT TOOL FOR THE JOB. Only use this tool for its intended purpose—do not force it or an attachment to do a job for which it was not designed. Never make unapproved modifications—modifying tool or using it differently than intended may result in malfunction or mechanical failure that can lead to personal injury or death!

AWKWARD POSITIONS. Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury.

CHILDREN & BYSTANDERS. Keep children and bystanders at a safe distance from the work area. Stop using machine if they become a distraction.

GUARDS & COVERS. Guards and covers reduce accidental contact with moving parts or flying debris. Make sure they are properly installed, undamaged, and working correctly BEFORE operating machine.

FORCING MACHINERY. Do not force machine. It will do the job safer and better at the rate for which it was designed.

NEVER STAND ON MACHINE. Serious injury may occur if machine is tipped or if the cutting tool is unintentionally contacted.

STABLE MACHINE. Unexpected movement during operation greatly increases risk of injury or loss of control. Before starting, verify machine is stable and mobile base (if used) is locked.

USE RECOMMENDED ACCESSORIES. Consult

this owner’s manual or the manufacturer for rec-

ommended accessories. Using improper accessories will increase the risk of serious injury.

UNATTENDED OPERATION. To reduce the risk of accidental injury, turn machine OFF and ensure all moving parts completely stop before walking away. Never leave machine running while unattended.

MAINTAIN WITH CARE. Follow all maintenance instructions and lubrication schedules to keep machine in good working condition. A machine that is improperly maintained could malfunction, leading to serious personal injury or death.

DAMAGED PARTS. Regularly inspect machine for damaged, loose, or mis-adjusted parts—or any condition that could affect safe operation. Immediately repair/replace BEFORE operating machine. For your own safety, DO NOT operate machine with damaged parts!

MAINTAIN POWER CORDS. When disconnecting cord-connected machines from power, grab and pull the plug—NOT the cord. Pulling the cord

cord/plug with wet hands. Avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, and wet/damp locations.

EXPERIENCING DIFFICULTIES. If at any time you experience difficulties performing the intended operation, stop using the machine! Contact our Technical Support at (570) 546-9663.

Model G0900 (Mfd. Since 11/23)

-9-

Additional Safety for Shapers

Serious cuts, amputation, entanglement, or death can occur from contact with rotating cutter. Cutters or other parts improperly secured to spindle can fly off and strike nearby operators with great force. Flying debris can cause eye injuries or blindness. To minimize risk of getting hurt or killed, anyone operating shaper MUST completely heed hazards and warnings below.

AVOIDING CUTTER CONTACT: Keep unused

portion of cutter below table. Use smallest table insert possible. Adjust fences and guards as close as practical to cutter, or use a zero-clearance fence or box guard. Always keep some type of

guard or other protective device between your hands and cutter at all times!

PROTECT HANDS/FINGERS: While feeding workpiece, avoid awkward hand positions. Never pass hands directly over, or in front of, cutter. As one hand approaches a 6-inch radius point from

, move it in an arc motion away from cutter,

cutter and reposition it on the outfeed side.

FEEDING WORKPIECE: To reduce risk of accidental cutterhead contact, always use push blocks or some type of fixture, jig, or hold-down device to safely feed workpiece while cutting. Use an outfeed support table if shaping long workpieces to ensure proper support throughout entire cutting procedure. ALWAYS feed workpiece AGAINST rotation of cutter. NEVER start shaper with workpiece contacting cutter!

CUTTING DEPTH: Never attempt to remove too much material in one pass. Doing this increases risk of workpiece kickback. Instead, make several light passes—this is a safer way to cut and it leaves a cleaner finish.

SMALL WORKPIECES: There is a high risk of accidental cutter contact with small workpieces, because they are closer to cutter and more difficult to control. To reduce your risk, only feed small workpieces using jigs or holding fixtures that allow your hands to stay safely away from cutter. When possible, shape longer stock and cut to size.

SAFE CUTTER CLEARANCES: Operator or bystanders may be hit by flying debris if cutter contacts fence, guard, or table insert upon startup. Always ensure any new cutter setup has proper cutter rotational clearance before startup.

SAFE CUTTER INSTALLATION: Improperly secured knives/inserts, cutters, or rub collars may become dangerous projectiles if they come loose. Always ensure keyed washer is directly under cap screw and that cap screw is very secure. If spindle does not use a keyed washer, always tighten two spindle nuts together, and ensure BOTH are very secure. Never use cutters/bits rated for an RPM lower than spindle speed.

AVOIDING CLIMB CUTS: Feeding workpiece in same direction of cutter rotation is a “climb cut.” Climb cutting can aggressively pull workpiece— and hands—into cutter. Always first verify direction of cutter rotation before starting, and always feed workpiece AGAINST cutter rotation.

WORKPIECE CONDITION: Shaping a workpiece with knots, holes, or foreign objects increases risk of kickback and cutter damage/breakage. Thoroughly inspect and prepare workpiece before shaping. Always “square up” a workpiece before shaping or flatten workpiece edges with a jointer or planer. Rough, warped, or wet workpieces increase risk of kickback.

CUTTER POSITIONING: Whenever possible, make shaping cuts with cutter on underside of workpiece to reduce operator exposure to cutter.

-10 -

SAFETY GUARDS. To reduce risk of unintentional contact with cutter, always ensure included cutter guard, or a properly dimensioned box guard, or some other type of guard is installed and correctly positioned before operation.

CONTOUR SHAPING: To reduce risk of unintentional cutter contact while freehand shaping or using a rub collar as a guide, always use an overhead or “ring” type guard. To reduce kickback risk, always use starting pin or pivot board when starting the cut. NEVER start shaping at a corner!

Model G0900 (Mfd. Since 11/23)

SECTION 2: POWER SUPPLY

Before installing the machine, consider the availability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by an electrician or qualified service personnel in accordance with all applicable codes and standards.

or equipment damage may occur if machine is not properly grounded and connected to power

The full-load current rating is the amperage a machine draws at 100% of the rated output power. On machines with multiple motors, this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations.

The full-load current is not the maximum amount of amps that the machine will draw. If the machine is overloaded, it will draw additional amps beyond the full-load rating.

If the machine is overloaded for a sufficient length of time, damage, overheating, or fire may result— especially if connected to an undersized circuit. To reduce the risk of these hazards, avoid overloading the machine during operation and make sure it is connected to a power supply circuit that meets the specified circuit requirements.

For your own safety and protection of

Note: Circuit requirements in this manual apply to

a dedicated circuit—where only one machine will be running on the circuit at a time. If machine will be connected to a shared circuit where multiple machines may be running at the same time, consult an electrician or qualified service personnel to ensure circuit is properly sized for safe operation.

A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine. The power supply circuit used for this machine must be sized to safely handle the full-load current drawn from the machine for an extended period of time. (If this machine is connected to a circuit protected by fuses, use a time delay fuse marked D.)

This machine is prewired to operate on a power supply circuit that has a verified ground and meets the following requirements:

Availability

Electrocution, fire, shock,

supply.

Full-Load Current Rating

Circuit Information

property, consult an electrician if you are unsure about wiring practices or electrical codes in your area.

Full-Load Current Rating at 220V ..... 18 Amps

Model G0900 (Mfd. Since 11/23)

Circuit Requirements

Nominal Voltage .........20 8V, 230V, 22 0V, 240V

..........................................................60 Hz

Cycle Phase Power Supply Circuit Plug/Receptacle

........................................... Single-Phase

......................... 30 Amps

.......................................L6-30

-11-

Improper connection of the equipment-grounding wire can result in a risk of electric shock. The wire with green insulation (with or without yellow stripes) is the equipment-grounding wire. If repair or replacement of the power cord or plug is necessary, do not connect the equipment-grounding wire to a live (current carrying) terminal.

Check with a qualified electrician or service personnel if you do not understand these grounding requirements, or if you are in doubt about whether the tool is properly grounded. If you ever notice that a cord or plug is damaged or worn, disconnect it from power, and immediately replace it with a new one.

We do not recommend using an extension cord with this machine. cord, only use it if absolutely necessary and only on a temporary basis.

Extension cords cause voltage drop, which can damage electrical components and shorten motor life. Voltage drop increases as the extension cord size gets longer and the gauge size gets smaller (higher gauge numbers indicate smaller sizes).

Any extension cord used with this machine must be in good condition and contain a ground wire and matching plug/receptacle. Additionally, it must meet the following size requirements:

Grounding Requirements

This machine MUST be grounded. In the event of certain malfunctions or breakdowns, grounding reduces the risk of electric shock by providing a path of least resistance for electric current.

This machine is equipped with a power cord that has an equipment-grounding wire and a grounding plug. Only insert plug into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances. DO NOT modify the provided plug!

No adapter should be used with plug. If plug does not fit available receptacle, or if

process. DO NOT connect to power until

L6-30 GROUNDED

LOCKING

RECEPTACLE

Grounding Prong

is Hooked

L6-30

LOCKING

PLUG

Serious injury could occur if you connect machine to power before completing setup

instructed later in this manual.

Current Carrying Prongs

Figure 6. Typical L6-30 plug and receptacle.

machine must be reconnected for use on a different type of circuit, reconnection must be performed by an electrician or qualified service personnel, and it must comply with all local codes and ordinances.

-12-

Extension Cords

If you must use an extension

Minimum Gauge Size ...........................12 AWG

Maximum Length (Shorter is Better).......50 ft.

Model G0900 (Mfd. Since 11/23)

SECTION 3: SETUP

This machine was carefully packaged for safe transport. When unpacking, separate all enclosed items from packaging materials and inspect them for shipping damage.

please

IMPORTANT:

you are completely satisfied with the machine and have resolved any issues between Grizzly or the shipping agent. You MUST have the original pack-

aging to file a freight claim. It is also extremely helpful if you need to return your machine later.

The following items are needed, but not included, for the setup/assembly of this machine.

Needed for Setup

This machine presents serious injury hazards to untrained users. Read through this entire manual to become familiar with the controls and operations before starting the machine!

Wear safety glasses during the entire setup process!

Description Qty

• Precision Level ........................................... 1

• Safety Glasses (for each person) ............... 1

• Solvent/Cleaner .......................................... 1

• Shop Rags .................................................. 1

• Lifting Straps (rated for at least 750 lbs.) ... 2

• Lifting Equipment

(rated for at least 750 lbs.) .......................... 1

• Dust Hose 4" .............................................. 2

• Dust Hose Clamp 4" ................................... 4

• Another Person .......................................... 1

HEAVY LIF T! Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk, get help from other people and use a forklift (or other lifting equipment) rated for weight of this machine.

Unpacking

If items are damaged

call us immediately at (570) 546-9663.

Save all packaging materials until

Model G0900 (Mfd. Since 11/23)

-13-

Inventory

The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them.

If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store.

NOTICE

If you cannot find an item on this list, carefully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpacking or they are pre-installed at the factory.

Box 1 (Figure 7) Qty

A. Shaper Unit ................................................ 1

Box 2 (Figure 8) Inside Cabinet Qty

B. Miter Gauge ................................................ 1

C. Drawbar ...................................................... 1

D. Starting Pin ................................................. 1

E. Table Featherboards .................................. 2

—Knob Bolts M5-.8 x 25

—Flat Washers 5mm.................................. 2

—Sliding Blocks

F. Spindles 3/4" w/Spacers .............................. 1

G. Spindles 11/4" w/Spacers ............................. 1

H. Spindle Wrench 50mm ............................... 1

I. Combo Screwdriver .................................... 1

J. Hex Wrenches 3, 6mm .........................1 Ea.

K. Open-End Wrench 22 x 24mm ................... 1

L. Open-End Wrench 14 x 17mm ................... 1

......................................... 2

............................ 2

Figure 7. Shaper unit.

Figure 8. Small parts inventory.

-14-

Model G0900 (Mfd. Since 11/23)

Cleanup

The unpainted surfaces of your machine are coated with a heavy-duty rust preventative that prevents corrosion during shipment and storage. This rust preventative works extremely well, but it will take a little time to clean.

Be patient and do a thorough job cleaning your machine. The time you spend doing this now will give you a better appreciation for the proper care of your machine's unpainted surfaces.

There are many ways to remove this rust preventative, but the following steps work well in a wide variety of situations. Always follow the manufacturer’s instructions with any cleaning product you use and make sure you work in a well-ventilated area to minimize exposure to toxic fumes.

Before cleaning, gather the following:

• Disposable rags

• Cleaner/degreaser (WD•40 works well)

• Safety glasses & disposable gloves

• Plastic paint scraper (optional)

Basic steps for removing rust preventative:

Many cleaning solvents

work in a well-ventilated

Cleanup

Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. Avo id using these products to clean machinery.

Put on safety glasses.

Coat the rust preventative with a liberal

amount of cleaner/degreaser, then let it soak for 5–10 minutes.

Wipe off the surfaces. If your cleaner/degreas-

er is effective, the rust preventative will wipe off easily. If you have a plastic paint scraper, scrape off as much as you can first, then wipe off the rest with the rag.

are toxic if inhaled. Only

area.

NOTICE

Avoid harsh solvents like acetone or brake parts cleaner that may damage painted surfaces. Always test on a small, inconspicuous location first.

T23692—Orange Power Degreaser

A great product for removing the waxy shipping grease from the non-painted parts of the machine during clean up.

Order online at

www.grizzly.com

Call 1-800-523-4777

Repeat Steps 2–3 as necessary until clean,

then coat all unpainted surfaces with a quality metal protectant to prevent rust.

Model G0900 (Mfd. Since 11/23)

Figure 9. T23692 Orange Power Degreaser.

-15-

Site Considerations

Weight Load

Refer to the of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.

Space Allocation

Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual.

See below for required space allocation.

Physical Environment

Extreme conditions for this type of machinery are

Place this machine near an existing power source.

other hazards. Make sure to leave enough space

Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated.

Machine Data Sheet for the weight

Children or untrained people may be seriously injured by this machine. Only install in an access restricted location.

Min. 30"

The physical environment where the machine is operated is important for safe operation and longevity of machine components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions.

generally those where the ambient temperature range exceeds 41°–104°F; the relative humidity range exceeds 20%–95% (non-condensing); or the environment is subject to vibration, shocks, or bumps.

Electrical Installation

Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or

around machine to disconnect power supply or apply a lockout/tagout device, if required.

Lighting

Wall

Lighting around the machine must be adequate enough that operations can be performed safely.

13"

-16 -

35½"

Figure 10. Minimum working clearances.

39½"

Model G0900 (Mfd. Since 11/23)

Anchoring machinery to the floor prevents tipping or shifting and reduces vibration that may occur during operation, resulting in a machine that runs slightly quieter and feels more solid.

If the machine will be installed in a commercial or workplace setting, or if it is permanently connected (hardwired) to the power supply, local codes may require that it be anchored to the floor.

If not required by any local codes, fastening the machine to the floor is an optional step. If you choose not to do this with your machine, we recommend placing it on machine mounts, as these provide an easy method for leveling and they have vibration-absorbing pads.

Lifting & Placing

Lag shield anchors with lag screws (see below) are a popular way to anchor machinery to a concrete floor, because the anchors sit flush with the floor surface, making it easy to unbolt and move the machine later, if needed. However, anytime local codes apply, you MUST follow the anchoring methodology specified by the code.

Shaper

The Model G0900 is a heavy machine. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use power equipment rated for at least 1500 lbs. to move the shipping crate and remove the machine from the crate.

The Model G0900 can be lifted with one of the following methods:

Anchoring to Floor

Number of Mounting Holes ............................ 4

Diameter of Mounting Hardware

.................1⁄2"

• Lifting Straps & Safety Hooks: Connect

two safety hooks to chains or web straps that are capable of securely hooking underneath the table edge at the locations shown in Figure 11. Then attach the chains or web straps to a center safety chain secured to the power lifting equipment.

Forklift Forks: Position the forks under the

•

table and close to the cabinet (see Figure

11). Use cardboard to protect the table and cabinet from the forks.

Figure 11. Locations for lifting.

Model G0900 (Mfd. Since 11/23)

Anchoring to Concrete Floors

Lag Screw

Flat Washer

Machine Base

Concrete

Figure 12. Popular method for anchoring

machinery to a concrete floor.

Lag Shield Anchor

Drilled Hole

-17-

Assembly

The machine must be fully assembled before it can be operated. Before beginning the assembly process, refer to

and gather

all

To ensure the assembly process

goes smoothly, first clean any

covered or coated in heavy-duty rust preventative (if applicable).

Adjusting

Table Inserts

Needed for Setup

listed items.

parts that are

Most of your Model G0900 has been assembled at the factory, but some parts must be assembled or installed after delivery.

In order to perform a test run, verify the following:

Table insert flushness (this page).

Spindle and drawbar assembly (Page 19).

Dust collection system connection (Page 20).

The Model G0900 is supplied with three table inserts which give you four possible opening diameters in the shaper table surface. Use the smallest opening that a particular cutter will allow to support the workpiece and reduce 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 removable table inserts and one semi-permanent table insert. The semi-permanent table insert must be flush with the top of the table.

To adjust insert:

Remove two smaller inserts from table

opening.

Lay straightedge across semi-permanent

insert and table surface in pattern shown in

Figure 13.

-18-

Phillips Head

Table Surface

Figure 13. Straightedge and surface pattern.

3. Adjust phillips head screws so that ends of

straightedge lay flat on table surface at all positions of pattern above.

IMPORTANT: Table insert and surface must

be aligned evenly to ensure workpiece does not catch on table insert or surface and kick back.

Model G0900 (Mfd. Since 11/23)

Screws (1 of 3)

Table Insert

Straightedge

Preparing Spindle

for Test Run

2. Insert spindle base into spindle cartridge (see Figure 15). Thread the spindle nut onto the

cartridge approximately 1 turn.

Each of the two spindles that come with the Model G0900 is sized to work efficiently with different sized cutters and spacers. The spindles must be inserted correctly 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:

Spindle

Base

Spindle

Cartridge

Figure 15. Inserting spindle into place.

3. Insert drawbar approximately 10-15 turns into

the bottom of the spindle base assembly, up through spindle pulley and assembled parts (see Figure 16).

Drawbar

1. Unlock spindle seat by pulling spindle assem-

bly lock handle and turning Figure 14). Turn V-belt and pulleys until click can be heard.

Spindle Assembly

Lock Handle

V-Belt

Figure 14. Spindle seat and pulleys.

⁄4 turn (see

Spindle Base

Assembly

10-15 Turns

Figure 16. Inserting drawbar into place (spindle

housing removed for clarity.

Make sure the spindle and drawbar are aligned and properly seated before tightening the drawbar nut. Improper assembly can create an unsafe condition and possible injury to the operator.

Model G0900 (Mfd. Since 11/23)

-19 -

4. Secure spindle nut with spindle wrench and tighten drawbar nut (see Figure 17). DO

NOT use excessive force.

Figure 17. Tightening drawbar nut (fence

removed for clarity).

5. Lock spindle seat by returning spindle assembly lock handle to original position. Spindle should rotate freely in both directions

securely.

Dust Collection

This machine creates a lot of wood chips/ dust during operation. Breathing airborne dust on a regular basis can result in permanent respiratory illness. Reduce your risk by wearing a respirator and capturing the dust with a dust-collection system.

Minimum CFM at Dust Port: 400 CFM

Do not confuse this CFM recommendation with the rating of the dust collector. To determine the CFM at the dust port, you must consider these variables: (1) CFM rating of the dust collector, (2) hose type and length between the dust collector and the machine, (3) number of branches or wyes, and (4) amount of other open lines throughout the system. Explaining how to calculate these variables is beyond the scope of this manual. Consult an expert or purchase a good dust collection "how-to" book.

To connect dust collection system to machine:

Fit 4" dust hoses over two dust ports and

1. secure in place with hose clamps (see Figure

18).

Figure 18. Attached dust hoses.

2. Tug hoses to make sure they do not come

off. Note: A tight fit is necessary for proper performance.

-20-

Model G0900 (Mfd. Since 11/23)

Test Run

Once assembly is complete, test run the machine to ensure it is properly connected to power and safety components are functioning correctly.

If you find an unusual problem during the test run, immediately stop the machine, disconnect it from power, and fix the problem BEFORE operating the machine again. The

table in the

SERVICE section of this manual can help.

DO NOT start machine until all preceding setup instructions have been performed. Operating an improperly set up machine

ed results that can lead to serious injury,

Serious injury or death can result from

Troubleshooting

Twist Emergency STOP button clockwise

until it springs out (see Figure 19). This resets the switch so the machine can start.

Figure 19. Resetting the switch.

The Test Run consists of verifying the following:

1) The motor powers up and runs correctly, and

2) the Emergency STOP button disables the machine properly.

using this machine BEFORE understanding its controls and related safety information. DO NOT operate, or allow others to operate, machine until the information is understood.

may result in malfunction or unexpect-

death, or machine/property damage.

To test run machine:

6. Press ON button to turn machine ON.

. Move FWD/REV switch to FWD position.

Verify motor starts up and runs smoothly without any unusual problems or noises.

. Move FWD/REV switch to STOP position and

allow spindle to come to a complete stop.

. Move FWD/REV switch to REV position.

Verify motor starts up and runs smoothly without any unusual problems or noises.

Press Emergency STOP button to turn

10.

machine OFF.

WITHOUT resetting Emergency STOP but-

11.

ton, try to start machine by pressing the ON button. The machine should not start.

— If the machine does not start, the safety

feature of the Emergency STOP button is working correctly. Congratulations! The Test Run is complete.

Clear all setup tools away from machine.

2. Press Emergency STOP button.

3. Move FWD/REV switch to STOP position.

4. Connect machine to power by inserting power

cord plug into a matching receptacle.

Model G0900 (Mfd. Since 11/23)

— If the machine does start, immediately

move FWD/REV switch to STOP and disconnect power. The safety feature of the Emergency STOP button is NOT working properly and must be replaced before further using the machine.

-21-

SECTION 4: OPERATIONS

To reduce your risk of serious injury, read this entire manual BEFORE

ing loss can occur while operating this

Keep hair, clothing, and

ing parts at all times. Entanglement can result in death, amputation, or

The purpose of this overview is to provide the novice machine operator with a basic understanding of how the machine is used during operation, so the

discussed later

in this manual

Due to the generic nature of this overview, it is not intended to be an instructional guide. To learn more about specific operations, read this entire manual,

training from experienced machine operators outside of this manual by reading "how-to" books, trade magazines, or websites.

Operation Overview

jewelry away from mov-

machine controls/components

are easier to understand.

seek additional

, and do additional research

using machine.

Eye injuries, respiratory problems, or hear-

severe crushing injuries!

If you are not experienced with this type of machine, WE STRONGLY RECOMMEND that you seek additional training outside of this manual. Read books/magazines or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.

To complete a typical operation, the operator does the following:

Examines the workpiece to make sure it is

suitable for cutting.

Installs the cutter onto the spindle and adjusts

the spindle height for the operation.

tool. Wear personal protective equipment to reduce your risk from these hazards.

-22-

Correctly adjusts the safety guard and fence

for the operation and locks them in place.

Checks the outfeed side of the machine

for proper support and to make sure the workpiece can safely move past the cutter without interference.

Model G0900 (Mfd. Since 11/23)

5. Places the workpiece on the infeed side

of the machine and stabilizes it with holddowns, jigs, or other safety workpiece holding devices.

Removes any clothing, apparel, or jewelry

that may become entangled in shaper.

Puts on safety glasses and a respirator, and

locates push sticks if needed.

Workpiece Inspection

Some workpieces are not safe to cut or may require modification before they are safe to cut.

Before cutting, inspect all workpieces for the following:

Starts dust collector, then turns machine ON.

Verifies cutter rotation and feed directions.

10. Feeds workpiece through the cut while main-

taining firm pressure on workpiece against both table and fence, while always keeping hands and fingers out of the cutting path.

Stops shaper, then turns OFF dust collector.

11.

• Material Type: This machine is intended for cutting natural and man-made wood products, laminate covered wood products, and some plastics. Cutting drywall or cementitious backer board creates extremely fine dust and may reduce the life of the bearings. This machine is NOT designed to cut metal, glass, stone, tile, etc.; cutting these materials with a shaper may lead to injury.

• Foreign Objects: Nails, staples, dirt, rocks and other foreign objects are often embedded in wood. While cutting, these objects can become dislodged and hit the operator, cause kickback, or break the blade, which might then fly apart. Always visually inspect your workpiece for these items. If they can't be removed, DO NOT cut the workpiece.

• Large/Loose Knots: Loose knots can become dislodged during the cutting operation. Large knots can cause kickback and machine damage. Choose workpieces that do not have large/loose knots or plan ahead to avoid cutting through them.

Model G0900 (Mfd. Since 11/23)

• Wet or "Green" Stock: Cutting wood with a moisture content over 20% causes unnecessary wear on the blades, increases the risk of kickback, and yields poor results.

• Excessive Warping: Workpieces with excessive cupping, bowing, or twisting are dangerous to cut because they are unstable and often unpredictable when being cut. DO NOT use workpieces with these characteristics!

• Minor Warping: Workpieces with slight cupping can be safely supported if the cupped side is facing the table or the fence. On the contrary, a workpiece supported on the bowed side will rock during a cut and could cause kickback or severe injury.

-23-

Using Featherboards

Featherboards are used to hold the workpiece flat on the table and snug against the fence. The G0900 includes two different types of featherboards: one for use with the table and one for use with the fence.

Using Fence Featherboards

Fence featherboards come pre-installed on fence faces, allowing clearance with table between 1"

and 5 clearance, you may remove the featherboard from the L-bracket it comes installed on.

To move featherboard to upper slot on fence:

⁄4". However, for 0" clearance and up to 23⁄4"

Using Table Featherboards

1. To install table featherboards, slide (2) T-slot

nuts into T-slot on table (see Figure 20). Tighten knobs at desired position. Adjust guard and fence to achieve anywhere from 0" to 8" of clearance.

T-Slot

Featherboard

T-Slot Nuts

Figure 20. Table featherboard installation.

1. Remove hardware securing featherboard to

bracket (see Figure 21).

L-Bracket

Knob Bolt

Flat Washer

Carriage Bolt

Figure 21. L-bracket and securing hardware.

2. Re-install hardware removed in Step 1 to

featherboard, then slide carriage bolts into upper slot on fence face (see Figure 22).

Note: Position a featherboard for both infeed and outfeed of workpiece to fully support throughout cut. Arrow on featherboard indicates workpiece travel.

-24-

Upper Slot

Carriage Bolt

Figure 22. 0" to 23⁄4" clearance placement.

Note: Position a featherboard for both infeed and

outfeed of workpiece to fully support throughout cut. Arrow on featherboard indicates workpiece travel.

Model G0900 (Mfd. Since 11/23)

Changing

Cutter Rotation

IMPORTANT: Always verify the direction of the

cutter rotation before any shaping operation. The cutting operation should feed AGAINST direction of cutter rotation.

The G0900 is equipped with a FWD/REV (forward/reverse) switch, as shown in Figure 23. In most cases, the shaper should be run in the FWD direction.

2. Open cabinet access door, then release belt tension by pulling the motor bracket handle (see Figure 24).

FWD/REV

Switch

Figure 23. Location of FWD/REV switch.

In some instances, it will be necessary to flip the cutter over and reverse the cutter rotation.

Whenever possible, mount the cutter so the stock is milled on the bottom side (the side away from the operator). This does a better job and it is safer for the operator. Refer to Using Rub Collars,

Page 30.

Changing

Spindle Speed

Figure 24. Location of motor bracket handle.

3. Move V-belt to a sheave on motor and spindle pulleys to select desired speed (see Figure 25.)

5,000

7,000

10,000

Figure 25. Speed change belt positions.

Tighten belt by locking motor bracket han-

dle. When belt is properly tensioned, there should be approximately in the center of the belt when you press it with your thumb. Refer to V-Belt Tension & Replacement on Page 45.

Spin pulley by hand to ensure proper tracking.

6. Close access door.

⁄4" of deflection

The Model G0900 Shaper 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 MACHINE FROM POWER!

Model G0900 (Mfd. Since 11/23)

-25-

Installing Cutters

Large cutters (31⁄2" or greater) must be operated at 5,000 or 7,000 RPM; smaller cutters can be operated at 10,000 RPM. Cutters are advertised with and should not exceed their rated RPM. Always use the largest spindle size possible, and never use a cutter bore more than one size larger than the spindle size.

Tools Needed: Qty

Spindle Wrench 50mm ...................................... 1

Hex Wrench 8mm

To install a cutter:

.............................................. 1

Tighten cap screw with hex wrench while

holding spindle stationary with spindle wrench (see Figure 27).

1. DISCONNECT MACHINE FROM POWER!

Raise safety guard out of the way and raise

spindle to maximum height.

Remove spindle cap screw and remove any

unneeded spacers.

Place the cutter on the spindle. Make sure

the rotation is correct for your application.

Use spacers to suit your particular application.

6. Place the corresponding spindle two-piece

keyed washer above the cutter and spacers and tighten the cap screw (see Figure 26).

Cap Screw

Two-Piece

Spacers

Keyed

Washer

Figure 27. Tightening spindle cap screw.

8. Replace safety guard and lower spindle to

desired height.

Adjusting

Spindle Height

To adjust cutter height:

Move spindle up or down with elevation

handwheel until desired position is achieved (see Figure 28).

Figure 26. Cutter and fasteners installed.

-26-

Cutter

Figure 28. Spindle elevation handwheel.

2. Return spindle elevation to 0" by pressing

zeroing button on control panel.

Model G0900 (Mfd. Since 11/23)

Adjusting

Cutterhead Guard

The cutterhead guard (see Figure 29) protects the user from exposure to the cutter and chips thrown by it. To minimize the risk of injury, the guard must be adjusted so it encloses as much of the spindle area as possible, while still allowing the workpiece to pass through the cut. Typically, this means the guard is positioned to just clear the top of the workpiece.

Adjusting Fence

The fence is a two-piece adjusting system. Each fence is independently adjustable to compensate for different cutting thicknesses and special shaping applications. One full turn of the knurled microadjustment knob moves the split fence approximately bly can also be adjusted as a whole by turning the fence assembly adjustment knob, with each full revolution equalling approximately 1 movement.

/64" (.015"). The fence support assem-

/8" of

To position cutterhead guard:

Loosen knob bolts and position guard as

needed. Tighten knob bolts to secure settings (see Figure 29).

Cutterhead Guard

Figure 29. Location of cutterhead guard.

All guards MUST be installed on your shaper before operating it. Shapers can quickly cause serious injury if some kind of guard is not used. To reduce your risk of injury, read and follow the entire Owner's Manual carefully and do additional research on shop-made guards and safety jigs.

Knob Bolts

(2 of 4)

To adjust individual fence:

Loosen fence lock handle (see Figure 30).

Turn fence micro-adjustment knob

(see Figure 30) until fence is set to desired position.

Micro-Adjustment

Knob (1 of 2)

Lock Knob

(1 of 2)

Figure 30. Location of fence controls.

3. Tighten fence lock handle.

4. Loosen fence lock knob to move fence closer

and further from the cutter. Tighten when desired position is achieved.

Note: More detailed information concerning

fence adjustments is covered in Straight Shaping on Page 28.

Lock Handle

(1 of 2)

Note: To make your own box guard, see Making Box Guards on Page 38 to find instructions and

tips.

Model G0900 (Mfd. Since 11/23)

-27-

Straight Shaping

The fence assembly is a two-piece, independently adjustable system. When removing material from the whole face of your workpiece, the outfeed fence can be adjusted to provide support for the workpiece as it passes over the cutter, or it can be set up for partial face removal.

Attempting to operate the shaper without proper knowledge of the machine could cause serious injury or death! Read through the entire manual carefully before attempting to make any cuts with your shaper.

When removing material from the entire board face, observe the following steps:

Unlock both fences with lock handles (see

1. Figure 31).

2. Set both fences to 0" by turning micro-adjust-

ment knob counterclockwise (see Figure 31).

All guards MUST be installed on shaper before operating it. Shapers are dangerous machines that can quickly cause serious injury if some kind of guard is not used. To protect yourself, read and follow entire instruction manual carefully and do additional research on shop made guards and safety jigs.

When cutter comes to complete stop, adjust

6. outfeed fence using technique used in Steps 1–2 to support new profiled edge (see Figure

32).

End View

Outfeed

Fence

Infeed Fence

Lock both fences in position with lock handle.

Adjust infeed fence by turning fence assem-

bly adjustment knob (see Figure 31) until workpiece contacts cutter in desired location.

Lock Handle

Fence Assembly

Adjustment Knob

Figure 31. Fence adjustments.

5. Turn shaper ON and advance a test sample

(at least 24" long) of desired cut about 8'', then stop. Swing test piece away from cutter and turn machine OFF.

Fence Scale

Micro-Adjustment

Knob

Direction of Feed

Supported

Figure 32. Support workpiece as it is fed

through the cut.

The miter gauge should not be used to feed material along the fence face when edge shaping. Use a push stick and hold-downs to keep the workpiece in position. The fence may not always be perfectly parallel to the miter slot; therefore, using the miter gauge can cause binding and possible kickback of the workpiece towards the operator. Serious personal injury could occur if this happens.

-28-

Model G0900 (Mfd. Since 11/23)

If the face of the workpiece will only be partially removed, observe the following steps:

Follow Steps 1–4 on Page 28.

Set fence faces so they barely clear cutter.

This allows maximum support possible for workpiece when passing the cutter.

Adjust outfeed fence face to same plane as

infeed fence. Remember to tighten fence facing before starting shaper.

Always cut the end grain first when putting an edge around the perimeter of your workpiece to minimize tearout (see Figure 34).

Turn shaper ON.

Run a test piece through shaper (see

5. Figure 33).

End View

Outfeed

Fence

Direction of Feed

Figure 33. Partial feed fence adjustment.

6. Turn shaper OFF.

Infeed Fence

Direction of Feed

Figure 34. Cut end grain first.

Digital Readout

Operation

To use digital readout:

Use 0" SET button to precisely return spindle

1. elevation height to 0" (see Figure 35).

2. Press mm/in. button to display height in either

inches or millimeters. Selected unit will be illuminated (see Figure 35).

The sound of this machine when it is running may be less than that of other devices such as a dust collector, which may be running at the same time. Because of this, it may be difficult to determine if the machine is ON merely by listening. It is necessary to make certain that this machine is OFF before attempting any setup or adjustments. Otherwise, serious personal injury could occur.

Model G0900 (Mfd. Since 11/23)

Use spindle handwheel to change spindle

height, observing DRO screen until desired height is achieved (see Figure 35).

Inch/Millimeter

Display

Zeroing Button

In./Mm. Button

Figure 35. DRO components.

DRO Screen

-29-

Rub

Collar

Not

Recommended!

Using Rub Collars

Rub collars are used when shaping curved or irregular workpieces, such as arched doors or round table tops, and to limit the depth of your cut.

There are two types of rub collars—solid and ballbearing. We recommend using ball bearing collars and we carry an extensive line that is designed for use with Grizzly shapers. See our current catalog or website for listings.

Rub collars may be used in any of the following positions:

1. Rub collar below cutter: When rub collar is placed below cutter, as shown in Figure 36, progress of the cut can be observed.

However, any unintentional movement may lift workpiece into the cutter, damaging your work and creating a dangerous situation. We

DO NOT recommend using rub collar in this position.

2. Above the cutter: When rub collar is used above cutter, cut cannot be seen (see Figure

37). This offers some advantage—stock is not affected by slight variations in thickness and accidental lifting will not damage workpiece. Simply correct any change in height by repeating operation.

Rub

Collar

Figure 37. Cutting with rub collar above cutter.

3. Between two cutters: Using a rub col-

lar between two cutters has the distinct advantage of performing two cuts at once or eliminating the need to change cutters for two different operations (see Figure 38). Notice that part of the edge is left uncut. The uncut portion rides on the rub collar.

Figure 36. Cutting with rub collar below cutter.

Rub

Collar

Figure 38. Using rub collar between cutters.

-30-

Model G0900 (Mfd. Since 11/23)

Irregular Shaping

Freehand shaping greatly increases the chance that the operator may lose control of the workpiece, which could result in serious personal injury. Therefore, a starting pin or support MUST be used to start an irregular shaping operation.

Irregular or freehand shaping takes a high degree of skill and dexterity. The fence assembly is not used in irregular shaping, so rub collars must be used (see Rub Collars on Page 30).

When doing freehand work, a starting pin must be used. The purpose of the starting pin

is to support the workpiece during the beginning of the cut. Your shaper is supplied with a starting pin that can be placed in one of the holes located in the shaper table. The work should be placed in the starting position using the starting pin for support, as shown in Figure 39.

Swing

Starting Pin

Next, swing the work into the cutter while holding the workpiece firmly against the starting pin. After the cut has been started, the work should be swung away from the starting pin and is supported just by the rub collar, as shown by the broken line positions shown in Figure 39.

ALWAYS FEED AGAINST THE ROTATION OF THE CUTTER.

All guards MUST be installed on your shaper before operating it. Shapers are dangerous machines that can quickly cause serious injury if some kind of guard is not used. To protect yourself, read and follow the entire manual carefully and do additional research on shop made guards and safety jigs.

Rub

Collar

Figure 39. Using a starting pin for irregular

Workpiece

Feed Direction

shaping.

To use starting pin:

DISCONNECT MACHINE FROM POWER!

2. Remove fence assembly.

3. Install appropriate cutter for your application

(see Installing Cutters on Page 26).

Check cutter rotation (see Changing Cutter

4. Rotation on Page 25).

Adjust spindle height to align cutter to

workpiece.

Model G0900 (Mfd. Since 11/23)

-31-

6. Insert a starting pin (see Figure 40) into table

surface, using the pin location that best supports your work.

Figure 40. Inserting starting pin.

7. Use some type of hold-down fixture and guard when doing freehand work (see Figure 41).

Incorrectly feeding stock—feeding with the rotation of the cutter—creates a potentially uncontrollable feed situation and may pull stock from your hands. This can result in serious personal injury.

Sometimes the starting pin will not be in the most advantageous position. If so, firmly clamp a board in the desired position to act as a starting pin (see Figure 42). Some type of pivot point must be used. Notice in Figures 41 & 42 the operator is not exposed to the cutting edge of the cutter. Cutters are removing material from the bottom of the workpiece.

Figure 41. Example of using guard when doing

freehand work. (Portion of guard removed for

clarity.)

Make a sample cut on a piece of scrap wood.

9. If everything is correct, feed your workpiece

along the cutter, using firm pressure to keep your work against the rub collar. Only feed against cutter rotation.

Figure 42. Example of using starting pin

substitute when needed (guard removed for

clarity.)

-32-

Model G0900 (Mfd. Since 11/23)

Pattern Work

When using a pattern, a rub collar or ball bearing can be positioned either above, below, or between cutters.

The pattern is usually used when the entire edge is to be shaped or when many duplicate pieces are needed. Pattern work is particularly useful when rough cutting irregular shapes oversize and then shaping the edge in a simple two-step operation. A pattern, when attached to a workpiece by adding toggle clamps, hand-holds, or other safety devices, make a fixture. Figure 43 shows proper setup of pattern and bearing rub collar.

You have greater flexibility when choosing the correct diameter rub collar for pattern work than for non-pattern work. If you look at Figure 43, you will notice that the position of the pattern determines the depth of cut. In other words, your pattern size is dependent upon the inter-relationship of the rub collar cutting diameter, and the desired amount of material removed. Changing either the cutter or the rub collar will change the amount of material removed. Planning ahead, you can best decide which rub collars are best suited for your application.

Things to consider when making a pattern or fixture:

Use a material that will smoothly follow rub

•

collar, ball bearing or fence.

Secure workpiece to a pattern (on sides that

•

will not be cut) with toggle clamps, or fasten with wood screws.

Make your fixture stable! Use proven meth-

•

ods and materials, and attach hand-holds for operator comfort and safety.

Ensure clamps and hidden screws do not

•

come into contact with cutter.

Design your fixture so that all cutting occurs

•

beneath workpiece.

Always consider rub collar diameter for cor-

•

rect depth-of-cut when designing your pattern.

Make sure your workpiece rests flat on work

•

table, not on work fixture.

Remember, there are tremendous cutting

•

forces involved. Fixtures must be solid and stable, and any workpiece must be firmly secured.

Always perform test cuts on scrap stock to ensure pattern works as required.

Rub

Template

Workpiece

Figure 43. Position of pattern on workpiece and

bearing size determine depth of cut.

Collar

Use care in designing and making fixtures. Clamps and screws cannot touch the cutter, and the fixtures must be stable in use, with the workpiece resting on the shaper table, not on the fixture. The workpiece must be fixed securely to the jig.

Model G0900 (Mfd. Since 11/23)

-33-

Shaping Small Stock

Feeding small stock through a shaper is always dangerous. If you must shape small stock, use a zero-clearance fence. This will provide greater protection for the operator, better workpiece support, and reduced tearout on narrow or fragile stock.

ALWAYS use hold-downs or featherboards and push sticks when shaping small or narrow stock. These devices keep your hands away from the spinning cutter and sufficiently support the stock to allow a safe and effective cut, reducing the risk of personal injury.

To shape small stock:

DISCONNECT MACHINE FROM POWER!

2. Create zero-clearance fence suitable for your application (see Making a Zero Clearance Fence on Page 35) and install on shaper.

Adjust infeed and outfeed table featherboards

to width of workpiece, positioning them as close to cutter as possible to support workpiece against fence through cut.

Note: When using zero-clearance fence,

the fence-mounted featherboards that come with the G0900 must either be clamped/ mounted to zero-clearance fence or appropriate featherboards must be constructed. The same is true if the size or positioning of included table featherboards will not appropriately support a small workpiece. For both of these scenarios, please refer to Making Featherboards on Page 36 for instructions on making shop-made featherboards.

Mount/clamp shop-made or included fence

featherboards to zero-clearance fence. Adjust to width of workpiece, positioning them as close to cutter as possible to support workpiece against fence through cut.

Connect machine to power.

7. Use push sticks to push workpiece through

cut (see Making Push Sticks on Page 37 to make your own).

Position safety guard as low as possible

while still clearing cutter or create custom box guard (see Making Box Guards on Page

38).

-34-

Model G0900 (Mfd. Since 11/23)

Zero Clearance Fence Steps

SECTION 5: SHOP-MADE

SAFETY ACCESSORIES

Making a Zero-

Clearance Fence

A shop-made zero-clearance fence provides more support than a standard fence and reduces tearout on narrow or fragile stock. Using a zeroclearance fence is the best way to reduce the risk associated with shaping inherently dangerous small stock.

Remove bracket cap screws (see Figure 45).

To make a zero-clearance fence:

DISCONNECT MACHINE FROM POWER!

2. Remove fence faces and mounting brackets

from fence supports by loosening fence lock knobs (see Figure 44).

Fence Support

(1 of 2)

Lock Knob

(1 of 2)

Figure 44. Fence lock knob location.

Cap Screws

Figure 45. Bracket cap screw location.

Select piece of straight and smooth stock that

is same height and thickness as fence faces and approximately 30" long.

Position board over length of guard/fence

assembly and mark mounting holes and outline cutter and spindle profile.

6. Cut an outline of spindle and cutter from center of stock, as illustrated in Figure 46.

Note: Make outline as close as possible to

cutter and spindle without interfering with rotation.

Drill two-step

holes

/4" or thicker wood stock

Model G0900 (Mfd. Since 11/23)

Cut out profile

of cutter & spindle

Figure 46. Example of a zero-clearance fence.

Mount with

existing hardware

-35-

Featherboards Steps

Drill countersunk mounting holes in zero-

clearance fence so fasteners from split fences can be used to secure it to fence supports in the same manner.

Note: Drilling the holes is a two-step process.

Drill the first holes all the way through the board with a diameter a little larger than the shaft of the mounting screw. Drill the second holes halfway through the boards with a diameter a little larger than the screw head. Drill these second holes deep enough that the screw heads will be well below the surface of the board.

30°-45°

4"-6"

15"-18"

/4"

Wood

stock

Figure 47. Basic featherboard construction.

Cut fingers

/8"-1/4" thick

Drill or rout hole for

T-slot mounting

4"-6"

Secure zero-clearance fence to fence sup-

ports, check for proper clearance, then run test piece through the cutter to verify results.

Making

Featherboards

Featherboards flex with minor height or width variations from stock as it passes through. Because of the consistent pressure featherboards place on the stock, cuts are more consistent, the risk of kickback is greatly reduced, and the operator's hands do not need to get near the cutter to maintain feeding pressure. If a kickback does occur, featherboards will also slow down or stop the workpiece.

Figure 47 shows the dimensions of a basic featherboard. The ultimate size is flexible and should be built around the size of stock you are shaping. The fingers can be cut with a bandsaw or table saw.

IMPORTANT: Cuts made across the grain result in weak fingers that easily break when flexed. When made correctly, the fingers should withstand flexing from moderate pressure. To test the finger flexibility, push firmly on the ends with your thumb. If the fingers do not flex, they are likely too thick (the cuts are too far apart).

As the G0900 includes featherboards for use with both the table and the fence, simply use the hardware included with these to affix shop-made featherboards to your shaper (see Figure 48).

To install a featherboard, feed a piece of stock halfway through the machine, then turn the machine OFF. Place the featherboard against the stock so all the fingers touch the edge of the stock, then use T-slot mounting hardware to secure the featherboard. For best results, place featherboards just before and just after the cutter.

-36-

Figure 48. Shop-made table featherboard using

included T-mount hardware.

Model G0900 (Mfd. Since 11/23)

Push Sticks Steps

Making Push Sticks

When used correctly, push sticks reduce the risk of injury by keeping hands away from the cutter. In the event of an accident, a push stick can absorb damage that would have otherwise happened to hands or fingers. Use push sticks whenever your hands will get within 12" of the cutter. To maintain control when shaping large workpieces, start by feeding with your hands then use push sticks to finish the operation, so your hands are not on the end of the workpiece as it passes through the cutter.

Feeding: Place the notched end of the push stick against the end of the workpiece (see Figure

50), and move the workpiece into the cutter with steady downward and forward pressure.

Supporting: A second push stick can be used to keep the workpiece firmly against the fence while cutting. When using this method, only apply pressure before the cutter; otherwise, pushing the workpiece against or behind the cutter will increase the risk of kickback.

Figure 49. Side view of push stick in use.

Making a Push Stick

Use this template to make

90º

Cut here to

⁄4" stock

push

Cut here to push 1⁄2" stock

Notch for placing on corners of workpieces

MATERIAL: Only use hardwood, sturdy plywood, or high-density plastic. Do not use softwood that may break under pressure or

⁄2" Grid

metal that can break teeth from the blade!

your own push stick.

Notch to help prevent hand from slipping

" Minimum Length

SANDING: Sand edges to remove rough edges and increase comfort.

SIZING: Push stick must be at least 15

long. Use

⁄2"–3⁄4" thick

material.

⁄4"

Figure 50. Template for a basic shop-made push stick (not shown at actual size).

Model G0900 (Mfd. Since 11/23)

-37-

Box Guard Steps

Making Box Guards

Shop-made box guards are an excellent way to enclose the cutter to virtually eliminate accidental contact with the cutter during operation. Having the cutter enclosed also helps increase the efficiency of dust collection. The drawback to box guards is that one size does not fit all. Often, professional woodworkers who use box guards make multiple guards that are different sizes.

Figure 51 shows one way to make and attach a box guard to the Model G0900. This guard replaces the vertical clear plastic guard that is included with the shaper. For durability and strength, use a hardwood when making box guards. When installing the box guard, adjust the box guard approximately featherboards on both sides.

⁄4" above the stock you will shape and use

Tips for making a custom box guard:

The thickness of your workpiece will determine the height of the box guard. Therefore, you will need to build a separate box guard for each workpiece of a different thickness. A box guard can be used with or without a zero-clearance fence (see Making Zero-Clearance Fence on Page 35 for instructions).

The box guard can either attach directly to wooden fence boards (or board) with screws (as shown in Figure 52) or attach directly to the guard fence assembly with the plastic guard hardware (as shown in Figure 51). In either case, featherboards should also be used on either side to support the workpiece. Construct the box guard in a way that it extends out over the cutter area while leaving enough distance between the guard and the table for the workpiece to easily pass by the cutter. Refer to Figure 52 for an example.

Note: DO NOT use the box guard as a hold- down or featherboard; instead, use the provided featherboard that has the ability to flex with the minor height variations of your stock.

Fence

Board

Box

Guard

Workpiece

Figure 52. Example of custom box guard

attached to wooden fence boards.

Figure 51. Box guard attached instead of

included clear plastic guard (fence and guard

components removed for clarity).

-38-

Model G0900 (Mfd. Since 11/23)

ACCESSORIES

Installing unapproved accessories may

order online at www.grizzly.com or call 1-800-523-4777

SECTION 6: ACCESSORIES

cause machine to malfunction, resulting in serious personal injury or machine damage. To reduce this risk, only install accessories recommended for this machine by Grizzly.

NOTICE

Refer to our website or latest catalog for additional recommended accessories.

W1164 —Spacer W1165 —Spacer W1166 —Spacer W116 7—Spacer W116 8—Spacer

⁄4" Bore, 1-1⁄4" OD, 1⁄4" High

⁄4" Bore, 1-1⁄4" OD, 3⁄8" High

⁄4" Bore, 1-1⁄4" OD, 1⁄2" High

⁄4" Bore, 1-1⁄4" OD, 3⁄4" High

⁄4" Bore, 1-1⁄4" OD, 1" High

Spacers allow you to position your shaper cutter anywhere on the spindle. Use them between cutters or stack them above the cutter to bear against the spindle nut. Every shaper owner needs a set of these on-hand.

G4179—

⁄2 HP Power Feeder

If you do any kind of hand ripping or milling, you know what a big chore it can be especially with longer and wider stock. For those of you who want to increase production, upgrade or add on an extra stock feeder, we have one that will match virtually any application and budget.

Figure 53. G4179 Power Feeder.

Figure 54. Shaper spindle spacers.

W1114 — W1116 — W1118 — W1119 — W1120 — W1122—

⁄4" Rub Collar, 15⁄8" Outside Dia.

⁄4" Rub Collar, 13⁄4" Outside Dia.

⁄4" Rub Collar, 17⁄8" Outside Dia.

⁄4" Rub Collar, 2" Outside Dia.

⁄4" Rub Collar, 21⁄8" Outside Dia.

⁄4" Rub Collar, 25⁄8" Outside Dia.

If you do any kind of irregular shaping, rub collars are a must! Rub collars are used for shaping curved work such as cathedral doors, as well as many custom shapes. They are also used for limiting depth-of-cut, like guide bearings on router bits.

Figure 55. Ball bearing rub collars.

Model G0900 (Mfd. Since 11/23)

-39-

order online at www.grizzly.com or call 1-800-523-4777

G0860—1.5 HP Portable Cyclone Dust Collector

The G0860 1.5 HP Cyclone Dust Collector is part of our new lineup of affordable, high-efficiency cyclones, and it's sure to be a perfection addition to your shop!

D4206—Clear Flexible Hose 4" x 10' D4256—45° Elbow 4" D4216—Black Flexible Hose 4" x 10' W1034—Heavy-Duty Clear Flex Hose 4" x 10' D2107—Hose Hanger 4 1⁄4" W1015—Y-Fitting 4" x 4" x 4" W1017—90° Elbow 4" W1019—Hose Coupler (Splice) 4" W1317—Wire Hose Clamp 4" W1007—Plastic Blast Gate 4" W1053—Anti-Static Grounding Kit

We've hand picked a selection of commonly used dust collection components for machines with 4" dust ports.

Figure 56. Model G0860 1.5 HP Portable

Cyclone Dust Collector.

T28172 —14" x 39" Heavy-Duty Roller Table T28369 —14" x 78" Heavy-Duty Roller Table T28370—14" x 118" Heavy-Duty Roller Table

Increase material handling and processing efficiency with one or more of these Heavy-Duty Roller Tables. Ideal for easily positioning material for cross cutting or cutting to length using a chop saw or metal cutting bandsaw. Simply place a roller table on one or both sides of your saw and production time is automatically improved!

D4206

D4256

W1053

W1007

W1317

Figure 58. Dust collection accessories.

T28000—”Bear Crawl” Mobile Base

We took years of input and months of testing and design to come out with the Grizzly “Bear Crawl” Mobile Base. Its 1200 lb. capacity, steel and rubber heavy-duty ball bearing wheels, and toe flipstops are only a few of the features that will make this mobile base a staple under your machines for years to come. Adjusts from 19" x 21" to 29½" x 29½"!

D4216

W1017

Figure 57. Heavy-duty roller tables.

Figure 59. T28000 Bear Crawl Mobile Base.

-40-

Model G0900 (Mfd. Since 11/23)

order online at www.grizzly.com or call 1-800-523-4777

C2026—1⁄8" & 3⁄8" Quarter Round & 1⁄4" Bead

⁄4" Bore, 25⁄8" Diameter, 1" Cutting Height

C2089—30˚ Bevel

⁄4" Bore, 3" Diameter, 1" Cutting Height

C2028—Tongue & Groove

⁄4" Bore, 25⁄8" Diameter, 1" Cutting Height

C2042—Drawer Joint

⁄4" Bore, 25⁄8" Diameter, 3⁄4" Cutting Height

C2083—Vertical Panel Raising

⁄4" Bore, 25⁄8" Diameter, 11⁄2 " Cutting Height

C2091—Bead & Cove

⁄4" Bore, 31⁄4" Diameter, 7⁄8" Cutting Height

C2092—Double Flute

⁄4" Bore, 25⁄8" Diameter, 7⁄8" Cutting Height

C2098—Ogee

⁄4" Bore, 25⁄8" Diameter, 1⁄2 " Cutting Height

C2085—Female Sash

⁄4" Bore, 25⁄8" Diameter, 5⁄8" Cutting Height

C2086—Male Sash

⁄4" Bore, 25⁄8" Diameter, 5⁄8" Cutting Height

C2101—Door Lip

⁄4" Bore, 25⁄8" Diameter, 13⁄16" Cutting Height

C2103—Door Edge

⁄4" Bore, 25⁄8" Diameter, 1" Cutting Height

Model G0900 (Mfd. Since 11/23)

-41-

SECTION 7: MAINTENANCE

To reduce risk of shock or accidental startup, always disconnect machine from power before adjustments,

maintenance, or service.

Schedule

For optimum performance from this machine, this maintenance schedule must be strictly followed.

Ongoing

To minimize your risk of injury and maintain proper machine operation, shut down the machine immediately if you ever observe any of the items below, and fix the problem before continuing operations:

• Loose mounting bolts.

• Worn or damaged cutters. Clean/lubricate table and miter gauge.

• Worn or damaged wires.

• Any other unsafe condition.

•

Cleaning &

Protecting

Cleaning the Model G0900 is relatively easy. Vacuum excess wood chips and sawdust, and wipe off the remaining dust with a dry cloth. Blow out any hard-to-reach areas with compressed air, and keep the spindle clear of wood dust and chips. If any resin has built up, use a resin dissolving cleaner to remove it.

Protect the unpainted cast iron table by wiping it clean after every use—this ensures moisture from wood dust does not remain on bare metal surfaces. Keep the table rust-free with regular applications of products like SLIPIT

G5562—SLIPIT G5563—SLIPIT

1 Qt. Gel

12 Oz. Spray

or Boeshield® T-9.

Weekly Check

• Clean/vacuum dust buildup from in and

around cabinet and off of motor.

Monthly Check

• Check/lubricate spindle slide and leadscrew

(Page 43).

• Check V-belt condition and tension (Page 45).

Annually Check

• Replace V-belt.

-42-

Figure 60. Recommended products for protect-

ing unpainted cast iron/steel parts on machinery.

Model G0900 (Mfd. Since 11/23)

Lubrication Steps

Lubrication

Since all bearings on the G0900 are sealed and permanently lubricated, simply leave them until they need to be replaced. DO NOT lubricate them.

Below is a list of components that require periodic lubrication. Do not over-lubricate these components. Large amounts of lubricant will attract sawdust, causing the metal components to gum up and bind.

Use rag and mineral spirits to clean away

grease and built up grime from surfaces of both slides and threads of leadscrew (see Figure 62).

Leadscrew

Items Needed Qty

Hex Wrench 4mm .............................................. 1

Mineral Spirits Shop Rags Lubrication Type

—Amount..............................................Thin Coat

—Frequency

T26419—Syn-O-Gen Synthetic Grease

Figure 61. T26419 Syn-O-Gen Synthetic

.................................... As Needed

......................................... As Needed

... T26419 or NLGI#2 Equivalent

...................................... As Needed

Grease.

Elevation Leadscrew & Spindle Slides

1. DISCONNECT MACHINE FROM POWER!

Lower spindle housing assembly fully by

turning handwheel counterclockwise.

Slide

Figure 62. Spindle slide and leadscrew location.

5. Apply a thin coat of lubricant to slides and

leadscrew.

Use handwheel to fully raise and lower

spindle housing to distribute grease.

Fence Rack & Pinion

1. DISCONNECT MACHINE FROM POWER!

Unlock guard and fence assembly from table

by loosening lock knobs pictured below in Figure 63.

Fence Assembly

Adjustment Knob

Use rag and mineral spirits to clean away

grease and built up grime from surfaces of both slides and threads of leadscrew (see Figure 62).

Model G0900 (Mfd. Since 11/23)

Rack

Figure 63. Fence rack and assembly location.

Fence/Guard Assembly

Lock Knobs (1 of 2)

-43-

3. Adjust fence assembly fully forward with

fence assembly adjustment knob then push assembly off of end of rack to fully reveal rack.

Remove cap screws securing sliding blocks

and rack to table.

Use a rag and mineral spirits to wipe off any

grease and sawdust build-up on rack.

. Apply a thin coat of lubricant to rack.

Replace fence and guard assembly to table,

seat on rack and sliding blocks. Use fence assembly adjustment knob to adjust assembly forward and back to distribute grease.

Replacing

Spindle Bearings

Loosen hex bolt on spindle cartridge bracket

(see Figure 64).

Hex Bolt

Figure 64. Loosening spindle cartridge bracket.

Carefully spread the casting to reduce the risk of the bearing housing falling and pinching fingers. To reduce damage, place a pad underneath the housing. The casting will break if too much pressure is applied.

Should a bearing fail, your shaper will develop a noticeable rumble, worse so when the machine is put under load. If the bad bearing is not replaced, it will eventually seize—possibly doing damage to the machine. Bearings are standard sizes and can be replaced through Grizzly.

Tools Needed Qty

Hex Wrench 8mm .............................................. 1

To replace spindle bearings:

DISCONNECT MACHINE FROM POWER!

Open cabinet access door.

Remove V-belt (refer to V-Belt Tension &

Replacement on Page 45).

5. Bearing housing will drop down. If you need

to spread spindle slide casting more, use a flat head screwdriver.

6. Remove spindle and replace bearings inside

bearing housing. If you need pointers regarding bearing replacement, call Technical Support.

To slide housing back in, reverse the

procedure. Make sure hex bolt is tightened securely.

Close access door.

-44-

Model G0900 (Mfd. Since 11/23)

V-Belt Tension &

Replacement

The V-belt transfers power from the motor to the spindle. If the V-belt does not have the proper tension or is damaged in any way, the shaper will not operate optimally, and unnecessary wear on the moving parts will occur. Regularly check the V-belt tension and replace it when necessary.

Tools Needed Qty

Open-End Wrench or Socket 19mm ................. 1

Move V-belt to sheave on motor and

spindle pulleys to select desired speed (see Figure 66.)

5,000 7,000

10,000

To tension V-belt:

DISCONNECT MACHINE FROM POWER!

2. Open cabinet access door, then release belt

tension by pulling motor bracket handle (see Figure 65).

— If V-belt is cracked, excessively worn, or

damaged, replace V-belt.

Adjustment

Hardware

Handle

Figure 66. Different speed options.

4. Tighten belt by replacing motor bracket han-

dle. When belt is properly tensioned, there should be approximately the center of the belt when you press it with your thumb, as shown in Figure 67.

⁄4" of deflection in

Pulley

Deflection

/4"

Pulley

Figure 67. Checking V-belt tension.

Figure 65. Handle for motor tension.

Model G0900 (Mfd. Since 11/23)

5. If there is not 1⁄4" of deflection, adjust belt ten-

sion by loosening/tightening adjustment hardware on motor bracket handle until proper tension achieved, see Figure 65.

Spin pulley by hand to ensure proper tracking.

7. Close access door.

-45-

Review the troubleshooting procedures in this section if a problem develops with your machine. If you need

the

serial number and manufacture date of your machine before calling.

SECTION 8: SERVICE

replacement parts or additional help with a procedure, call our Technical Support. Note: Please gather

Troubleshooting

Motor & Electrical

Symptom Possible Cause Possible Solution

Machine does not start, or power supply breaker immediately trips after startup.

Machine stalls or is underpowered.

Machine has vibration or noisy operation

E-Stop button depressed/at fault.

2. Incorrect power supply voltage or circuit size.

3. Cabinet door open/door safety switch at fault.

4. Power supply circuit breaker tripped or fuse blown.

5. Overload relay has tripped/at fault.

6. Motor wires connected incorrectly.

7. Start capacitor at fault.

8. Contactor not energized/at fault.

9. Wiring broken, disconnected, or corroded.

10. ON button or spindle rotation switch at fault.

11. Motor at fault.

1. Workpiece material not suitable for machine.

2. Feed rate/cutting speed too fast.

3. Machine undersized for task.

4. Workpiece crooked; fence loose or misadjusted.

5. Belt slipping/pulleys misaligned.

6. Run capacitor at fault.

7. Contactor not energized/at fault.

8. Motor at fault.

1. Shaper cutter at fault.

2. Motor or component loose.

3. V-belt worn, loose, or pulleys misaligned.

4. Pulley loose.

5. Elevation housing loose or damaged.

6. Spindle loose, improperly installed, or damaged.

7. Motor fan rubbing on fan cover.

8. Spindle bearings at fault.

9. Motor bearings at fault.

1. Twist E-Stop button to reset. Replace if at fault.

2. Ensure correct power supply voltage and circuit size

(Page 11).

3. Close door/replace switch.

4. Ensure circuit is sized correctly and free of shorts. Reset circuit breaker or replace fuse.

5. Reset. Adjust/replace if at fault.

6. Correct motor wiring connection (Page 54).

7. Test/replace if at fault.

8. Test all legs for power; replace if necessary.

9. Fix broken wires or disconnected/corroded connections.

10. Test/replace button/switch.

11. Test/repair/replace.

1. Only cut wood /ensure moisture is below 20%.

2. Decrease feed rate/cutting speed.

3. Use correct cutter/reduce feed rate or depth of cut.

4. Straighten or replace workpiece/adjust fence (Page

27).

5. Tension/replace belt; ensure pulleys aligned (Pages 45, 52).

6. Test/repair/replace.

7. Test all legs for power; repair/replace if at fault.

8. Test/repair/replace.

1. Replace cutter.

2. Replace damaged or missing bolts/nuts or tighten if loose.

3. Inspect/replace belt with a new one; realign pulleys if necessary (Pages 45, 52).

4. Secure pulley on shaft (Page 52).

5. Tighten the elevation housing gibs; replace cracked elevation housing (Page 53).

6. Tighten loose spindle, reinstall spindle ensuring mating surfaces are clean, replace spindle if damaged.

7. Fix/replace fan cover, replace loose/damaged fan.

8. Replace spindle bearings (Page 44).

9. Test by rotating shaft; rotational grinding/loose shaft requires bearing replacement.

-46-

Model G0900 (Mfd. Since 11/23)

Machine Operation

Symptom Possible Cause Possible Solution

Workpiece is burned when cut.

Fuzzy grain. 1. Wood may have high moisture content or

Chipping. 1. Cutting against grain of wood.

Divots in edge of cut.

Workpiece kicks back toward operator.

Workpiece pulls forward/ejects from operator's hands.

Workpiece hits outfeed fence.

Excessive snipe (gouge in end of board that is uneven with rest of cut).

1. Dull cutter.

2. Too slow of a feed rate.

3. Pitch build-up on cutter.

4. Cutter rotating in wrong direction/stock fed in wrong direction.

5. Taking too deep of cut.

surface wetness.

2. Dull cutter.

2. Nicked or chipped cutter.

3. Feeding workpiece too fast.

4. Taking too deep of a cut.

5. Knots in wood.

Inconsistent feed speed.

2. Inconsistent pressure against fence and rub collar.

3. Fence not adjusted correctly.

1. Taking too deep of a cut.

2. Workpiece is warped, rough, has high moisture content, or large/loose knots.

3. Workpiece pinched between cutter and table or between cutter and guard.

Feeding workpiece in same direction of cutter

rotation (climb cut).

Fence not adjusted correctly. 1. Adjust fence (Page 27). Align fence boards with

Fence not adjusted correctly.

2. Incorrect workpiece pressure.

1. Replace cutter, or have it professionally sharpened.

2. Increase feed speed (Page 25).

3. Clean cutter with blade and bit cleaning solution.

4. Reverse direction of cutter rotation/reverse feed

direction (Page 25).

5. Make several passes of light cuts.

1. Check moisture content and allow to dry if moisture is more than 20%.

2. Replace cutter, or have it professionally sharpened.

1. Cut with grain of wood.

2. Replace cutter, or have it professionally sharpened.

3. Decrease feed rate.

4. Take a smaller depth of cut. (Always reduce cutting depth when working with hard woods.)

Inspect workpiece. Use a different workpiece if

necessary.

1. Move smoothly or use a power feeder.

2. Apply constant pressure.

3. Adjust fence (Page 27).

1. Make several passes of light cuts.

2. Inspect workpiece; only use smooth, dry stock without large/loose knots.

3. Ensure proper clearance between cutter, guard, and table.

Feed workpiece in opposite direction of cutterhead

1. rotation.

straightedge, verify parallelism (Page 50).

1. Adjust outfeed/infeed fence parallelism to support workpiece as it passes cutterhead (full face removal) (Page 50).

2. Apply even pressure to workpiece throughout cut and use featherboards or power feeder.

Model G0900 (Mfd. Since 11/23)

-47-

Adjusting

Table Inserts

The removable table inserts are held in place by a semi-permanent insert ring, which should be adjusted level with the table top. This is necessary to avoid the workpiece catching on the insert or ring during operation, causing an unsafe condition and poor cutting results.

Tools Needed Qty

Flat Head Screwdriver #1 .................................. 1

Hex Wrench 2mm Precision Straightedge

To make insert and insert rings level with table top:

DISCONNECT MACHINE FROM POWER!

2. Remove two smaller table insert.

Lay straightedge across semi-permanent

insert and table surface in pattern shown in

Figure 68.

Table Surface

.............................................. 1

...................................... 1

Phillips Head

Screws (1 of 3)

4. Adjust flat head screws (see Figure 69) so

that ends of straightedge lay flat on table surface at all positions of pattern in Figure 68.

Figure 69. Example of table insert adjustment.

IMPORTANT: Table insert and surface must

be aligned evenly to ensure workpiece does not catch on table insert or surface and kick back.

5. Replace smaller table inserts, one at a time,

then use the straightedge to re-check the inserts. If necessary, adjust set screws in inserts to seat them level with table in all directions using the same technique as Step 4.

-48-

Table Insert

Straightedge

Figure 68. Straightedge pattern.

Model G0900 (Mfd. Since 11/23)

Zeroing Out Fence Steps

Zeroing Out Fence

The G0900 features forward and backward spindle rotation; either fence face can function as the infeed or outfeed fence. However, the scales indicating the fence face placement on the fence assembly need to be accurately calibrated to allow for accurate micro-adjusting. The factory made these adjustments during production, but you may need to adjust the settings if they have been altered.

2. Loosen gib adjustment set screws and hex

nuts on fence or fences that do not display "0" (see Figure 70).

Lock Handle

Micro-Adjustment

Knob

Tools Needed Qty

Hex Wrench 3mm .............................................. 1

Socket or Wrench 10mm

To calibrate scales:

Unlock both fence lock handles and turn both

microadjustment knobs fully counterclockwise (see Figure 70).

— If fence scales both indicate 0", no calibra-

tion is required.

— If fences display different measurements

on scales, proceed to the following steps to calibrate.

................................... 1

Gib Adjustment

Hardware

Figure 70. Gib adjustment settings location.

3. Use fence micro-adjustment knobs to adjust

fences until 0" measurement is achieved on both sides.

4. Tighten gib adjustment hardware to secure

setting.

5. Proceed to Aligning Fence Faces to ensure

fence faces are parallel.

Model G0900 (Mfd. Since 11/23)

-49-

Aligning

Fence Faces

For safe and accurate shaping, the fence boards must be parallel with one another so that they properly support the workpiece through the entire cutting operation.

Tools Needed Qty

Hex Wrench 6mm .............................................. 1

Precision Straightedge 24"

To make fence boards parallel:

DISCONNECT MACHINE FROM POWER!

2. Raise and lock guard so it's out of the way.

3. Set both fences to 0" by turning micro-

adjustment knobs fully counterclockwise, lock them, then place straightedge against both fence faces, as shown in Figure 71.

................................ 1

4. Check to see if straightedge is flat against

fence faces and that there are no gaps along its length.

— If there are no gaps anywhere between

the straightedge and the fence faces, fences are parallel.

— If there is a gap between the straightedge

and the fence boards, continue to the following step.

With straightedge against fence faces, adjust

fence set screws in small increments until any gaps are bridged (see Figure 72).

Figure 71. Example of aligning fence boards.

— If fence scales do not display 0" when

knob is fully turned, refer to the Zeroing Out Fence section on Page 49.

Set Screws

Figure 72. Fence face set screw locations.

-50-

Model G0900 (Mfd. Since 11/23)

Truing

Wooden Fence

A flat and properly aligned fence creates a safer, smoother cutting operation. A damaged or worn fence should be replaced. If choosing to replace or use wooden boards as fence faces, follow the instructions below to ensure each is properly flattened and aligned correctly.

To align wooden fences:

Ensure bolts through wood fence facing on

each side are tight and adequately countersunk.

To align fence faces, follow Steps 1–5 of

2. Aligning Fence Faces on Page 50.

If fences are not coplanar with each other,

remove both fences and resurface as one unit. You can perform this operation on a jointer as shown in Figure 73.

Make sure screws are countersunk deep enough so workpiece will not come in contact with heads of screws! Check screw depth after each pass to ensure that screws will not contact knives!

Figure 73. Example of resurfacing fences on a

jointer.

Model G0900 (Mfd. Since 11/23)

-51-

Aligning Pulleys

Pulley alignment is important to the performance of your shaper. If the pulleys are just slightly out of alignment, the shaper may suffer from power loss and decreased V-belt life. When the pulleys are parallel and aligned with each other, they are said to be coplanar—in the same plane.

Remove motor access panel, then loosen the

four motor mounting hex bolts, as shown in Figure 75. It may be easier to access back bolts from cabinet access door.

Checking Pulley Coplanarity

Tools Needed Qty

Precision Straightedge ...................................... 1

To check alignment of pulleys:

DISCONNECT MACHINE FROM POWER!

2. Open cabinet access door.

3. Hold straightedge up to pulleys to determine

if they are both aligned and parallel, as shown in Figure 74.

— If pulleys are not parallel or aligned with

each other, perform appropriate steps in following procedures.

Mounting

Bolts

(2 of 4)

Figure 75. Motor mounting bolts location.

3. Using straightedge as a guide, adjust height

of motor until pulleys are aligned, then retighten hex bolts.

Note: When adjusting spindle alignment,

take not only spindle height into account, but also consider motor and motor pulley angle in relation to spindle (see Figure 76).

Same height,

different angle

Figure 74. Example of straightedge used to

check pulley alignment.

Aligning Pulleys

Tools Needed Qty

Precision Straightedge ...................................... 1

Precision Level Open-End Wrench or Socket 16mm

To align pulleys:

DISCONNECT MACHINE FROM POWER!

-52-

.................................................. 1

................. 1

Same height,

same angle

Figure 76. Spindle alignment height and angle.

Use level to check pulley angles, and adjust

hex bolts until parallel.

Replace motor access panel and ensure

V-belt is properly seated for desired speed (see Speed Changes on Page 25) before reconnecting machine to power.

Model G0900 (Mfd. Since 11/23)

Adjusting

Spindle Gib

Adjusting Gib

Tools Needed Qty

Open-End Wrench 30mm ................................. 1

Hex Wrench 10mm

............................................ 1

The gib controls the smoothness of the slide movement, as well as the run-out or end play of the spindle. Tightening the gib too much will make it hard to adjust the height of the spindle and cause excessive wear on the slide. Loosening the gib too much will introduce spindle end play and cause poor cutting results and excessive wear on the spindle bearings.

Checking Gib Adjustment

1. DISCONNECT MACHINE FROM POWER!

2. Use spindle height handwheel to raise

spindle to its highest position.

— If it is difficult to turn handwheel or you

feel resistance from spindle slide, gib may need to be loosened.

Attempt to wiggle top of spindle. If there is

movement, gib may need to be tightened.

To adjust gib:

DISCONNECT MACHINE FROM POWER!

2. Loosen jam nuts on gib adjustment set

screws (see Figure 77).

Gib

Adjustment

Set Screws &

Jam Nuts

(1 of 4)

Figure 77. Location of gib set screws and jam

nuts.

3. Evenly adjust set screws small amounts, then

test results.

When you are satisfied with gib adjust-

ment, re-tighten jam nuts without turning set screws.

Re-check gib adjustment. If necessary, repeat

5. Steps 2–4.

Model G0900 (Mfd. Since 11/23)

-53-

These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Compare the manufacture date of your machine to the one

number and manufacture date of your

machine before calling. This information can be found on the main machine label.

machine

SECTION 9: WIRING

stated in this manual, and study this section carefully.

If there are differences between your machine and what is shown in this section, call Technical Support at (570) 546-9663 for assistance BEFORE making any changes to the wiring on your machine. An updated wiring diagram may be available. Note: Please gather the serial

Wiring Safety Instructions

SHOCK HAZARD. Working on wiring that is con-

nected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical components!

MODIFICATIONS. Modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire. This includes the installation of unapproved aftermarket parts.

WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections.

CIRCUIT REQUIREMENTS. You MUST follow the requirements at the beginning of this manual when connecting your machine to a power source.

WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components.

MOTOR WIRING. The motor wiring shown in these diagrams is current at the time of printing but may not match your machine. If you find this to be the case, use the wiring diagram inside the motor junction box.

CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors.

EXPERIENCING DIFFICULTIES. If you are experiencing difficulties understanding the information included in this section, contact our Technical Support at (570) 546-9663.

The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.grizzly.com.

-54-

Model G0900 (Mfd. Since 11/23)

Wiring Diagram

MOTOR

220V

JUNCTION BOX

SWITCH

MJ2-1306

MOTOR

LIMIT

Ground

COM

AUSPICIOUS

C170

Top

Bottom

FWD/REV

Switch

5 V

6 14

CONTROL PANEL

13NO

3L2

CONTACTOR

1L1 5L3

14NO

220V

4T2

NHD C-18D

2T1 6T3

Ground

DRO Circuit Board

OL RELAY

Ground

NHD

NTH-21

9798 9596

KEYON

KB2-BE102

2T1 4T2 6T3

OFF/Reset

Button

10A250VAC

7.5A380VAC

ON Button

Start

Capacitor

400MFD 330VAC

Run

Capacitor

35MFD

35uF

450VAC

Ground

Hot

1 2 3 4

Terminal

Plug

HEIGHT

SENSOR

Circuit Board

220 VAC

L6-30 PLUG

POWER

JUNCTION BOX

GND

Model G0900 (Mfd. Since 11/23)

READ ELECTRICAL SAFETY

ON PAGE 54!

-55-

Electrical Components

Figure 78. Contactor and overload relay.

-56-

Figure 79. Power junction box.

Figure 80. DRO circuit board. Figure 82. Height sensor circuit board.

READ ELECTRICAL SAFETY

ON PAGE 54!

Figure 81. Motor junction box.

Model G0900 (Mfd. Since 11/23)

Figure 83. ON/OFF buttons.

Figure 86. Spindle rotation switch.

Figure 84. Start capacitor.

Figure 85. Run capacitor.

Figure 87. Limit switch.

Model G0900 (Mfd. Since 11/23)

READ ELECTRICAL SAFETY

ON PAGE 54!

-57-

SECTION 10: PARTS

We do our best to stock replacement parts when possible, but we cannot guarantee that all parts shown are available for purchase. Call (800) 523-4777 or visit www.grizzly.com/parts to check for availability.

Guard, Fence & Table

181-2

181-3

181-1

181-4

181

157

39-1

8V2 9

39-2

39-3

39-4

6 15

39-2

171

39-1

125

171

126

125

128

129

127

15 16

-58-

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Model G0900 (Mfd. Since 11/23)

39-5

39-6

Guard, Fence & Table Parts List

REF P ART # DES CRIPTI ON REF PART # DES CRIP TI ON

1 P0900001 FRONT CUTTER GUARD 30 P0900030 EXT RETAINING RING 20MM 2 P0900002 CAP SCREW M6-1 X 12 31 P0900031 FENCE SIDE COVER 3 P0900003 LOCK WASHER 6MM 32 P0900032 FENCE 4 P0900004 KNOB BOLT M6-1 X 20, 6-LOBE, D40 33 P0900033 CAP SCREW M5-.8 X 16 5 P0900005 TOP CUTTER GUARD 34 P0900034 FENCE BASE SLIDE BLOCK 6 P0900006 PHLP HD SCR M6-1 X 12 35 P0900035 RACK 7 P0900007 SPINDLE DUST PORT 4" 36 P0900036 CAP SCREW M5-.8 X 12 8V2 P0900008V2 KNOB M12-1.75, 9-LOBE, D63 V2.11.23 37 P0900037 FLAT WASHER 5MM 9 P0900009 ROLL PIN 4 X 18 38 P0900038 FENCE BASE RACK SLIDE BLOCK 10 P0900010 SHAFT 39 P0900039 FENCE FEATHERBOARD ASSEMBLY 11 P0900011 EXT RETAINING RING 15MM 39-1 P0900039-1 ADJUSTABLE HANDLE M5-.8, 44L 12 P0900012 KNOB BOLT M12-1.75 X 42, 9-LOBE, D80 39-2 P0900039-2 FENDER WASHER 5MM 13 P0900013 FLAT WASHER 12MM 39-3 P0900039-3 FEATHERBOARD MOUNTING BRACKET 14 P0900014 FENCE BRACKET STOP PLATE 39-4 P0900039-4 FEATHERBOARD 15 P0900015 SET SCREW M6-1 X 20 39-5 P0900039-5 CARRIAGE BOLT M5-.8 X 16 16 P0900016 HEX NUT M6-1 39-6 P0900039-6 CARRIAGE BOLT M5-.8 X 30 17 P0900017 KNOB 3/4-16, 1-5/8D, ROUND KD 40 P0900040 TABLE 18 P0900018 SET SCREW M6-1 X 8 125 P0900125 SET SCREW M4-.7 X 4 19 P0900019 SET SCREW M6-1 X 30 126 P0900126 TABLE INSERT RING 2-1/2" ID 20 P0900020 ADJUSTABLE HANDLE M6-1 X 32, 50L 127 P0900127 TABLE INSERT RING 4-1/8" ID 21 P0900021 SCALE INDICATOR 128 P0900128 FLAT HD SCR M5-.8 X 12 22 P0900022 FENCE SUPPORT 129 P0900129 TABLE INSERT RING 5-3/4" ID 23 P0900023 GIB 157 P0900157 STARTING PIN 24 P0900024 FENCE SCALE 171 P0900171 SET SCREW M12-1.75 X 12 PLASTIC 25 P0900025 FLAT WASHER 6MM 181 P0900181 TABLE FEATHERBOARD ASSEMBLY 26 P0900026 FENCE BRACKET (L) 181-1 P0900181-1 FEATHERBOARD 27 P0900027 SLIDING BLOCK 181-2 P0900181-2 KNOB BOLT M5-.8 X 25 28 P0900028 FENCE BRACKET (R) 181-3 P0900181-3 FLAT WASHER 5MM 29 P0900029 FENCE ADJUSTMENT SHAFT 181-4 P0900181-4 SLIDING BLOCK

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-59-

Cabinet, Controls & Tools

150

151

122

149

148

152

122

110

154-51

154-29

154-30

154-4V2

154-8

111

154-19

154-49

154-48

154-5

154-6

113

154-47

154-2

112

154-21

154-10

154-9

154-20

154-7

174

187

121

122

154-22

154-16

154-17

175

176

120

119

154-50V2

154-1

154-18

154-46

185

116

117

118

154-28

154-42

154-37

154-43

154-44

154-45

154

114

115

184

183

186

123

188

180

179

178

177

162

172

158

159

160

161

153-6

153-7

153-1

153-2

153-3 153-4

153-16

153-5

153-1

153-8

153-10

153-11

153-12

153-13

153-14

153-9

153-15

153-9

124

153

-60-

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Model G0900 (Mfd. Since 11/23)

REF PART # DESCRI PTI ON REF PART # DESCRI PTI ON

Cabinet, Controls & Tools Parts List

2 P0900002 CAP SCREW M6-1 X 12 154-2 P0900154-2 CONTROL PLATE 6 P0900006 PHLP HD SCR M6-1 X 12 154-4V2 P0900154-4V2 FORWARD/REVERSE SWITCH AUS C170 V2.04.23 53 P0900053 HEX BOLT M10-1.5 X 25 154-5 P0900154-5 ON BUTTON YK A600 25MM GRN 54 P0900054 LOCK WASHER 10MM 154-6 P0900154-6 E-STOP BUTTON KEYON KB2-ESS42+KB2 BE102 55 P0900055 FENDER WASHER 10MM 154-7 P0900154-7 PHLP HD SCR M6-1 X 12 67 P0900067 LOCK WASHER 8MM 154-8 P0900154-8 PHLP HD SCR M3-.5 X 12 71 P0900071 CAP SCREW M8-1.25 X 16 154-9 P0900154-9 OVERLOAD RELAY NTH-21 17-21A 74 P0900074 HEX NUT M8-1.25 154-10 P0900154-10 CONTACTOR SHERN DIAN C-18D10 (220V) 110 P0900110 SIDE COVER 154-16 P0900154-16 PHLP HD SCR M5-.8 X 8 111 P0900111 CABINET 154-17 P0900154-17 EXT TOOTH WASHER 5MM 112 P0900112 CABLE CHAIN 154-18 P0900154-18 GROUND LABEL 113 P0900113 DOOR STOP 154-19 P0900154-19 DRO COVER 114 P0900114 PHLP HD SCR 3/16-24 X 1/4 154-20 P0900154-20 PLATE ATBS, PF-B GIKOKA 115 P0900115 JUNCTION BOX 154-21 P0900154-21 PHLP HD SCR M4-.7 X 6 116 P0900116 PHLP HD SCR M5-.8 X 10 154-22 P0900154-22 RAIL TS-35 X 55MM 117 P0900117 JUNCTION BOX BASE 154-28 P0900154-28 CONTROL PANEL CORD 12G 3W 78.5" 118 P0900118 STRAIN RELIEF TYPE-3 PG16 154-29 P0900154-29 MOTOR CORD 12G 4W 67" 119 P0900119 STRAIN RELIEF TYPE-1 1 154-30 P0900154-30 LIMIT SWITCH CORD 18G 2W 55" 120 P0900120 EXT TOOTH WASHER 5MM 154-37 P0900154-37 FIX PLATE 121 P0900121 PHLP HD SCR M4-.7 X 8 154-42 P0900154-42 CAP SCREW M5-.8 X 8 122 P0900122 FLAT WASHER 4MM 154-43 P0900154-43 STRAIN RELIEF TYPE-1 1/2 123 P0900123 CABINET DOOR 154-44 P0900154-44 STRAIN RELIEF TYPE-1 7/8 124 P0900124 LATCH 154-45 P0900154-45 STRAIN RELIEF TYPE-1 5/8 148 P0900148 LOCK NUT M4-.7 154-46 P0900154-46 STRAIN RELIEF TYPE-1 3/4 149 P0900149 LIMIT SWITCH MOUNTING BRACKET 154-47 P0900154-47 SENSOR BOARD 150 P0900150 LIMIT SWITCH COVER 154-48 P0900154-48 STANDOFF-HEX MF M3-.5 X 8, M3-.5 PLASTIC 151 P0900151 LIMIT SWITCH MOUJEN MJ2-1306 154-49 P0900154-49 HEX NUT M3-.5 PLASTIC 152 P0900152 PHLP HD SCR M4-.7 X 35 154-50 P0900154-50 SENSOR CORD 22G 5W 75" V1 153 P0900153 MITER GAUGE ASSEMBLY 158 P0900158 SPINDLE WRENCH 50MM 153-1 P0900153-1 PHLP HD SCR 3/16-24 X 3/8 159 P0900159 COMBO SCREWDRIVER #1 X 1/4" 153-2 P0900153-2 POINTER 160 P0900160 HEX WRENCH 3MM 153-3 P0900153-3 POINTER MOUNTING BLOCK 161 P0900161 HEX WRENCH 6MM 153-4 P0900153-4 POINTER SHAFT 162 P0900162 WRENCH 22 X 24MM OPEN-ENDS 153-5 P0900153-5 SCALE 172 P0900172 WRENCH 14 X 17MM OPEN-ENDS 153-6 P0900153-6 PHLP HD SCR 5/32-32 X 5/8 174 P0900174 STRAIN RELIEF TYPE-1 1/2 153-7 P0900153-7 HEX NUT 5/32-32 175 P0900175 STRAIN RELIEF TYPE-1 5/8 153-8 P0900153-8 SHOULDER SCR 1/4-20 X 7/16, 5/16 X 3/16 176 P0900176 STRAIN RELIEF TYPE-1 7/8 153-9 P0900153-9 SET SCREW M5-.8 X 12 177 P0900177 FRONT COVER

153-10 P0900153-10 FIXED HANDLE 38 X 110, M10-1.5 X 38 178 P0900178 PLATE 153-11 P0900153-11 FLAT WASHER 8MM 179 P0900179 FLAT WASHER 5MM 153-12 P0900153-12 MITER GAUGE BODY 180 P0900180 HEX NUT M5-.8 153-13 P0900153-13 MITER BAR 183 P0900183 SPACER 5.5ID X 9OD X 11L 153-14 P0900153-14 T-SLOT WASHER 7.8 X 22.5 X 3MM 184 P0900184 TERMINAL BAR 5P M5 X 30 X 14.2 TM4 153-15 P0900153-15 FLAT HD SCR M6-1 X 8 185 P0900185 PHLP HD SCR M5-.8 X 30 153-16 P0900153-16 O-RING 4.8 X 1.9 P5 186 P0900186 POWER CORD 12G 3W 138" L6-30P 154 P0900154 CONTROL PANEL ASSEMBLY 187 P0900187 STRAIN RELIEF TYPE-1 3/4 154-1 P0900154-1 CONTROL BOX 188 P0900188 FOOT M8-1.25 X 130

Model G0900 (Mfd. Since 11/23)

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-61-

Motor, Handwheel & Spindles

52-1

52-2

52-3

52-4

52-5

52-6

50-1

50-2

50-3

50-4

50-5

130-1

130-2

130-3

3 43

131

52-7

52-8

52-9

52-10

52-11

104

105

103

106

102

101

109

50-6

50-5

50-6

50-5

50-6

50-7

50-10

100

107

108

107

130

95V2

189V2

96V2

190

130-4

130-5

130-4

130-5

130-4

130-6

130-9

191

133

144

132

134

170

77 78

81 82 83

173

142

141

143

140

141

135

145

155

156

163

138

137

136

147

146

139

143

-62-

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Model G0900 (Mfd. Since 11/23)

Motor, Handwheel & Spindles Parts List

REF PART # DESCRIPTION REF PART # DESCRIPTION

2 P0900002 CAP SCREW M6-1 X 12 80 P0900080 THRUST BEARING 51202 3 P0900003 LOCK WASHER 6MM 81 P0900081 BEVEL GEAR 6 P0900006 PHLP HD SCR M6-1 X 12 82 P0900082 BUSHING 18 P0900018 SET SCREW M6-1 X 8 83 P0900083 SENSOR PLATE 25 P0900025 FLAT WASHER 6MM 84 P0900084 LOCK NUT M10-1.25 30 P0900030 EXT RETAINING RING 20MM 85 P0900085 SUPPORT 41 P0900041 EXT RETAINING RING 40MM 86 P0900086 CAP SCREW M10-1.5 X 20 42 P0900042 BUTTON HD CAP SCR M6-1 X 20 87 P0900087 SET SCREW M8-1.25 X 35 43 P0900043 UPPER BEARING HOUSING 88 P0900088 CAP 44 P0900044 BALL BEARING 6008-2RS 89 P0900089 HEX NUT M20-1.5 45 P0900045 QUILL 90 P0900090 ADJUSTMENT BOLT M20-1.5 46 P0900046 LOWER BEARING HOUSING 91 P0900091 FLAT WASHER 12MM 47 P0900047 BUSHING 92 P0900092 LOCK WASHER 12MM 48 P0900048 SPINDLE BASE 93 P0900093 CAP SCREW M12-1.75 X 80 49 P0900049 DRAWBAR 5/8-11 X 10-5/16 94 P0900094 CAP SCREW M10-1.5 X 40 50 P0900050 SPINDLE ASSEMBLY 1-1/4" 95V2 P0900095V2 PHLP HD SCR M2-.6 X 6 V2.03.20 50-1 P0900050-1 CAP SCREW M10-1.5 X 30 96V2 P0900096V2 BRACKET V2.03.20 50-2 P0900050-2 ROLL PIN 4 X 20 97 P0900097 PLATE 50-3 P0900050-3 SPINDLE WASHER 10.5 X 45 X 5 98 P0900098 BRACKET 50-4 P0900050-4 SPINDLE LOCK COLLAR 99 P0900099 SET SCREW M5-.8 X 5 50-5 P0900050-5 SPACER 1-1/4"ID X 2"OD X 3/4"L 100 P0900100 BEVEL GEAR 50-6 P0900050-6 SPACER 1-1/4"ID X 2"OD X 1/2"L 101 P0900101 WOODRUFF KEY 5 X 20 50-7 P0900050-7 SPINDLE 1-1/4" 102 P0900102 SET SCREW 5/16-18 X 5/16 50-10 P0900050-10 HEX NUT M36-4 103 P0900103 FLAT HD CAP SCR M6-1 X 12 51 P0900051 POLY V-BELT 9V X 25L 104 P0900104 HANDWHEEL TYPE-24 200D X 20B-N X M10-1.5 52 P0900052 MOTOR 5HP, 220V, 1-PH 105 P0900105 FOLDING HANDLE 30 X 90, M6-1 X 12 52-1 P0900052-1 MOTOR FAN COVER 106 P0900106 KNOB BOLT M10-1.5 X 25, 8-LOBE, D60 52-2 P0900052-2 MOTOR FAN 107 P0900107 FLAT WASHER 19MM 52-3 P0900052-3 CONTACT PLATE 25MM X 37.5MM INT 108 P0900108 SHAFT 52-4 P0900052-4 S CAPACITOR COVER 109 P0900109 COLLAR 52-5 P0900052-5 S CAPACITOR 400M 330V 2 X 4 130 P0900130 SPINDLE ASSEMBLY 3/4" 52-6 P0900052-6 CENTRIFUGAL SWITCH 3/4 3600 130-1 P0900130-1 CAP SCREW M10-1.5 X 30 52-7 P0900052-7 R CAPACITOR COVER 130-2 P0900130-2 SPACER 2/5"ID X 1-1/10"OD X 1/5" 52-8 P0900052-8 R CAPACITOR 35M 450V 2 X 3-1/2 130-3 P0900130-3 SPINDLE LOCK COLLAR 52-9 P0900052-9 MOTOR JUNCTION BOX 130-4 P0900130-4 SPACER 3/4"ID X 1-1/4"OD X 1/2" 52-10 P0900052-10 BALL BEARING 6206-2RS 130-5 P0900130-5 SPACER 3/4"ID X 1-1/4"OD X 3/4" 52-11 P0900052-11 BALL BEARING 6204-2RS 130-6 P0900130-6 SPINDLE 3/4" 53 P0900053 HEX BOLT M10-1.5 X 25 130-9 P0900130-9 HEX NUT M36-4 54 P0900054 LOCK WASHER 10MM 131 P0900131 KEY 8 X 7 X 43 RE 55 P0900055 FLAT WASHER 10MM 132 P0900132 SPINDLE PULLEY 56 P0900056 SHAFT 133 P0900133 EXT TOOTH WASHER 25MM 57 P0900057 MOTOR BRACKET 134 P0900134 LOCK NUT M25-1.5 58 P0900058 FLAT WASHER 21MM 135 P0900135 BUTTON HD CAP SCR M8-1.25 X 20 59 P0900059 LOCK NUT M20-1.5 136 P0900136 STRAIN RELIEF TYPE-3 PG16 60 P0900060 SHAFT 137 P0900137 MOTOR LABEL 61 P0900061 FIXED HANDLE 25 X 90 138 P0900138 WIRE NUT 62 P0900062 COMPRESSION SPRING 1 X 12 X 38 139 P0900139 FIXED HANDLE 38 X 110, M10-1.5 X 15 63 P0900063 ROLL PIN 4 X 20 140 P0900140 BRACKET 64 P0900064 SPINDLE LOCK SHAFT 141 P0900141 HEX BOLT M8-1.25 X 45 65 P0900065 SPINDLE LOCK SHAFT SEAT 142 P0900142 BRACKET 66 P0900066 CAP SCREW M10-1.5 X 55 143 P0900143 LOCK NUT M8-1.25 67 P0900067 LOCK WASHER 8MM 144 P0900144 CAP SCREW M8-1.25 X 30 68 P0900068 HOSE CLAMP 4" 145 P0900145 SHAFT 69 P0900069 DUST CHUTE 4" 146 P0900146 HEX NUT M10-1.5 70 P0900070 DUST TRAY 147 P0900147 HEX BOLT M10-1.5 X 55 71 P0900071 CAP SCREW M8-1.25 X 16 155 P0900155 MOTOR PULLEY 72 P0900072 BUSHING 156 P0900156 SET SCREW M6-1 X 8 73 P0900073 GAS STRUT 163 P0900163 KEY 5 X 5 X 50 1RE 74 P0900074 HEX NUT M8-1.25 170 P0900170 SPINDLE HOUSING 75 P0900075 GIB 173 P0900173 FLAT WASHER 10MM 76 P0900076 ELEVATION LEADSCREW 189V2 P0900189V2 MAGNETIC HEAD V2.03.20 77 P0900077 KEY 5 X 5 X 12 RE 190 P0900190 SENSOR BOX 78 P0900078 BUSHING 191 P0900191 PHLP HD SCR M3-1 X 8 79 P0900079 GASKET

Model G0900 (Mfd. Since 11/23)

BUY PARTS ON LINE AT GRI ZZLY.COM!

Scan QR code to visit our Parts Store.

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Labels & Cosmetics

REF PART # DESCRI PTIO N RE F PART # DES CRIPTI ON

Specifications

Motor: 5 HP, 220V, Single-Phase, 60Hz Full-Load Current Rating: 18A Motor Speed: 3450 RPM Spindle Sizes: 3/4", 1-1/4" Spindle Travel: 4" Spindle Speeds: 5000, 7000, 10,000 RPM Maximum Cutter Diameter: 7" Table Size: 39-1/4" X 31-1/2" Table Insert Sizes: 2-1/2", 4-1/8", 5-3/4" Table Counterbore: 5-3/4" X 5/8" Weight: 657 lbs.

Date

S/N

Mfd. for Grizzly in Taiwan

202

Keep hands away during operation and only operate with guard

203

installed.

G0900

205

grizzly.com

MODEL G0900

5 HP DELUXE SPINDLE SHAPER

WARNING!

To reduce risk of serious injury when using this machine:

1. Read and understand owner’s manual before operating.

2. Always wear approved eye protection and respirator.

3. Avoid entanglement with moving parts—tie back long hair, roll up long sleeves, and do not wear loose clothing, gloves, or jewelry.

4. Disconnect power before changing cutters or adjusting/servicing shaper.

5. Before starting, ensure shaper is stable and properly set up, guards

are in place, and two-piece keyed washer and cap screw are tight.

6. Always use overhead guard or a guarding fixture when free-hand shaping or when adjustable fence is not in place.

7. Always keep fingers at least 6" away from spinning cutter—use jigs, holding fixtures, or a power feeder when necessary to maintain a safe distance.

8. Always feed workpiece against rotation of cutter.

9. Do not use awkward hand positions while feeding workpiece.

10. Reduce risk of kickback by taking multiple passes when removing a large amount of material.

11. Never operate shaper while intoxicated, distracted, or tired.

12. Do not expose machine to rain or dampness.

13. Prevent unauthorized use by children or untrained users; restrict access or disable machine when unattended.

ROTATING CUTTER!

204

206

201V2

215

210

211

207

208

To reduce risk of death or serious injury, read manual BEFORE using machine.

To get a new manual, call (800) 523-4777 or go to www.grizzly.com.

209

INJURY HAZARD!

To reduce risk of shortand long-term injury, wear safety glasses, hearing protection, and a respirator when using this machine.

WARNING!

ENTANGLEMENT

HAZARD! Tie back long hair, roll up long sleeves, and remove loose clothing, jewelry, or gloves to prevent getting caught in moving parts.

DISCONNECT

POWER BEFORE

CHANGING

BLADE

SPEEDS!

WARNING!

WARNING

ACCIDENTAL INJURY

HAZARD! Doors and covers must be closed and latched before starting machine!

213

212

214

207

5000 7000

10000

Spindle Motor

207

201V2 P0900201V2 MACHINE ID LABEL V2.11.23 209 P0900209 EYE/EAR/LUNG INJURY HAZARD LABEL 202 P0900202 CUTTER HAZARD LABEL 210 P0900210 ENTANGLEMENT HAZARD LABEL 203 P0900203 MODEL NUMBER LABEL 211 P0900211 DISCONNECT POWER 220V 204 P0900204 SPINDLE ELEVATION HEIGHT LABEL 212 P0900212 SPINDLE SPEEDS LABEL 205 P0900205 GRIZZLY NAMEPLATE-LARGE 213 P0900213 CLOSE DOOR LABEL 206 P0900206 GRIZZLY.COM LABEL 214 P0900214 TOUCH-UP PAINT, GRIZZLY GREEN 207 P0900207 ELECTRICITY LABEL 215 P0900215 TOUCH-UP PAINT, GRIZZLY BEIGE 208 P0900208 READ MANUAL LABEL

Safety labels help reduce the risk of serious injury caused by machine hazards. If any label comes off or becomes unreadable, the owner of this machine MUST replace it in the original location before resuming operations. For replacements, contact (800) 523-4777 or www.grizzly.com.

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BUY PARTS ON LINE AT GRI ZZLY.COM!

Scan QR code to visit our Parts Store.

Model G0900 (Mfd. Since 11/23)

WARRANTY & RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants. In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special, or consequential damages arising from the use of our products.

The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment. We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty.

In the event you need to use this warranty, contact us by mail or phone and give us all the details. We will then issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the carton. We will not accept any item back without this number. Proof of purchase must accompany the merchandise.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.

To you can applicable information for

take advantage of this warranty, you must register it at https://www.grizzly.com/forms/warranty, or

scan the QR code below to be automatically directed to our warranty registration page. Enter all

the product.

WARRANTY

Grizzly G0900 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

Contact Info

Manual Accuracy

Identification

Machine Data Sheet

SECTION 1: SAFETY

Safety Instructions for Machinery

Additional Safety for Shapers

SECTION 2: POWER SUPPLY

SECTION 3: SETUP

Needed for Setup

Unpacking

Inventory

Cleanup

Site Considerations

Anchoring to Floor

Assembly

Dust Collection

Test Run

SECTION 4: OPERATIONS

Operation Overview

Workpiece Inspection

Using Featherboards

Installing Cutters

Adjusting Fence

Straight Shaping

Using Rub Collars

Irregular Shaping

Pattern Work

Shaping Small Stock

Making Push Sticks

Making Box Guards

SECTION 6: ACCESSORIES

SECTION 7: MAINTENANCE

Schedule

Lubrication

SECTION 8: SERVICE

Troubleshooting

Zeroing Out Fence

Aligning Pulleys

SECTION 9: WIRING

Wiring Safety Instructions

Wiring Diagram

Electrical Components

SECTION 10: PARTS

Guard, Fence & Table

Cabinet, Controls & Tools

Motor, Handwheel & Spindles

Labels & Cosmetics

WARRANTY & RETURNS