Grizzly G9860 User guide

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READ THIS FIRST

Model G9860/ZX, G9953ZX/ZXF

***IMPORTANT UPDATE***

For Machines Mfd. Since 03/23

and Owner's Manual Revised 10/20

For questions or help with this product contact Tech Support at (570) 546-9663 or techsupport@grizzly.com

The following changes were recently made since the owner's manual was printed:

• Parts have changed.

Aside from this information, all other content in the owner's manual applies and MUST be read and understood for your own safety. IMPORTANT: Keep this update with the owner's manual for future reference.

For questions or help, contact our Tech Support at (570) 546-9663 or techsupport@grizzly.com.

Old Dust Port New Dust Port

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

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

#KS22795 PRINTED IN TAIWAN

G9860/ZX Revised Parts

REF PART # DES CRIP TI ON

17V2

201V2

G9953ZX/ZXF Revised Parts

16V2

6V3

13V3

32V3

35V3

2V2

1V2

1V2 P9860001V2 BASE V2.01.21 2V2 P9860002V2 FENCE SEAT V2.03.23 17V2 P9860017V2 HEX BOLT M6-1 X 12 V2.01.21 32V3 P9860032V3 DUST PORT PANEL 5" V3.01.21 35V3 P9860035V3 DUST CHUTE 5" V3.01.21 201V2 P9860201V2 FENCE BASE V2.03.23

1V2

1V2 P9953ZX001V2 BASE V2.01.21 6V3 P9953ZX006V3 DUST HOOD 5" V3.01.21 13V3 P9953ZX013V3 DUST CHUTE 5" V3.01.21 16V2 P9953ZX016V2 HEX BOLT M6-1 X 12 V2.01.21

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G9860/ZX, G9953ZX/ZXF Update (Mfd. 03/23)

MODEL G9860, G9860ZX,

G9953ZX, & G9953ZXF

EXTREME SERIES JOINTER

OWNER'S MANUAL

(For models manufactured since 10/20)

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

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

#TS11249 PRINTED IN TAI WAN

V6.10.20

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 ............................................................................................................................... 3

Manual Accuracy Contact Info Machine Description Identification Model Specification Comparison

.........................................................................................................................3

.................................................................................................................................3

....................................................................................................................3

................................................................................................................................4

.................................................................................................5

SECTION 1: SAFETY

Safety Instructions for Machinery Additional Safety Instructions for Jointers

SECTION 2: POWER SUPPLY

Model G9953ZXF 440V Conversion

SECTION 3: SETUP

Needed for Setup Unpacking Inventory Clean Up Site Considerations Mounting to Shop Floor Moving & Assembling Jointer Adjusting Cutterhead Guard Tension Setting Outfeed Table Height Dust Collection Test Run Recommended Adjustments

SECTION 4: OPERATIONS

Basic Controls Stock Inspection & Requirements Squaring Stock Surface Planning Edge Jointing Bevel Cutting

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

....................................................................................................................................14

...................................................................................................................................14

....................................................................................................................................22

....................................................................................................................... 6

........................................................................................................ 9

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.........................................................................................11

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.............................................................................................26

SECTION 5: ACCESSORIES

SECTION 6: MAINTENANCE......................................................................................................... 33

Schedule Cleaning & Protecting Lubrication V-Belts

SECTION 7: SERVICE

Troubleshooting Infeed Table Stop Bolt Rotating/Replacing Cutterhead Inserts Air Pressure Torque Wrench Adjusting/Replacing Cutterhead Knives Setting Fence Stops Adjusting Table Parallelism

...................................................................................................................................33

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SECTION 8: WIRING ...................................................................................................................... 48

Wiring Safety Instructions G9860 & G9860ZX Wiring Diagram G9953ZX Wiring Diagram G9953ZXF 220V Wiring Diagram G9953ZXF 440V Wiring Diagram

.........................................................................................................48

..........................................................................................49

.........................................................................................................50

.............................................................................................51

.............................................................................................52

SECTION 9: PARTS

G9860/ZX Cabinet G9860/ZX Cutterhead & Motor G9860/ZX Fence G9860/ZX Table G9860/ZX Handwheel G9953ZX/ZXF Cabinet G9953ZX/ZXF Cutterhead G9953ZX/ZXF Fence G9953ZX/ZXF Table G9953ZX/ZXF Handwheel G9953ZX/ZXF Motor Labels & Cosmetics

WARRANTY & RETURNS

Like all machinery there is potential danger when operating this machine. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this machine with respect and caution to decrease the risk of operator injury. If normal safety precautions are overlooked or ignored, serious personal injury may occur.

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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.

INTRODUCTION

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

from the

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

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.

Manual Accuracy

made every effort to be exact with the

sometimes the machine

www.grizzly.com.

Manufacture Date and Serial Number

manual updates for free

e post

Contact Info

and manufacture date

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

Manufacture Date

Serial Number

Machine Description

A jointer is used to flatten the face or edge of a workpiece, which is required when properly “squaring up” a workpiece for later construction or jointing. A jointer can also cut bevels and other specialized cuts with various jigs or fixtures.

A typical cut on a jointer is made by firmly holding a workpiece against the infeed table and fence, then moving the workpiece over the cutterhead while using the fence as a guide. As the workpiece moves over the cutterhead, the knives or cutters make many shallow cuts that “shave” off the surface of the workpiece. Since only a small amount of the workpiece is removed during a jointer cut, most jointer cuts are repeated many times to yield a desired result.

Extreme Series Jointer (Mfd. Since 10/20)

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Identification

Figure 1. Model G9860/G9860ZX identification.

A. Outfeed Table B. Fence

Cutterhead Guard

C. D. Fence Controls (refer to Fence Controls on Page 25 for detailed Information)

Control Panel (refer to Control Panel on Page 24 for detailed information).

Infeed Table

F. G. Depth of Cut Scale & Pointer H. Infeed Table Handwheel & Lock I. Outfeed Table Handwheel & Lock

For Your Own Safety Read Instruction Manual Before Operating Jointer

a) Wear eye protection. b) Always keep cutterhead and drive guards in place and in proper operating condition. If

removed, ALWAYS replace cutterhead guard immediately after rabbeting operations. c) Never make cuts deeper than 1⁄8"per pass. d) Always use hold-down or push blocks when jointing material narrower than 3" or planing

material thinner than 3". e) Never perform jointing, planing, or rabbeting cuts on pieces shorter than 12" in length.

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Extreme Series Jointer (Mfd. Since 10/20)

Model Specification Comparison

G9860 G9860ZX G9953ZX G9953ZXF Motor HP Motor Voltage Motor Phase Table

Dimension 12

Cutterhead Type Knife Spiral Spiral Spiral

Number of Knives 4 N/A N/A N/A

Number of Cutter Inserts N/A 84 120 120

Number of Cutter Spirals N/A 6 6 6

Cutterhead Speed 5900 RPM 5900 RPM 5000 RPM 5000 RPM

Number of Cuts/Min. 23600

Max. Width of Cut 11

Max. Depth of Cut

Table Length x Width 80" x 12

Fence Length x Height 39

Fence Stops 45° & 90° Floor-to-Table

Height 30 Table

Movement Parallelogram Cabinet

& Fence Construction Cast Iron

Table Construction Precision Ground Cast Iron

Dust Port 1 @ 5" Country of

Origin Taiwan (ISO 9001 Factory) Weight 1200 lbs. 1200 lbs. 1650 lbs. 1650 lbs.

3 3 5 5

220V 220V 220V 220V/440V

Single Single Single 3-Phase

⁄2 "W x 80"L 12 1⁄2 "W x 80"L 16 1⁄4"W x 99 1⁄4"L 16 1⁄4"W x 99 1⁄4"L

Effective

35400

⁄16 " 11 13⁄16 " 16" 16"

⁄16 "

⁄2 " 80" x 12 1⁄2 " 99 1⁄4" x 16 1⁄4" 99 1⁄4" x 16 1⁄4"

⁄4" x 4 3⁄4" 39 1⁄4" x 4 3⁄4" 43 1⁄4" x 6 5⁄8" 43 1⁄4" x 6 5⁄8"

⁄16 "

⁄4"

Effective

30000

⁄16 "

Effective

30000

⁄16 "

Figure 2. Model specification comparison chart.

Extreme Series Jointer (Mfd. Since 10/20)

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safety instructions

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-

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Extreme Series Jointer (Mfd. Since 10/20)

WEARING PROPER APPAREL. Do not wear clothing, apparel 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 recommended 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 may damage the wires inside. Do not handle 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.

Extreme Series Jointer (Mfd. Since 10/20)

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Additional Safety Instructions for Jointers

Serious cuts, amputation, entanglement, or death can occur from contact with rotating cutterhead or other moving components! Flying chips from cutting operations can cause eye injuries or blindness. Workpieces or inserts/knives thrown by cutterhead (kickback) can strike nearby operator or bystanders with deadly force. To reduce the risk of serious personal injury from these hazards, operator and bystanders MUST completely heed the hazards and warnings below.

KICKBACK. Occurs when workpiece is ejected

from machine at a high rate of speed. Kickback injuries occur from getting struck by workpiece or hands being pulled into cutterhead. To reduce the risk of kickback, only use proper workpieces, safe feeding techniques, and proper machine setup or maintenance.

GUARD REMOVAL. Operating jointer without guards unnecessarily exposes operator to knives/ inserts and other hazardous moving parts. Except when rabbeting, never operate jointer or allow it to be connected to power if any guards are removed. Turn jointer OFF and disconnect power before clearing any shavings or sawdust from around cutterhead. After rabbeting or maintenance is complete, immediately replace all guards and ensure they are properly installed/adjusted before resuming regular operations.

DULL OR DAMAGED KNIVES/INSERTS. Dull or damaged knives/inserts increase risk of kickback and cause poor workpiece finish. Only use sharp, undamaged knives/inserts.

OUTFEED TABLE ALIGNMENT. Setting outfeed table too high can cause workpiece to hit table or get stuck while feeding. Setting outfeed table too low may cause workpiece to rock or shift while feeding. Both of these results will increase risk of kickback. Always keep outfeed table even with knives/inserts at highest point during rotation.

INSPECTING STOCK. Impact injuries or kickback may result from using improper workpieces. Thoroughly inspect and prepare workpiece before cutting. Verify workpiece is free of nails, staples, loose knots or other foreign material. Always joint warped workpieces with cupped side facing down.

MAXIMUM CUTTING DEPTH. To reduce risk of kickback, never cut deeper than

⁄8" per pass.

GRAIN DIRECTION. Jointing against the grain or end grain can increase risk of kickback. It also requires more cutting force, which produces chatter or excessive chip out. Always joint or surface plane WITH the grain.

CUTTING LIMITATIONS. Cutting workpieces that do not meet minimum dimension requirements can result in kickback or accidental contact with cutterhead. Never perform jointing, planing, or rabbeting cuts on pieces smaller than specified in machine data sheet.

PUSH BLOCKS. Push blocks reduce risk of accidental cutterhead contact with hands. Always use push blocks when planing materials less than 3" high or wide. Never pass your hands directly over cutterhead without a push block.

WORKPIECE SUPPORT. Poor workpiece support or loss of workpiece control while feeding will increase risk of kickback or accidental contact with cutterhead. Support workpiece with fence continuously during operation. Support long stock with auxiliary tables if necessary.

FEED WORKPIECE PROPERLY. Kickback or accidental cutterhead contact may result if workpiece is fed into cutterhead the wrong way. Allow cutterhead to reach full speed before feeding. Never start jointer with workpiece touching cutterhead. Always feed workpiece from infeed side to outfeed side without stopping until cut is complete. Never move workpiece backwards while feeding.

SECURE KNIVES/INSERTS. Loose knives or improperly set inserts can be thrown from cutterhead with dangerous force. Always verify knives/ inserts are secure and properly adjusted before operation. Straight knives should never project more than

⁄8" (0 .125 ") from cutterhead body.

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Extreme Series Jointer (Mfd. Since 10/20)

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.)

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.

Extreme Series Jointer (Mfd. Since 10/20)

Circuit Requirements for G9860/ G9860ZX

Full-Load Current Rating ................... 16 Amps

Nominal Voltage

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

Cycle Phase Circuit Rating Plug/Receptacle Cord

.................................................... 1-Phase

.........3-Wire, 12 AWG, 300VAC, “S”-Type

G9860 &

G9860ZX

Current Carrying Prongs

6-20 PLUG

Figure 3. Typical 6-20 plug and receptacle.

.............................. 220V/240V

...................................... 20 Amps

............................. NEMA 6-20

GROUNDED

6-20 RECEPTACLE

Grounding Pin

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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.

process. DO NOT connect to power until

Circuit Requirements for G9953ZX

A permanently connected (hardwired) power supply is typically installed with wires running through mounted and secured conduit. A disconnecting means, such as a locking switch (see following figure), must be provided to allow the machine to be disconnected (isolated) from the power supply when required. This installation must be performed by an electrician in accordance with all applicable electrical codes and ordinances.

This machine can be converted to operate on a power supply circuit that has a verified ground and meets the requirements listed below. (Refer to Voltage Conversion instructions for details.)

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

Full-Load Current Rating ................... 25 Amps

Nominal Voltage

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

Cycle Phase Circuit Rating Plug/Receptacle Cord

.................................................... 1-Phase

.........3-Wire, 10 AWG, 300VAC, “S”-Type

.............................. 220V/240V

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

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

G9953ZX

Grounding Prong

Current Carrying Prongs

Figure 4. Typical L6-30 plug and receptacle.

L6-30 GROUNDED

LOCKING

RECEPTACLE

is Hooked

L6-30

LOCKING

PLUG

G9953ZXF Circuit Requirements for 220V Operation

Full-Load Current Rating ................... 14 Amps

Nominal Voltage

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

Cycle Phase Circuit Rating Connection

.................................................... 3-Phase

.............................. 220V/240V

...................................... 20 Amps

...... Hardwire with Locking Switch

G9953ZXF

Power

Source

Ground

Figure 5. Typical setup of a permanently

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

instructed later in this manual.

Locking

Disconnect Switch

Machine

ConduitConduit

Ground

connected machine.

G9953ZXF Circuit Requirements for 440V Operation

Full-Load Current Rating ..................... 7 Amps

Nominal Voltage

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

Cycle Phase Rated Size Connection

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.................................................... 3-Phase

........................................... 15 Amps

.............................. 440V/480V

...... Hardwire with Locking Switch

Extreme Series Jointer (Mfd. Since 10/20)

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.

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:

NOTICE

No adapter is available or should be used with this machine. If the machine must be reconnected for use on a different type of electric circuit, the reconnection should be made by qualified service personnel; and after reconnection, the machine must comply with all local codes and ordinances.

Model G9953ZXF

440V Conversion

To operate your jointer with 440V power, you must: 1) replace the magnetic switch contactor, 2) replace the overload relay, 3) replace the power lamp and ON button light bulbs, 4) re-wire the motor, and 5) have an electrician hardwire the machine to a locking disconnect switch.

Refer to Page 52 for the full 440V Wiring

Diagram.

You MUST disconnect the machine from the power source before beginning any of the following 440V conversion procedures to avoid serious personal injury or death by electrocution.

Extension Cords (G9860, G9860ZX, & G9953ZX Only)

If you must use an extension

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

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

Extreme Series Jointer (Mfd. Since 10/20)

Replacing Contactor & Overload Relay

1. DISCONNECT JOINTER FROM POWER!

2. Remove the control panel from the electrical

pedestal to access the contactor and overload relay.

Replace the existing contactor and overload

relay with those from the 440V Conversion Kit (Part Number P9953ZXF042) (refer to Pages 51– 52 for detailed illustrations), then set the overload relay load dial to 7, as shown in Figure 6 on the next page.

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Load Dial

TECO

O/L Relay

LOAD

A1 A2 95 96 98

1/2 3/4 5/6

Figure 6. 440V overload relay set at 7 amps.

RHN-10

3. Use a small, flat screwdriver to move the

power lamp assembly lock latch to the left, as shown in Figure 7, pull the assembly loose from the panel, then replace the light bulb.

Re-install the lamp assembly, move the lock

latch to the right to secure it.

Repeat Steps 3–4 for the ON button, then

re-install the control panel onto the electrical pedestal.

Rewiring Motor

1. DISCONNECT JOINTER FROM POWER!

4. Replace the control panel before connecting

the jointer to power.

Replacing Control Panel Light Bulbs

1. DISCONNECT JOINTER FROM POWER!

2. Remove the control panel from the electrical

pedestal to access the rear of the power lamp and ON button assemblies (see Figure 7).

Button Assembly

Lock Latch

2. Remove the rear motor access panel, then

remove the motor wiring junction box cover.

Configure the terminal jumpers as shown in

3. Figure 8.

Terminal

4 5 6

Jumper

7 8 9

Ground

1 2 3

Figure 8. Illustration of motor wired for 440V

operation.

Figure 7. Accessing the light bulb from the rear

of the control panel.

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4. Replace the motor junction box cover and access panel before connecting the jointer to power.

Extreme Series Jointer (Mfd. Since 10/20)

SECTION 3: SETUP

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!

The Extreme Series Jointer 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.

Read through the entire SETUP section to understand the procedures and items required to correctly move, place, and assemble your machine.

The following are needed to complete the setup process, but are not included with your machine:

Description Qty

• Forklift or Hoist (rated for 1500 lbs) ............ 1

• Lifting Straps (rated for 1000 lbs. each) ..... 2

• Assistants ..................................... At Least 1

• Safety Glasses ................. 1 Pair per Person

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

• Metal Floor Shims ...................... As Needed

• Floor Mounting Hardware ........... As Needed

• Cleaning Solvent & Shop Rags .. As Needed

• Precision Straightedge 6' ........................... 1

• Phillips Screwdriver #2 ............................... 1

• Hex Wrench 10mm ..................................... 1

• Wrench 18mm ............................................ 1

Unpacking

Your machine was carefully packaged for safe transportation. Remove the packaging materials from around your machine and inspect it. If you discover the machine is damaged, please imme-

diately call Customer Service at (570) 546-9663 for advice.

Extreme Series Jointer (Mfd. Since 10/20)

Save the containers and all packing materials for possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the condition of your shipment, inventory the contents.

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Inventory

Clean Up

The following is a description of the main components shipped with your machine. Lay the components out to inventory them.

Note: If you can't find an item on this list, check the mounting location on the machine or examine the packaging materials carefully. Occasionally we pre-install certain components for shipping purposes.

Inventory: (Figure 9) Qty

A. Fence Assembly ......................................... 1

B. Cutterhead Guard ....................................... 1

Push Blocks ................................................ 2

D. Fence Support (G9860/G9860ZX) ............. 1

Fence Lock Assembly (G9860/G9860ZX) . 1

Fence Tilt Handle ....................................... 1

The unpainted surfaces are coated with a waxy oil to prevent corrosion during shipment. Remove this protective coating with a solvent cleaner or degreaser, such as shown in Figure 10. For thorough cleaning, some parts must be removed.

For optimum performance, clean all moving parts or sliding contact surfaces. Avoid chlo-

rine-based solvents, such as acetone or brake parts cleaner that may damage painted surfaces.

Always follow the manufacturer’s instructions

when using any type of cleaning product.

Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. DO NOT use these products to clean the machinery.

Figure 9. Inventory.

Hardware & Tools: (not shown) Qty

• Combo Wrench 10mm ............................... 1

• Open-End Wrench 11/13mm ...................... 1

• Hex Wrenches 3, 4, 5, 6, 8mm..........1 Each

• Knife Cutterhead Models:

—Knife Setting Gauge ............................... 1

• Spiral Cutterhead Models:

—Pneumatic Torque Wrench Assembly ..... 1

— T-Handle Driver ....................................... 1

— Torx Bits T-20 ........................................ 15

— Indexable Inserts 14 x 14 x 2mm .......... 10

— Flat Head Torx Screws T-20 M6-1 x 15.. 30

Many cleaning solvents are toxic if inhaled. Minimize risk by only using these products in a well ventilated area.

G2544—Solvent Cleaner & Degreaser H9692—Orange Power Degreaser

Great products for removing shipping grease.

Figure 10. Cleaner/degreasers available from

Grizzly.

-14-

Extreme Series Jointer (Mfd. Since 10/20)

Site Considerations

Floor Load

Refer to the Model Specification Comparison chart on Page 5 for the weight and footprint speci- fications of your machine. Some residential floors may require additional reinforcement to support both the machine and operator.

Placement Location

Consider existing and anticipated needs, size of material to be processed through each machine, and space for auxiliary stands, work tables or other machinery when establishing a location for your new machine. See Figures 11–12 for the minimum working clearances.

Mounting to Shop

Floor

Although not required, we recommend that you mount your new machine to the floor. Because this is an optional step and floor materials may vary, floor mounting hardware is not included. Generally, you can either bolt your machine to the floor or mount it on machine mounts. Both options are described below. Whichever option you choose, it is necessary to level your machine with a precision level.

Bolting to Concrete Floors

Anchor studs and lag shield anchors with lag bolts (Figure 13) are two popular methods for anchor- ing an object to a concrete floor. We suggest you research the many options and methods for mounting your machine and choose the best that fits your specific application.

Figure 11. Minimum working clearances.

Model A B

G9860 80" 35"

G9860ZX 80" 35"

G9953ZX 99

G9953ZXF 99

Figure 12. Minimum working clearances by

Children and visitors may be seriously injured if unsupervised around this machine. Lock entrances to the shop or disable start switch or power connection to prevent unsupervised use.

⁄2 " 45 1⁄2 "

model.

NOTICE

Anchor studs are stronger and more permanent alternatives to lag shield anchors; however, they will stick out of the floor, which may cause a tripping hazard if you decide to move your machine.

Anchor Studs

Lag Shield & Bolt

Figure 13. Typical fasteners for mounting to

concrete floors.

Extreme Series Jointer (Mfd. Since 10/20)

-15-

Using Machine Mounts

Using machine mounts, shown in Figure 14, gives the advantage of fast leveling and vibration reduction. The large size of the foot pads distributes the weight of the machine to reduce strain on the floor.

Moving &

Assembling Jointer

Your Extreme Series Jointer 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.

Figure 14. Machine mount example.

NOTICE

We strongly recommend securing your machine to the floor if it is hardwired to the power source. Consult with your electrician to ensure compliance with local codes.

Moving & Placing Jointer

1. Review the Power Supply section beginning on Page 9 and Mounting to Shop Floor on Page 15, then prepare the permanent loca-

tion for your jointer.

Remove the top and sides of the shipping

crate, then place the small items aside in a safe location.

Remove the four pre-installed cap screws

from the back of the jointer, then, with assistance, secure the pedestal to the jointer with these cap screws, as shown in Figure 15.

-16-

x 4

Figure 15. Installing control panel pedestal.

Extreme Series Jointer (Mfd. Since 10/20)

NOTICE

Make sure the straps do not touch the control panel pedestal in the next step. Also, make sure they stay under the base and do not slip to the infeed or outfeed tables to avoid damaging the machine.

4. Position the lifting straps under the ends of

the cast iron base, as shown in Figure 16, then secure them to the power lifting equipment.

Note: Before the jointer was shipped from the

factory, the infeed table was fully raised and the stop bolt was threaded up against the bottom of it to safely secure it during transit.

To prevent damaging the table elevation

gearing, you MUST adjust the position of the infeed stop bolt to the operating position before attempting to lower the infeed table.

NOTICE

To prevent damage to the table elevation gearing, NEVER force the table handwheels if you feel resistance. Check the positions of the stop bolts or for obstructions.

8. Loosen the jam nut (see Figure 17) on the

infeed stop bolt, then unthread the stop bolt until the distance from the top of the bolt and the bottom of the infeed table is the same as the maximum depth of cut specified for your jointer (refer to the Model Specification

Comparison chart for your model on Page 5).

Figure 16. Lifting straps properly positioned.

5. Tension the lifting straps with the forklift to

make sure they stay in place, then unbolt the jointer from the shipping pallet.

With assistance to steady the load, raise the

jointer just enough to clear the shipping pallet and any floor obstacles, then move it to the prepared location.

Note: In the next step, use shims between

the base mounting points and the floor to avoid warping or cracking the cast iron.

7. As you mount the jointer to the floor, use the

precision level to make sure the table is level from side-to-side and from front-to-back.

Stop Bolt

Jam Nut

Figure 17. Infeed table stop bolt (viewed from

underneath the table).

Extreme Series Jointer (Mfd. Since 10/20)

-17-

Installing Fence (G9860/G960ZX)

1. Remove the motor access panel on the back

of the machine.

Remove the cap screws and lock wash-

ers that are pre-installed on the bottom of the fence support, then, with assistance, secure the support to the jointer with these cap screws and lock washers, as shown in

Figure 18.

To secure the fence assembly, thread the

T-slot nut onto the bottom of the lock shaft so that nut fits up into the slot of the fence support, as shown in Figure 20.

Fence Lock

Fence Support

Figure 18. Installing the fence support.

3. Align the keyway underneath the fence sup-

port key (see Figure 19), then place the fence assembly on top of the support.

Fence Support Key

T-Slot Nut

Figure 20. Installing the fence lock.

Installing Fence (G9953ZX/G9953ZXF)

1. Remove the six pre-installed cap screws and

lock washers on either side of the fence base support (see Figure 21).

With assistance, place the fence assembly

onto the fence base support.

Fence Assembly

Figure 19. Fence support key.

4. Slide the flat washer onto the fence lock

shaft, insert the shaft into the hole on the top of the fence assembly and through the slot of the support.

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Fence Mounting Cap

Screws (3 of 6)

Fence

Base

Support

Figure 21. Fence assembly installed.

3. Secure the fence assembly with the six cap screws and lock washers removed in Step 1.

Extreme Series Jointer (Mfd. Since 10/20)

Adjusting Cutterhead

Setting Outfeed

Guard Tension

The cutterhead guard is a critical safety feature of this jointer. You MUST install and verify its operation before using the jointer! Failure to properly install this guard will greatly increase the risk of serious personal injury.

To adjust the cutterhead guard tension:

DISCONNECT MACHINE FROM POWER!

2. Loosen the lock knob shown in Figure 22

that secures the cutterhead guard shaft.

Cutterhead Guard

Table Height

The outfeed table height MUST be even with the knives/cutters when they are at top-dead-center (TDC) to ensure safe operation and good results.

If the outfeed table is set too low, the workpiece will have increased snipe. If the outfeed table is set too high, the workpiece will hit the edge of the outfeed table and increase the risk of kickback.

To set the outfeed table height:

DISCONNECT JOINTER FROM POWER!

2. Models G9860 & G9860ZX: Remove the

cutterhead guard, fence assembly, and rear motor access cover to access the cutterhead pulley.

Models G9953ZX, & G9953ZXF: Remove

the cutterhead guard and fence assembly, then open the rear cutterhead cover to access the cutterhead pulley.

Lock Knob

Cutterhead

Guard Shaft

Figure 22. Installing the cutterhead guard.

Install the guard shaft into the mounting hole,

then tighten the lock knob.

Lock the fence out of the way toward the

back, then test the return tension of the guard by swinging it counterclockwise and releasing it.

— If the guard does not return swiftly toward

the fence, loosen the lock knob, lift the guard so the shaft clears the hole, rotate the guard clockwise, then re-install it and lock it in place.

Re-test and, if necessary, repeat Step 4 until

the guard has the correct tension.

Extreme Series Jointer (Mfd. Since 10/20)

Cutterhead knives and inserts are extremely sharp and can quickly slice your hands or fingers. ALWAYS wear heavy leather gloves when handling these cutters to avoid personal injury.

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Place the straightedge on the center of

the outfeed table and over the cutterhead, then use the cutterhead pulley to rotate the cutterhead until the cutter edge is at the topdead-center, as shown in Figure 23.

Knife-Style Cutterhead

Straightedge

Note: On the knife-style cutterhead models,

rotate the knurled knob on the cutterhead lock pin underneath the back of the fence assembly until it pops in toward the cutterhead. As you rotate the cutterhead pulley, the pin will engage one of the four indents on the stop plate and lock the cutterhead in the correct position for this procedure (see Figure 24). To disengage the pin, pull it out and rotate it

⁄2 turn.

Outfeed Infeed

Spiral Cutterhead

Straightedge

Outfeed Infeed

Figure 23. Cutter edge at top-dead-center.

Stop Plate Indent

Knurled

Knob

Lock Pin

Fence Support

Figure 24. Cutterhead lock pin engaged.

When the outfeed table height is correctly set

and the cutter is at the top of its rotation, the cutter edge will just touch the straightedge without lifting it.

Note: Use the cutterhead pulley to rock the

cutterhead back-and-forth to make sure the cutter is at TDC.

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— If your outfeed table height is correctly

set, no further adjustments are necessary. Continue with Step 6.

— If the height setting is not correct, continue

with Step 5.

Extreme Series Jointer (Mfd. Since 10/20)

Loosen the outfeed table lock and rotate the

handwheel until the cutter edge just touches the straightedge when at TDC, then tighten the table lock.

The outfeed table MUST be even with the cutter edges to reduce the risk of kickback and to help ensure good cutting results.

Tip: Some advanced woodworkers have found

that they can virtually eliminate snipe by setting the outfeed table in the following manner: Perform Steps 1–5. Then lower the outfeed table slightly so the knife or insert lifts the straightedge off the table. Place a ruler next to the straightedge and rotate the cutterhead, watching how far the carbide insert pulls the straightedge. Adjust the outfeed table and recheck until the knife or insert moves the

straightedge only

⁄32".

6. Loosen the jam nut and adjust the outfeed stop bolt underneath the table so that it just touches the bottom of the tables, as shown in Figure 25, then re-tighten the jam nut.

Note: When adjusted to the correct outfeed

table height, use the stop bolt for a convenient method of ensuring the outfeed table is set at the proper height.

Stop Bolt

Jam Nut

Figure 25. Table stop bolt (viewed from

underneath the table).

Re-install the motor access cover, fence

assembly, and cutterhead guard.

Extreme Series Jointer (Mfd. Since 10/20)

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Dust Collection

DO NOT operate your jointer without an adequate dust collection system. This machine creates substantial amounts of wood dust while operating. Failure to use a dust collection system can result in short and long-term respiratory illness.

Recommended 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 a dust collection hose:

Fit a 5" dust hose over the dust port, as

shown in Figure 26, then secure it in place with a hose clamp.

Test Run

Once the assembly is complete, test run your machine to make sure it runs properly and is ready for regular operation. The test run consists of verifying the following: 1) The motor powers up and runs correctly, 2) the stop button safety feature works correctly, and, if equipped, 3) the cutterhead brake works properly.

If, during the test run, you cannot easily locate the source of an unusual noise or vibration, stop using the machine immediately, then review Troubleshooting on Page 36.

If you cannot find a remedy, contact our Tech Support at (570) 546-9663 for assistance.

Before starting the jointer, make sure you have performed the preceding assembly and adjustment instructions, and you have read through the rest of the manual and are familiar with the various functions and safety features on this machine. Failure to follow this warning could result in serious personal injury or even death!

To test run the machine:

Dust Port

Figure 26. Dust hose attached to dust port.

2. Tug the hose to make sure it does not come

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

-22-

Make sure you understand the safety instruc-

tions at the beginning of the manual and that the machine is set up properly.

Make sure all tools and objects used during

setup are cleared away from the machine.

Push the stop button in, then twist it clock-

wise so it pops out. When the stop button pops out, the switch is reset and ready for operation (see Figures 27–28).

OFF Button

Figure 27. Resetting the stop button.

Extreme Series Jointer (Mfd. Since 10/20)

— If the cutterhead is rotating counterclock-

wise (from right-to-left), the motor is wired out of phase. Disconnect the jointer from power, then switch any two hot leads coming from the power source.

If not already done, use the stop button to

turn the machine OFF.

WITHOUT resetting the stop switch, press

10.

the ON button. The machine should not start.

Power Lamp Stop Button ON Button

Figure 28. Control panel.

4. Verify that the outfeed table height is properly

set (refer to Setting Outfeed Table Height on Page 19).

Connect the machine to the power source.

6. Verify that the machine is operating correctly

by pushing the ON button.

—When operating correctly, the machine

runs smoothly with little or no vibration or rubbing noises.

— Investigate and correct strange or unusual

noises or vibrations before operating the machine further. Always disconnect the machine from power when investigating or correcting potential problems.

If equipped on your jointer, rotate the

cutterhead brake handle to stop the machine and cutterhead.

—If the machine does not start, the stop but-

ton safety feature is working correctly. The Test Run is complete.

—If the machine does start (with the stop

button pushed in), immediately disconnect power to the machine. The stop button safety feature is not working correctly. This safety feature must work properly before proceeding with regular operations. Call Tech Support at (570) 546-9663 for help.

Recommended

Adjustments

For your convenience, the adjustments listed below have been performed at the factory and no further setup is required to operate your machine.

However, because of the many variables involved with shipping, we recommend that you at least verify the following adjustments to ensure the best possible results from your new machine.

— If the machine does not turn OFF, use the

stop button to turn it OFF and immediately disconnect power to the machine. The cutterhead brake feature is not working correctly. This safety feature must work properly before proceeding with regular operations. Call Tech Support for help.

8. Model G9953ZXF Only: Press the stop but-

ton to turn the machine OFF and observe the cutterhead rotation.

Extreme Series Jointer (Mfd. Since 10/20)

Step-by-step instructions for these adjustments can be found in the SERVICE section, beginning on Page 36.

Factory adjustments that should be verified:

• Table Parallelism (Page 44).

• Model G9860 Knife Height (Page 39).

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SECTION 4: OPERATIONS

To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations.

Damage to your eyes, lungs, and ears could result from using this machine without proper protective gear. Always wear safety glasses, a respirator, and hearing protection when operating this machine.

Basic Controls

Refer to Figures 29–33 and the following descrip- tions to become familiar with the functions of the control panel, table controls, and fence controls.

Control Panel

Loose hair, clothing, or jewelry could get caught in machinery and cause serious personal injury. Keep these items away from moving parts at all times to reduce this risk.

Power Lamp

Figure 29. Control panel.

Power Lamp: Lights when the machine is con-

nected to power.

Stop Button: Turns the motor OFF. This button does NOT disconnect the machine from power!

ON Button: Turns the motor ON. The stop button must be reset before this button will work.

Stop Button

ON Button

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Extreme Series Jointer (Mfd. Since 10/20)

Table Controls

Fence Tilt Handle Adjustment

Handwheel

Depth of Cut Scale

& Pointer

Outfeed Handwheel

& Lock

Figure 30. Table controls.

Depth of Cut Scale & Pointer: Indicates the

amount of workpiece surface that will be removed. Marked in

Infeed & Outfeed Handwheels & Locks: Raises and lowers the respective table. Rotate the handwheels clockwise to raise and counterclockwise to lower the table. Tighten the lock knob in the center of the handwheel to secure the setting.

⁄16 " increments.

Infeed Handwheel

& Lock

Fence

Tilt Lock

Fence

90º Stop 45º Stop

Figure 32. Fence controls (Models G9953ZX,

and G9953ZXF).

Fence Tilt Lock: Locks the fence tilt angle in place when tightened.

Fence Stops: Provide positive stops for the fence at 90° and 45°.

Fence Adjustment Handwheel (Model 9953ZX/ G9953ZXF): Moves the fence forward and back

when rotated.

Lock

Fence Controls

Fence Tilt

Handle

Fence

Lock

Fence Tilt Lock

Fence Stops

Figure 31. Fence controls (Model G9860 and

G9860ZX).

Fence Lock: Locks the fence assembly in place.

Fence Tilt Handle: Tilts the fence when the tilt

lock is loose.

Cutterhead Brake (Model G9953ZX/ G9953ZXF Only)

Cutterhead

Brake Handle

Figure 33. Cutterhead brake.

Cutterhead Brake: Turns the machine OFF and

brings the cutterhead to a rapid stop when the handle is rotated.

Extreme Series Jointer (Mfd. Since 10/20)

-25-

12" Min.

1" Min.

/2" Min.

stock inspection

Stock Inspection &

Requirements

• Scrape all glue off the workpiece before jointing. Glue deposits on the workpiece,

hard or soft, will gum up the cutterhead and produce poor results.

Follow these rules when choosing and jointing stock:

• DO NOT joint or surface place stock that contains large or loose knots. Injury to the

operator or damage to the workpiece can occur if a knot becomes dislodged during the cutting operation.

• Jointing and surface planing with the

grain is safer for the operator and produces a better finish. Cutting against the

grain increases the likelihood of kickback and workpiece tear-out. DO NOT cut against the grain! Cutting with the grain is feeding the stock across the cutterhead so the grain points down and toward you, as viewed from the edge of the stock (see Figure 34).

Note: If the grain changes direction along the

edge of the workpiece, decrease the depth of cut and make additional passes.

CORRECT

• Remove foreign objects from the workpiece. Make sure that any stock you

process with the jointer is clean and free of dirt, nails, staples, tiny rocks or any other foreign objects, that could damage the cutterhead. These particles could also cause a spark as they strike the cutterhead and create a fire hazard.

Note: Wood stacked on a concrete or dirt

surface can have small pieces of concrete or stone pressed into the surface.

• Make sure all stock is sufficiently dried

before jointing. Wood with a moisture content over 20% will cause unnecessary wear on the cutters and poor cutting results. Excess moisture can also hasten rust and corrosion.

• Make sure your workpiece exceeds the

minimum dimension requirements, as shown in Figure 35, before processing it through the jointer, or the workpiece may break or kick back during the operation.

With Grain

INCORRECT

Against Grain

Figure 34. Proper grain alignment with the

cutterhead.

• Only process natural wood fiber through your jointer. Your jointer is designed to cut only natural wood stock. Attempting to process any other synthetic or natural material will damage the cutterhead and cause injury hazards for the operator.

12" Min.

1" Min.

/2" Min.

12" Min.

/2" Min.

1" Min.

Figure 35. Minimum stock dimensions for the

jointer.

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Extreme Series Jointer (Mfd. Since 10/20)

Before turning the jointer ON, make sure the

Previously Surface

Planed Face

Previously

Jointed

Edge

outfeed table height is properly set (refer to Page 19 for detailed instructions) to avoid workpiece kickback and to ensure good results. Kickback of the workpiece could cause serious personal injury!

3. Edge Joint on the Jointer: The concave

edge of the workpiece is jointed flat with the jointer (see Figure 38).

Squaring Stock

Squaring stock involves four steps performed in the following order:

1. Surface Plane on the Jointer: The concave

face of the workpiece is surface planed flat with the jointer (see Figure 36).

Figure 36. Surface planing on the jointer.

2. Surface Plane on a Thickness Planer:

The opposite face of the workpiece is surface planed flat with a thickness planer (see

Figure 37).

Figure 38. Edge jointing on the jointer.

4. Rip Cut on a Table Saw: The jointed edge

of the workpiece is placed against the table saw fence and the opposite edge is cut off (see Figure 39).

Figure 39. Rip cutting on a table saw.

Making adjustments to the jointer while the machine is ON greatly increases the risk to the operator from the rotating cutterhead. ALWAYS make sure the jointer is OFF and disconnected from power before performing adjustments, maintenance, or service on the machine!

Figure 37. Surface planing on a thickness

Extreme Series Jointer (Mfd. Since 10/20)

planer.

-27-

Surface Planning

Removed

Surface

To surface plane the workpiece on the jointer:

DISCONNECT JOINTER FROM POWER!

The purpose of surface planing on the jointer is to make one face of the workpiece flat (see Figures 40–41). This is a necessary step when squaring a workpiece for a thickness planer.

NOTICE

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

2. Make sure you read and follow the Safety Instructions beginning on Page 6 and the Stock Inspection & Requirement rules

beginning on Page 26.

Verify that the outfeed table height is properly

set (refer to Setting Outfeed Table Height on Page 19).

Set the depth of cut for your operation and

the fence to 90°.

Note: We suggest a 1⁄32" depth of cut for sur-

face planing, and a more shallow depth for hardwood species or for wide stock.

If your workpiece is cupped or warped, place

it so the concave side is face down on the infeed table.

Connect the jointer to power and turn it ON.

Figure 40. Example of surface planing with the

jointer.

Figure 41. Illustration of surface planing results.

Failure to use push blocks when surface planing could result in your hands contacting the rotating cutterhead, which will cause serious personal injury. ALWAYS use push blocks when surface planing on the jointer!

7. With a push block in each hand, press

the workpiece against the infeed table and the fence with firm pressure, then feed the workpiece over the cutterhead.

Note: When your leading hand comes within

4" of the cutterhead, lift that push block up and place it on the workpiece portion that is on the outfeed table. Now, focus the downward pressure with the leading hand while feeding, then repeat the same action with your trailing hand when it comes within 4" of the cutterhead. Keep your hands safe! DO NOT allow them to get any closer than 4" to the cutterhead.

Repeat Step 7 until the entire workpiece sur-

face is flat.

-28-

Extreme Series Jointer (Mfd. Since 10/20)

Edge Jointing

Removed

Surface

To edge joint on the jointer:

DISCONNECT JOINTER FROM POWER!

The purpose of edge jointing is to produce a finished, flat-edged workpiece surface that is suitable for joinery or finishing (see Figures 42–43). It is also a necessary step when squaring rough or warped stock.

Figure 42. Example of edge jointing operation.

2. Make sure you read and follow the Safety Instructions beginning on Page 6 and the Stock Inspection & Requirement rules

beginning on Page 26.

Verify that the outfeed table height is properly

set (refer to Setting Outfeed Table Height on Page 19).

Set the depth of cut for your operation and

the fence to 90°.

Note: We suggest 1⁄16"–1⁄8" depth of cut for

edge jointing, and a more shallow depth for hardwood species or for wide stock.

If your workpiece is cupped or warped, place

it so the concave side is face down on the infeed table.

Connect the jointer to power and turn it ON.

7. With a push block in each hand, press

the workpiece against the infeed table and the fence with firm pressure, then feed the workpiece over the cutterhead.

Figure 43. Illustration of edge jointing results.

Note: When your leading hand comes within

Repeat Step 7 until the entire workpiece

edge is flat.

Extreme Series Jointer (Mfd. Since 10/20)

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Bevel Cutting

Removed

Surface

To bevel cut on the jointer:

DISCONNECT JOINTER FROM POWER!

The purpose of bevel cutting on the jointer is to cut a specific angle of the workpiece edge (see Figures 44–45.

Your jointer has fence stops that can be set at 90° or 45°. If your operation requires a different angle, the fence can be locked in place anywhere between these angles.

Figure 44. Fence setup for a bevel cut of 45°.

2. Make sure you read and follow the Safety Instructions beginning on Page 6 and the Stock Inspection & Requirement rules

beginning on Page 26.

Verify that the outfeed table height is properly

set (refer to Setting Outfeed Table Height on Page 19).

Set the depth of cut for your operation and

the fence to the required angle.

Note: We suggest 1⁄16"–1⁄8" depth of cut for

bevel cutting, and a more shallow depth for hardwood species or for wide stock.

If your workpiece is cupped or warped, place

it so the concave side is face down on the infeed table.

Connect the jointer to power and turn it ON.

7. With a push block in each hand, press

the workpiece against the infeed table and the fence with firm pressure, then feed the workpiece over the cutterhead.

Figure 45. Illustration of bevel cutting results.

Note: When your leading hand comes within

Repeat Step 7 until the bevel cut is satisfac-

tory.

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Extreme Series Jointer (Mfd. Since 10/20)

ACCESSORIES

Installing unapproved accessories may

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

SECTION 5: 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.

T21992 — Power Tw ist

Smooth running with less vibration and noise than solid belts. The Power Twist be customized in minutes to any size—just add or remove sections to fit your needs. Size: 4'; replaces all "A" sized V-belts (Requires two

Power Twist

V-belts to replace the stock V-belt

on Models G9953ZX, and G9953ZXF).

V-Belt 1⁄2" x 4'

V-belt can

⁄2" x

H7319—Indexable Carbide Inserts, 10 Pk.

These indexable carbide inserts can be rotated to provide four factory sharp edges before replacement. 14mm x 14mm x 2mm.

Figure 47. Model H7319 indexable carbide

insert for spiral cutterheads.

T21152—12" HSS Dispoz-A-Blade

Self-Set System (Includes 4 Holders & Knife Inserts)

H7287—12" Cobalt Dispoz-A-Blade

Knife

Inserts (Set of 4)

Effortless knife changes with precision accuracy every time. Includes one set of reusable Self-Set

knife holders and one set of disposable double

edge HSS Dispoz-A-Blade

knives that are correctly sized for your machine. All that is required for future knife changes is the purchase of inex-

pensive Dispoz-A-Blade

double edge replace-

ment knives in HSS or Cobalt steel.

Figure 46. Model T21992 Power Twist® V-Belt.

Figure 48. Dispoz-A-Blade® Holder and Knife.

Extreme Series Jointer (Mfd. Since 10/20)

-31-

Basic Eye Protection

T20501—Face Shield Crown Protector 4" T20502—Face Shield Crown Protector 7" T20503—Face Shield Window T20451—“Kirova” Clear Safety Glasses T20452—“Kirova” Anti-Reflective S. Glasses T20456—DAKURA Safety Glasses, Black/Clear

G4181—Power Feeder, 1 HP Single-Phase

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

G7873—Power Feeder, 1 HP 3-Phase

These industrial power feeders feature 4 speeds forward or reverse, X-, Y-, Z-axis adjustment, and three synthetic rubber rollers. 220V.

T20502

T20503

T20456

Figure 49. Eye protection assortment.

G5562—SLIPIT G5563—SLIPIT G2871—Boeshield G2870—Boeshield H3788—G96 H3789—G96

1 Qt. Gel

12 oz Spray

T-9 12 oz Spray

Gun Treatment 12 oz Spray

Gun Treatment 4.5 oz Spray

T-9 4 oz Spray

T20452

T20451

Figure 51. Model G4181/G7873 Power Feeder.

G0862—3 HP Portable Cyclone Dust Collector

The capstone of our new line of affordable, highquality cyclones, the G0862 features a 3 HP motor, a whopping 1941 CFM of airflow capacity, and a 55-gallon collection capacity. It's packed with features like a quick-release collection drum, latching system, high-efficiency, two-stage separation driven by a 15" welded steel impeller, durable powder coated finish, and a heavy-duty steel frame and housing.

Figure 50. Recommended products for protecting unpainted cast iron/steel part on machinery.

Figure 52. Model G0862 3 HP Portable Cyclone

Dust Collector.

-32-

Extreme Series Jointer (Mfd. Since 10/20)

SECTION 6: MAINTENANCE

Cleaning &

Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious personal injury.

Schedule

For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.

Daily Maintenance:

• Check for loose mounting bolts.

• Check/replace/sharpen damaged or dull cut-

ters.

Check/repair/replace worn or damaged wires.

•

Check/resolve any other unsafe condition.

•

Clean the tables and exterior of machine.

•

Protecting

Use a brush and shop vacuum to remove chips and debris from the jointer. Wipe the tables clean after every use—this ensures moisture from wood dust does not remain on bare metal surfaces.

Remove any rust from the unpainted cast iron surfaces of your jointer, then treat them with regular applications of products such as G96 Gun Treatment, SLIPIT Section 5: Accessories on Page 32 for more details).

, or Boeshield® T-9 (see

Every 40 Hours of Operation:

• Check for V-belt tension, damage, or wear

(Page 35).

• Clean/vacuum dust buildup from inside the cabinet and off the motor.

• Lubricate the pivot points of the fence assembly (Page 34).

• Lubricate the cutterhead bearing blocks (Page 34).

Every 160 Hours of Operation:

• Lubricate the table elevation gears and leadscrew (Page 34).

Note: This maintenance schedule is based on average usage. Adjust the maintenance schedule to match your actual usage to keep your jointer running smoothly and to protect your investment.

Extreme Series Jointer (Mfd. Since 10/20)

-33-

Lubrication

Other than lubrication points covered in this section, all other bearings are internally lubricated and sealed at the factory. Simply leave them alone unless they need to be replaced.

An essential step for lubrication is cleaning the components before lubricating them. This idea is critical because dust and chips build up on lubricated components and make the them hard to move. Simply adding more grease to the components with built-up grime on them will not yield smooth moving components.

Clean the components in this section with an oil/ grease solvent or mineral spirits. Make sure the surfaces are dry before applying additional lubricant.

DISCONNECT THE MACHINE FROM POWER BEFORE PERFORMING LUBRICATION!

Cutterhead Bearing Blocks

Lubricant Frequency Qty

NLGI #2 or Equivalent Every 40 Hours

of Operation

The cutterhead bearing blocks are located on either end of the cutterhead (refer to Cutterhead Breakdown on Pages 54 & 61 for detailed illustrations). The grease fitting for the front bearing block is accessed through a hole in the front table cover. To access the grease fitting for the back bearing block, you must remove the fence.

Clean debris and grime from the grease fitting and the surrounding area, then use a grease pump to add lubricant.

1 Pump

Table Elevation Gears & Leadscrew

Lubricant Frequency Qty

NLGI #2 or Equivalent

Every 160 Hours of Operation

1 Pump

Fence Assembly Pivot Points

Lubricant Frequency Qty

ISO 68 Oil or Equivalent

The fence assembly has many metal-to-metal pivot points. Use a shop rag and mineral spirits to clean away debris and grime from these points. Add a small amount of lubricant, then move the component to distribute the lubricant.

Every 40 Hours of Operation

1–2 Drops

Remove the rear motor access cover to access the elevation gears for the infeed and outfeed tables (see Figure 54). Use shop rags, a stiff brush, and mineral spirits to clean away the builtup grime from the gears and elevation leadscrew, then brush on a thin coat of lubricant to these parts.

Gears

Leadscrew

Figure 54. Table elevation gears and leadscrew.

-34-

Extreme Series Jointer (Mfd. Since 10/20)

V-Belts

V-belts will wear and stretch with extended use. Maintaining proper tension of V-belts and making sure they are in good condition will increase the efficiency of the cutterhead and reduce wear on the bearings.

When a V-belt can no longer be properly tensioned or is cracked/damaged, replace both V-belts as a matched set.

Tools Needed Qty

Phillips Screwdriver ........................................... 1

Wrench or Socket 19mm

To properly tension the V-belts:

DISCONNECT JOINTER FROM POWER!

2. Remove the rear access motor cover to

access the V-belts (see Figure 55).

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

Loosen the two motor mounting bolts, then,

with assistance, raise or lower the motor assembly until there is the proper tension on the V-belts.

Note: The V-belts are properly tensioned

when there is approximately between the pulleys when moderate pressure is applied with your finger, as shown in Figure 56.

/4"

Deflection

⁄4" of deflection

Pulley

V-Belts

Motor Pulley

Figure 55. V-belts and pulleys.

Cutterhead

Pulley

Mounting

Bolt

Figure 56. The correct amount of V-belt

deflection between the pulleys.

4. When you have properly tensioned the

V-belts, re-tighten the motor mounting bolts and re-install the motor access cover.

To replace the V-belts:

DISCONNECT JOINTER FROM POWER!

2. Remove the rear access motor cover, then

loosen the motor mounting bolts.

With assistance, raise the motor assembly up

until you can roll the V-belts off the pulleys.

Replace the V-belts with a new, matched

set, then properly tension them as instructed above.

Extreme Series Jointer (Mfd. Since 10/20)

-35-

SECTION 7: SERVICE

Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem develops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical Support at (570) 546-9663.

Troubleshooting

Motor & Electrical

Symptom Possible Cause Possible Solution

Machine does not start or a breaker trips.

Machine stalls or is underpowered.

Machine has vibration or noisy operation.

1. Stop push-button engaged/faulty.

2. Power supply switched OFF or at fault.

3. Plug/receptacle at fault/wired wrong.

4. Motor connection wired wrong.

5. Thermal overload relay has tripped.

6. Wall circuit breaker tripped.

7. Contactor not energized/has poor contacts.

8. Wiring open/has high resistance.

9. Motor ON/OFF switch at fault.

10. Brake switch at fault (G9953ZX & G9953ZXF only).

11. Motor at fault.

1. Feed rate/cutting speed too fast.

2. Workpiece material not suitable for machine.

3. Dust collection ducting problem.

4. V-belt(s) slipping.

5. Motor wired incorrectly.

6. Plug/receptacle at fault.

7. Pulley/sprocket slipping on shaft.

8. Motor bearings at fault.

9. Machine undersized for task.

10. Contactor not energized/has poor contacts.

11. Motor overheated.

12. Motor at fault.

1. Motor or component loose.

2. Knives/gibs at fault.

3. V-belt(s) worn or loose.

4. Pulley loose.

5. Machine incorrectly mounted.

6. Motor fan rubbing on fan cover.

7. Motor bearings at fault.

1. Rotate button to reset/replace it.

2. Ensure power supply is on/has correct voltage.

3. Test for good contacts; correct the wiring.

4. Correct motor wiring connections (Page 48).

5. Reset; adjust trip load dial if necessary; replace.

6. Ensure circuit size is correct/replace weak breaker.

7. Test all legs for power/replace if faulty.

8. Check/fix broken, disconnected, or corroded wires.

9. Replace switch.

10. Inspect/replace switch.

11. Test/repair/replace.

1. Decrease feed rate/cutting speed.

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

3. Clear blockages, seal leaks, use smooth wall duct, eliminate bends, close other branches.

4. Tension/replace belt(s); ensure pulleys are aligned (Page 35).

5. Wire motor correctly (Page 48).

6. Test for good contacts/correct wiring.

7. Replace loose pulley/shaft.

8. Test/repair/replace.

9. Use sharp knives/inserts; reduce feed rate/ depth of cut.

10. Test all legs for power/replace if faulty.

11. Clean motor, let cool, and reduce workload.

12. Test/repair/replace.

1. Inspect/replace damaged bolts/nuts, and re-tighten with thread locking fluid.

2. Resharpen/replace knives; set knife alignment/ height correctly.

3. Inspect/replace belts with a new matched set.

4. Realign/replace shaft, pulley, setscrew, and key.

5. Tighten mounting bolts; relocate/shim machine.

6. Fix/replace fan cover; replace loose/damaged fan.

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

-36-

Extreme Series Jointer (Mfd. Since 10/20)

Operations

Symptom Possible Cause Possible Solution

Tables are hard to adjust.

1. Table lock is engaged.

2. Table stop bolts blocking movement.

1. Loosen the table lock.

2. Adjust table stop bolts (Page 46).

Excessive snipe or gouge in the workpiece end that is uneven with the rest of the cut.

Workpiece stops in the middle of the cut.

Chipping or stuttering patterns in workpiece.

Fuzzy grain left in workpiece.

Long lines or ridges along the length of workpiece.

Wavy finish or chatter marks.

Workpiece surface is concave/ convex after jointing.

1. Outfeed table is set too low.

2. Too much downward pressure on workpiece end.

1. Outfeed table is set too high. 1. Align outfeed table height with cutterhead TDC

1. Knots or conflicting grain direction in stock.

2. Nicked or chipped knife or insert.

3. Feeding workpiece too fast.

4. Depth of cut too much.

5. Poor dust collection, chips not being cleared from workpiece.

1. Wood moisture too high.

2. Dull knives or inserts.

1. Nicked or chipped knife or insert.

2. Loose or incorrectly installed insert.

1. Feed workpiece too fast.

2. Knives set unevenly.

1. Board not held with even pressure during cut.

2. Stock has excessive bow or warp.

3. Insufficient number of passes.

1. Align outfeed table height with cutterhead TDC

(Page 44).

2. Reduce downward pressure on that end of the workpiece.

(Page 44).

1. Inspect workpiece for defects, cut with grain (Page 26).

2. Replace/rotate knives/inserts (Pages 38–39).

3. Reduce feed rate.

4. Reduce the depth of cut.

5. Check dust collection for proper operation; clear blockages; reconfigure ducting system.

1. Stock moisture content should be less than 20%; sticker and let dry if necessary.

2. Replace/rotate knives/inserts (Pages 38–39).

1. Replace/rotate knives/inserts (Pages 38–39).

2. Remove/replace insert and install properly (Page 38).

1. Reduce feed rate.

2. Check/adjust all knives for correct installation and height (Page 39).

1. Maintain even downward pressure on workpiece during operation.

2. Surface plane one face to use against the jointer fence.

3. Increase number of passes until the workpiece face is flat.

Extreme Series Jointer (Mfd. Since 10/20)

-37-

Infeed Table Stop

Bolt

Tools Needed Qty

T-Handle Wrench w/T-20 Torx Bit ..................... 1

Precision Straightedge

To rotate or replace a spiral cutterhead insert:

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

The infeed table has a stop bolt that can be set to limit the how much the infeed table can be lowered (see Figure 57). We recommend that this stop bolt be set for the recommended maximum depth of cut specified for your jointer.

Stop Bolt

Jam Nut

Figure 57. Table stop bolt (viewed from

underneath the table).

DISCONNECT JOINTER FROM POWER!

2. Put on heavy leather gloves to protect your

fingers and hands.

Remove any sawdust or debris from the head

of the insert, Torx screw, and the surrounding area.

Remove the Torx screw and the insert, then

clean all dust and debris from both parts and the pocket they were removed from.

Note: Proper cleaning of the insert, Torx

screw, and the cutterhead pocket is critical to achieving a smooth finish. Dirt or dust trapped between the insert and cutterhead will slightly raise the insert, and make noticeable marks on your workpiece the next time you cut.

Tip: Use low-pressure compressed air or a

vacuum nozzle to clean out the cutterhead pocket.

Rotating/Replacing

Cutterhead Inserts

The spiral cutterhead is equipped with indexable carbide inserts that can be rotated to reveal any one of their four cutting edges. If one edge of the insert becomes dull or damaged, simply rotate it 90° to reveal a fresh cutting edge, as shown in

Figure 58.

Figure 58. Insert rotating sequence.

Replace the insert so that a fresh cutting

edge faces outward.

— If all four insert cutting edges have been

used, replace it with a new one. Always position the reference dot in the same position when installing a new insert to aid in the rotational sequencing.

Lubricate the Torx screw threads with a small

amount of light machine oil, wipe the excess off, and torque the screw to 50–55 inch/ pounds.

Note: If you use the included air pressure

torque wrench, refer to the detailed instructions on the next page for its use.

-38-

Extreme Series Jointer (Mfd. Since 10/20)

Position the straightedge on the outfeed table

and over the insert to make sure that it is installed correctly and at the same height as the other inserts.

While carefully holding the insert in position,

insert the bit into the Torx screw and press the operation lever to seat the insert. Repeat this step with all remaining inserts.

— If the insert is raised above the correct

height, remove it and repeat the above procedure until it is properly installed.

Air Pressure Torque

Wrench

To fully tighten the Torx screws with the included air pressure torque wrench:

1. Insert a Torx bit into the collet of the wrench.

Make sure the pressure gauge is fully thread-

ed onto the wrench, as shown in Figure 59.

Pressure

Adjustment

Knob

Pressure

Gauge

Setting

Dial

Figure 59. Components of the air pressure

Direction

Switch

torque wrench.

Collet

Adjust the air pressure to 40 PSI, then fully

7`.

tighten the Torx screw to a final torque setting of approximately 50–55 inch/pounds. Repeat with all remaining inserts.

Adjusting/Replacing

Cutterhead Knives

If your jointer has a knife-style cutterhead, correctly setting the height of the knives is crucial to the proper operation of the jointer and is very important in keeping the knives sharp. If one knife is higher than the others, it will do the majority of the work, and thus, dull much faster than the others.

There are several methods for setting the knives. The Jointer Pal simple to use and is designed to hold the knives at the correct setting while you secure them. If you choose to use the Jointer Pal tions that are included with it.

The straightedge method is described below and produces the same results as the Jointer

. This method uses a high-quality, precision

Pal straightedge held flat against the outfeed table and over the cutterhead, then the knife heights are set to the bottom of the straightedge, as shown in Figure 60.

included with your jointer is

, follow the instruc-

Add two drops of pneumatic tool oil to the

incoming valve of the wrench to keep the internal components lubricated.

Connect the wrench to a source of 90 PSI

air pressure, then use the adjustment knob of the pressure gauge to initially set the air pressure to 20 PSI on the gauge.

Set the direction switch for clockwise rotation

and the setting dial to 2.

Extreme Series Jointer (Mfd. Since 10/20)

-39-

Black Lines Represent Straightedge Positions From Overhead View

Straightedge

Make sure the outfeed table is parallel to

the cutterhead body and the table height is correct (refer to Adjusting Outfeed Table Parallelism on Page 44 for detailed instruc- tions).

Cutterhead knives are extremely sharp and can quickly slice your hands or fingers. ALWAYS wear heavy leather gloves when handling these cutters to avoid personal injury.

Outfeed Infeed

Figure 60. Checking knife height with a

straightedge.

Tools Needed Qty

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

Hex Wrench 4mm Wrench 10mm

To adjust or replace the knives:

DISCONNECT JOINTER FROM POWER!

Note: Since the height of the knives is set

from the outfeed table height, the next step is crucial to correctly adjusting the knives.

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

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

3. Remove the cutterhead guard, fence assem-

bly, and rear motor access cover to access the cutterhead pulley.

Use the cutterhead pulley to rotate the

cutterhead and gain access to one of the knives, then lock the cutterhead in place with the cutterhead lock pin (refer to Page 20 for detailed instructions).

Turn the cutterhead gib bolts clockwise, start-

ing in the middle, then alternating back and forth until the gib is loose (see Figure 61).

Beveled Edge

Gib Bolt

Gib

-40-

Jack Screw

Figure 61. Knife correctly positioned in the

cutterhead.

Extreme Series Jointer (Mfd. Since 10/20)

Carefully remove the knife and gib.

7. If the knife is dull or damaged, replace it with

a new one.

Clean the knife, gib, and inside the cutterhead

slot to remove all the pitch or sawdust. Coat the knife and gib with a metal protectant (refer to Page 32), then fit the gib back into the cutterhead with the knife.

12. Rotate all of the gib bolts counterclockwise

just enough so the gib holds the knife in place.

Repeat Steps 11–12 on the other end of the

13.

cutterhead, then repeat Steps 4–12 with the rest of the knives.

Rotate the cutterhead to the first knife you

14.

started with.

Make sure the beveled side of the knife is

against the cutterhead, as shown in Figure 61.

Position the straightedge on the outfeed

10.

table and over one end of the knife, then use magnets or an assistant to make sure the straightedge stays in full contact with the outfeed table along its full length.

Insert the 3mm hex wrench through the

11.

access holes in the cutterhead, then rotate the jack screws to raise or lower the knife (see Figure 62). When the knife is set correctly, it will just touch the bottom of the straightedge without lifting it.

Slightly tighten all the gib bolts, starting in

15.

the middle and working your way to the ends by alternating left and right, as illustrated in Figure 63. Repeat this step with the rest of the knives.

Figure 63. Knife gib bolt tightening sequence.

16.

Repeat Step 15.

Repeat Step 15 again, but final tighten each

17.

gib bolt.

Replace the motor access cover, the fence

18.

assembly, and the cutterhead guard.

Jack Screw

Access Hole

Figure 62. Jack screw access hole.

Extreme Series Jointer (Mfd. Since 10/20)

-41-

Setting Fence Stops

The fence stops simplify the task of setting the fence to 90° and 45° (135°).

Models G9860 & G9860ZX

Tools Needed Qty

Machinist's Square ............................................ 1

Bevel Square Hex Wrench 3mm Wrench 10mm

To set the 90° fence stop:

DISCONNECT JOINTER FROM POWER!

2. Loosen the fence tilt lock and the jam nut on

the 90° stop, then back off the set screw (see Figure 64).

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

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

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

Place the machinist's square flat on the

outfeed table fairly close to the cutterhead, as shown in Figure 65, adjust the fence to the square, then tighten the fence tilt lock to secure the setting.

Figure 65. Setting the fence to 90° (cutterhead

guard moved away for clarity).

Adjust the 90° set screw until it just touches

the tilting arm, then re-tighten the jam nut.

Tilt Lock

45° Stop

90° Stop

Figure 64. Fence stop controls.

To set the 45° fence stop:

DISCONNECT JOINTER FROM POWER!

2. Loosen the fence tilt lock and the jam nut on

the 45° stop, then back off the set screw (see Figure 64 on the previous page).

Place the bevel square set at 135° flat against

the outfeed table close to the cutterhead, as shown in Figure 66, adjust the fence to match the angled face of the square, then retighten the tilt lock.

-42-

Figure 66. Setting the fence to 45° (135°), with

the cutterhead guard removed for clarity.

Adjust the 45° set screw until it just touches

the tilting arm, then re-tighten the jam nut.

Extreme Series Jointer (Mfd. Since 10/20)

Models G9953ZX, G9953ZXF

Tools Needed Qty

Machinist's Square ............................................ 1

Bevel Square Open-End Wrench 12mm Hex Wrench 8mm

To set 90° fence stop:

DISCONNECT JOINTER FROM POWER!

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

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

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

To set 45° fence stop:

DISCONNECT JOINTER FROM POWER!

2. Loosen fence tilt lock and 45° stop jam nut,

then back off stop bolt (see Figure 68).

Place bevel square (set at 135°) flat against

outfeed table near cutterhead, as shown in Figure 66 on Page 42, adjust fence to match angled face of square, then tighten tilt lock.

2. Loosen fence tilt lock and 90° stop jam nut, then back off stop bolt (see Figure 67).

90° Stop

Block

Tilt Lock

Stop Bolt

Jam Nut

Figure 67. Fence 90º stop block components.

3. Place machinist's square flat on outfeed table near cutterhead, as shown in Figure 65 on Page 42, adjust fence to the square, then

tighten fence tilt lock to secure setting.

Tighten stop bolt toward fence assembly until

it becomes snug, then tighten jam nut.

45° Stop

Block

Tilt Lock

Stop Bolt

Jam Nut

Figure 68. Fence 45º stop block components.

Tighten stop bolt toward fence assembly until

it becomes snug, then tighten jam nut.

Extreme Series Jointer (Mfd. Since 10/20)

-43-

Adjusting Table

Parallelism

The tables of your jointer MUST be parallel with the cutterhead and each other (see Figure 68) to ensure good cutting results and to reduce the risk of workpiece kickback.

Black Lines Represent Straightedge Positions From Overhead View

Figure 69. Illustration of table parallelism

concept.

Tools Needed Qty

Precision Straightedge 6'L ................................ 1

Feeler Gauge Phillips Screwdriver Hex Wrench 4mm Hex Wrench 13mm Wrench or Socket 13mm Wrench or Socket 32mm

⁄64" (1.3mm) ................................ 1

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

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

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

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

Adjusting Outfeed Table Parallelism

1. DISCONNECT JOINTER FROM POWER!

Cutterhead knives and inserts are extremely sharp and can quickly slice your hands or fingers. ALWAYS wear heavy leather gloves when handling these cutters to avoid personal injury.

Adjusting table parallelism is a task of precision, time, and patience. Fortunately, this is considered a permanent adjustment that should not need to be repeated for the life of the machine.

Due to the complex nature of this task, we recommend that you carefully double-check the current table parallelism to be sure that adjustments need to be made.

Note:

in parallelism between the tables is considered acceptable.

When adjusting table parallelism, you must do the following: 1) Properly adjust the outfeed table height and parallelism in relation to the cutterhead, and 2) adjust the infeed table parallel to the outfeed table.

Note: If your jointer uses a knife-style cutterhead, you will also have to adjust the knives as the last procedure to bring the outfeed table surface and cutting edges of the knives to the same height.

Typically, a tolerance of 0.005" or less

2. Models G9860 & G9860ZX: Remove the

cutterhead guard, fence assembly, and rear motor access cover to access the cutterhead pulley.

Models G9953ZX, & G9953ZXF: Remove

the cutterhead guard and fence assembly, then open the rear cutterhead cover to access the cutterhead pulley.

Note: The cutterhead pulley is used in the

following steps to rotate the cutterhead.

Lower the outfeed table stop bolt and loosen

the table lock so that they do not interfere with adjustments.

-44-

Extreme Series Jointer (Mfd. Since 10/20)

4. Make sure the precision straightedge and the table surface are free of debris, then place the straightedge on the back of the outfeed table and across the cutterhead.

Note: In the following steps, the process

of checking the outfeed table for the correct height above the cutterhead is different between knife-style and spiral cutterheads.

Knife-Style Cutterhead: The correct outfeed

table height is

⁄64" (1.3mm) above the

cutterhead BODY, as measured with a feeler gauge (see Figure 69). Rotate the cutterhead to make sure the knives do not interfere with proper measurement.

Spiral Cutterhead: The outfeed table is

at the correct height above the cutterhead when an insert is at the top-dead-center or at its highest point of rotation just touches the straightedge without lifting it, as shown in Figure 69. Rotate the cutterhead pulley to properly position an insert below the straightedge.

If the outfeed table surface is not at the right

height, use the handwheel to bring the table to the correct height above the cutterhead, then tighten the table lock to secure the setting.

To check the outfeed table parallelism with

the cutterhead body, place the straightedge on the front of the table and measure the height above the cutterhead, as instructed in Step 4.

— If the measurements of the front and back

of the table are within 0.002" or less of each other, no further adjustments to the outfeed table are required. Proceed to Step 12.

— If the front table measurement is NOT cor-

rect and within the tolerance of the back measurement, continue to Step 7.

Remove the front table cover to expose

the table adjustment bolts, as shown in Figure 70.

Knife-Style Cutterhead

⁄64" (1.3mm)

Straightedge

Outfeed Table

Feeler Gauge

Spiral Cutterhead

Straightedge

Outfeed Infeed

Note: For Models G9953ZX, and G9953ZXF,

you will need to remove the brake handle and hub before removing the cover.

Table Adjustment Bolts

Figure 71. Front table cover removed to expose

the table adjustment bolts.

Figure 70. Checking the outfeed table for the

correct height above the cutterhead.

Extreme Series Jointer (Mfd. Since 10/20)

-45-

8. Loosen the cap screw in the center of the outfeed table adjustment bolt three full turns, then loosen the set screw that is directly underneath the adjustment bolt (see Figure 71).

When the outfeed table height is correct

11.

and parallel to the cutterhead, re-tighten the adjustment bolt cap screw and set screw (see Figure 71), then make sure the table lock is tightened.

Note: Both of these screws are used to lock

the adjustment bolt in place.

Table

Cam

Adjustment

Bolt

Cap

Set Screw

Figure 72. Illustration of the table adjustment

bolt components.

Note: The goal of the next step is to bring the

outfeed table parallel to the cutterhead body from front-to-back by raising or lowering the front corner of the outfeed table.

Screw

12. Loosen the jam nut and adjust the outfeed

stop bolt underneath the table so that it just touches the bottom of the tables, as shown in Figure 72, then re-tighten the jam nut.

Note: When adjusted to the correct outfeed

table height, use the stop bolt for a convenient method of ensuring the outfeed table is set at the proper height.

Stop Bolt

Jam Nut

The adjustment bolt shaft is cam-shaped, as

shown in Figure 71, and connects the table to the lifting arm. Rotate the adjustment bolt in very small increments to raise or lower the front corner of the outfeed table until the surface is the correct height above the cutterhead, as instructed in Step 4.

Re-check the table height at the back edge of

10.

the table, as instructed in Step 4.

— If the table height is correct from front-to-

back, no further adjustments are necessary. Go to Step 11 to finish this procedure.

— If the table height from front-to-back is not

correct and the same, loosen the table lock and use the handwheel to bring the back of the table to the correct height above the cutterhead body, then repeat Step 9. Continue this process until the table height is correct and the same from front-to-back.

Figure 73. Outfeed table stop bolt (viewed from

underneath the table).

When the Adjusting Outfeed Table

13. Parallelism procedure is successfully com- pleted, proceed to Adjusting Infeed Table Parallelism.

Adjusting Infeed Table Parallelism

1. Make sure that all steps in the Adjusting Outfeed Table Parallelism procedure have

been successfully completed and that the jointer is still disconnected from power.

Make sure the table surfaces and the preci-

sion straightedge are free from any debris that would interfere with taking measurements, then place the straightedge equally over the back of the outfeed and infeed tables.

Note: Make sure the straightedge is not in

contact with a knife or insert.

-46-

Extreme Series Jointer (Mfd. Since 10/20)

3. With the use of a magnet or an assistant,

make sure that the straightedge stays flat against the full length of its contact with the outfeed table during the following steps.

Use the handwheel to adjust the infeed table

as close as possible to the straightedge, then look closely for any gaps between the infeed table and the straightedge. Repeat this process on the front of the infeed table.

— If there are no gaps as the straightedge is

positioned on both the back and front of the tables, then the infeed table is parallel with the outfeed table and the cutterhead— thus, no further adjustments are required. Proceed to Step 7.

— If there are gaps between the straightedge

and the infeed table, make a note of how much and where the gaps are, then proceed to Step 5.

Repeat Steps 4–5 until the infeed table is

completely parallel to the outfeed table, which will also make it parallel to the cutterhead.

If the table adjustment cap and set screws

are loose, re-tighten them and re-install the previously removed parts.

Loosen the screw that secures the depth of

cut pointer (see Figure 74), adjust the pointer to "0", then re-tighten the screw.

Note: To access the table adjustment bolts

on the back side of the infeed table, remove the back table cover.

Use the same process you performed in Step

5. 9 on Page 46 to raise or lower the left or right

end of the infeed table to eliminate the gaps. Adjust the adjustment bolts equally on each side for the targeted end of the table, one after the other, in very small increments (see Figure 73).

Rear

Infeed

Left

Adjustment

Bolt Locations

Right

Figure 75. Depth of cut scale and pointer.

If your jointer uses a knife-style cutterhead,

re-adjust the knife heights as instructed in the

Adjusting/Replacing Cutterhead Knives subsection on Page 39.

Front

Figure 74. Locations of the infeed table

adjustment bolts.

Extreme Series Jointer (Mfd. Since 10/20)

-47-

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 8: 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.

-48-

Extreme Series Jointer (Mfd. Since 10/20)

G9860 & G9860ZX Wiring Diagram

Electrical Pedestal

Ground

2T1 4T2 6T3

LR97D 25

POWER

LOAD(A)

A1 A2 98 95 96

D-TIME

0-TIME

O/L Relay

STOP

LAMP

L1/1 L3/5

L2/3

13NO

Ground

WARNING!

SHOCK HAZARD!

Disconnect power before working on wiring.

0.5

0.3 1

RESET

TEST

2T1 6T3

4T2

TECO

Contactor

CU-18 220V

14NO

STOP

Control Panel

Ground

Motor

Extreme Series Jointer (Mfg. Since 10/20)

Start Capacitor

400MFD 250VAC

Ground

Hot

220

VAC

Hot

220VAC

NEMA 6-20 Plug

(As Recommended)

READ ELECTRICAL SAFETY

-49-

ON PAGE 48!

G9953ZX Wiring Diagram

Electrical Pedestal

97 98 95 96

T1 T2 T3

Ground

O/L Relay

RHU-80A2

24.5

LOAD

TECO

3 2

T1/2 T3/6

T2/4

TECO

Contactor

CU-27 220V

22NC

14NO

21NC

L1/1 L3/5

L2/3

13NO

Ground

Motor

POWER

LAMP

Ground

Run Capacitor

30MFD 350VAC

STOP

Control Panel

Start Capacitor

800MFD 250VAC

NC NO COM

Hot

Cutterhead

Brake Switch

Hot

Ground

NEMA L6-30

L6-30 PLUG

(as recommended)

-50-

READ ELECTRICAL SAFETY

ON PAGE 48!

Extreme Series Jointer (Mfg. Since 10/20)

g9953zxf 220v wiring

G9953ZXF 220V Wiring Diagram

Ground

2T1 4T2 6T3

O/L Relay

LOAD

TECO

RHU-10

Electrical Pedestal

3 2

2T1 6T3

4T2

14NO

TECO

Contactor

CU-18 220V

1L1 5L3

3L2

13NO

Ground

Motor

POWER

Ground

LAMP

4 5 6

7 8 9

1 2 3

STOP

Control Panel

NC NO COM

Cutterhead

Brake Switch

220VAC 3-Phase

Locking Disconnect Switch

(As Recommended)

Extreme Series Jointer (Mfg. Since 10/20)

READ ELECTRICAL SAFETY

ON PAGE 48!

-51-

440v wiring diagram

G9953ZXF 440V Wiring Diagram

Ground

2T1 4T2 6T3

LOAD

O/L Relay

TECO

RHU-10

Electrical Pedestal

7.2

3 2

2T1 6T3

4T2

14NO

TECO

Contactor

CU-18 440V

1L1 5L3

3L2

13NO

Ground

Motor

POWER

Ground

LAMP

4 5 6

7 8 9

1 2 3

STOP

Control Panel

NC NO COM

Cutterhead

Brake Switch

440VAC 3-Phase

Locking Disconnect Switch

(As Recommended)

-52-

READ ELECTRICAL SAFETY

ON PAGE 48!

Extreme Series Jointer (Mfg. Since 10/20)

SECTION 9: PARTS

REF P ART # DE S CRIP TION REF P ART # DE S CRIP TION

G9860/ZX Cabinet

32V2

35V2

237V4

236V2

POWER

STOP

5000

MIN

1 P9860001 BASE 17 P9860017 PHLP HD SCR M6-1 X 10 3 P9860003 INFEED TABLE SUPPORT 23 P9860023 PHLP HD SCR M6-1 X 10 4 P9860004 INFEED TAB LE L I FTI NG ARM 26 P9860026 FLAT WASHER 10MM 5 P9860005 OUTFEED TABLE SUPPORT 27 P9860027 CAP SCREW M10-1.5 X 25 9 P9860009 TABLE HEIGHT SPINDLE 30 P9860030 FRONT CABINET ACCESS COVER 10 P9860010 OUTFEED TABLE LIFTING ARM 31 P9860031 HEX BOLT M6-1 X 12 11 P9860011 MOTOR ACCESS COVER 32V2 P9860032V2 DUST PORT 5" V2.10.20 12 P9860012 CONTROL PANEL PEDESTAL 33 P9860033 LOCK COLLAR 13 P9860013 CONTROL PANEL 34 P9860034 SET SCREW M8-1.25 X 8 14 P9860014 ON BUTTON 35V2 P9860035V2 DUST CHUTE 5" V2.10.20 15 P9860015 STOP BUTTON 236V2 P9860236V2 CONTACTOR TECO CU-18 220V V2.05.08 16 P9860016 POWER LAMP 237V4 P9860237V4 OL RELAY TE LR97D25M7 5-25A V4.09.11

Extreme Series Jointer (Mfd. Since 10/20)

-53-

G9860 cutterhead

120

G9860/ZX Cutterhead & Motor

119

106

108

105

104

114

107

103

110

115

116

118

117

101

101A

709

708

707

122

706

111

112

710

711

702

701-1

701-4

704

703

705

701

701-3

113

Model G9860

101-1

121

110

102

104

109

Model G9860ZX

Spiral Cutterhead

701-2

802

801

803

-54-

Extreme Series Jointer (Mfd. Since 10/20)

G9860 Cutterhead & Motor Parts List

REF PART # DE S CRIPTI ON REF PART # DE S CRIPTI ON

REF PART # DES CRIPTION REF PART # DES CRIPTION

101-1 P9860101-1 J OINTER PAL CARBIDE JIG 119 P9860119 SET SCREW M8-1.25 X 20 101 P9860101 CUTTERHEAD 3 KNIVE V1.08.02 120 P9860120 SPECIAL HEX NUT M17-1.5 101A P9860101A CUTTERHEAD 4 KNIFE V2.03.05 121 P9860121 J ACK SCREW M6-1 X 16 102 P9860102 FRONT BEARI NG HOUSI NG 122 P9860122 FLAT WASHER 10MM 103 P9860103 REAR BEARING HOUSING 701 P9860701 MOTOR 3HP 220V 1PH 104 P9860104 BALL BEARING 6305VV 701-1 P9860701-1 MO TOR FAN COVER 105 P9860105 SPANNER NUT M21-1. 5 701-2 P9860701-2 MOTOR FAN 106 P9860106 CUTTERHEAD PULLEY 701-3 P9860701-3 MOTOR WI RI NG J UNCTI ON BOX 107 P9860107 CUTTERHEAD STOP PLATE 701-4 P9860701-4 S CAP. 400M 250V 1-3/4 X 3-1/2 108 P9860108 REAR BEARING CAP 702 P9860702 MOTOR PULLEY 109 P9860109 FRONT BEARI NG CAP 703 P9860703 KEY 7 X 7 X 35 110 P9860110 GREASE FI TTI NG 704 P9860704 SET SCREW 5/16-18 X 1/2 111 P9860111 LOCK WASHER 10MM 705 P9860705 HEX NUT M10-1. 5 112 P9860112 CAP SCREW M10-1.5 X 45 706 P9860706 LOCK WASHER 10MM 113 P9860113 KNIFE 1-3/16" X 12" X 1/8" 707 P9860707 HEX BOLT M10-1.5 X 40 114 P9860114 KNIFE GIB 12" 708 P9860708 FLAT WASHER 1/2 115 P9860115 GIB BOLT M8-1.25 X 10 709 P9860709 HEX BOLT M12-1.75 X 40 116 P9860116 BRACKET 710 P9860710 MOTOR MOUNT PLATE 117 P9860117 FLAT WASHER 10MM 711V2 P9860711V2 V-BELT A47 118 P9860118 HEX BOLT M10-1.5 X 16

G9860ZX Cutterhead & Motor Parts List

102 P9860ZX102 FRONT BEARING HOUS I NG 701-1 P9860ZX701-1 MOTO R FAN COV ER 103 P9860ZX103 REAR BEARING HOUSING 701-2 P9860ZX701-2 MOTOR FAN

104 P9860ZX104 BALL BEARING 6305VV 701-3 P9860ZX701-3 MO TOR WI RI NG J UNCTI ON BO X 105 P9860ZX105 SPANNER NUT M21-1. 5 701-4 P9860ZX701-4 S CAP. 400M 250V 1-3/4 X 3-1/ 2 106 P9860ZX106 CUTTERHEAD PULLEY 702 P9860ZX702 MOTOR PULLEY 107 P9860ZX107 CUTTERHEAD STOP PLA TE 703 P9860ZX703 KEY 7 X 7 X 35 108 P9860ZX108 REAR BEARING CAP 704 P9860ZX704 SET SCREW 5/16-18 X 1/2 109 P9860ZX109 FRONT BEARING CAP 705 P9860ZX705 HEX NUT M10-1 . 5 110 P9860ZX110 GREASE FI TTI NG 706 P9860ZX706 LOCK WASHER 10MM 111 P9860ZX111 LOCK WASHER 10MM 707 P9860ZX707 HEX BOLT M10-1.5 X 40 112 P9860ZX112 CAP SCREW M10-1.5 X 45 708 P9860ZX708 FLAT WASHER 1/2 116 P9860ZX116 BRACKET 709 P9860ZX709 HEX BOLT M12-1.75 X 40 117 P9860ZX117 FLAT WASHER 10MM 710 P9860ZX710 MOTOR MO UNT PLA TE 118 P9860ZX118 HEX BOLT M10-1.5 X 16 711V2 P9860ZX711V2 V-BELT A47 119 P9860ZX119 SET SCREW M8-1.25 X 20 801 P9860ZX801 FLAT HD TORX T20 M6-1 X 15 120 P9860ZX120 SPECIAL HEX NUT M17-1.5 802 P9860ZX802 I NDEXABLE INSERT 14 X 14 X 2MM 122 P9860ZX122 FLAT WASHER 10MM 803 P9860ZX803 SPIRAL CUTTERHEAD 12" 701 P9860ZX701 MOTOR 3HP 220V 1PH

Extreme Series Jointer (Mfd. Since 10/20)

-55-

G9860/ZX Fence

217

208

205

211

206

210

209

202

212

221

220

219

218

207

216

214

215

201

203

216

204

213

222

603

605

Model G9860

602

601

604

607

606

18-1

-56-

Extreme Series Jointer (Mfd. Since 10/20)

G9860/ZX Fence Parts List

REF PART # DES CRIPTION REF PART # DES CRIPTION

2 P9860002 FENCE SEAT 212 P9860212 CAP SCREW M5-.8 X 16 18 P9860018 KEY 10 X 8 X 300 213 P9860213 SET SCREW M6-1 X 12 18-1 P9860018-1 ROLL PIN 5 X 25 214 P9860214 SET SCREW M6-1 X 35 19 P9860019 FENCE LOCK T-NUT 215 P9860215 HEX NUT M6-1 20 P9860020 LOCK WASHER 16MM 216 P9860216 FLAT WASHER 1/2 21 P9860021 FLAT WASHER 16MM 217 P9860217 FENCE LOCK LEVER ASSY 22 P9860022 CAP SCREW M12-1.75 X 30 218 P9860218 FLAT WASHER 10MM 201 P9860201 FENCE BASE 219 P9860219 CAP SCREW M10-1.5 X 25 202 P9860202 PIVOT BRACKET 220 P9860220 FENCE ADJ USTMENT HA NDLE 203 P9860203 CONNECTOR BRACKET 221 P9860221 KNOB 3/8"-16 204 P9860204 TILT LOCK LEVER ASSY 222 P9860222 DUST CO VER 205 P9860205 LOWER FENCE ROD 601 P9860601 ROD 206 P9860206 CLAMP ROD 602 P9860602 COLLAR 207 P9860207 STOP BRACKET 603 P9860603 KNURLED KNOB 208 P9860208 FENCE 604 P9860604 BRAKE CASING 209 P9860209 UPPER FENCE ROD 605 P9860605 ROLL PIN 3 X 18 210 P9860210 EXT RETAI NI NG RI NG 1 6MM 606 P9860606 SET SCREW M6-1 X 6 211 P9860211 CAP SCREW M5-.8 X 20 607 P9860607 COMPRESSION SPRING

Extreme Series Jointer (Mfd. Since 10/20)

-57-

G9860 /ZX Table

315

REF PART # DESCRIP TION REF PART # DESCRIP TION

314

313

319

405

403

402

401

404

306

312

311

308

320

303

310

301

316

304

310

302

311

309

305

307

6 P9860006 FRONT TABLE COVER 310 P9860310 BED PIVOT PIN 7 P9860007 INFEED TABLE REAR COVER 311 P9860311 CAP SCREW M10-1. 5 X 45 8 P9860008 OUTFEED TABLE REAR COVER 312 P9860312 J -ROD SHORT

24 P9860024 FLAT WAS HER 8MM 313 P9860313 FLAT WASHER 1/2 25 P9860025 HEX BOLT M8-1.25 X 16 314 P9860314 FLAT WASHER 3/8 29 P9860029 KNOB M10-1. 5 X 30 315 P9860315 HEX NUT M12-1.75 301 P9860301 OUTFEED TABLE 316 P9860316 TABLE PIVOT ROD SHORT 302 P9860302 TABLE PIVOT ROD LONG 319 P9860319 SPRING SHAFT COVER 303 P9860303 SET SCREW M8-1.25 X 10 320 P9860320 INFEED TABLE 304 P9860304 NOISE DAMPER 401 P9860401 CUTTERHEAD GUARD 305 P9860305 CAP SCREW M6-1 X 12 402 P9860402 CAP SCREW M8-1.25 X 25 306 P9860306 COVER 403 P9860403 SPRI NG SHAFT HOUSI NG 307 P9860307 PHLP HD SCR M6-1 X 12 404 P9860404 SPRING SHAFT 308 P9860308 J-RO D LONG 405 P9860405 CAP SCREW M12-1.75 X 20 309 P9860309 TENSI ON SPRI NG

-58-

Extreme Series Jointer (Mfd. Since 10/20)

G9860/ZX Handwheel

520

522

REF PART # DESCRIP TION REF PART # DESCRIP TION

523

511

510

502

509

512

521

516

519

517

518

501

508

506

513

507

515

514

503

505

504

522

523

501 P9860501 LI FT RO D BRACKET 513 P9860513 CAP SCREW M10-1.5 X 40 502 P9860502 HANDWHEEL 514 P9860514 HEX NUT M10- 1. 5 503 P9860503 BEVEL GEAR 515 P9860515 SET SCREW M4-.7 X 10 504 P9860504 SLEEVE 516 P9860516 GREAS E FI TTI NG 505 P9860505 LI FT RO D 517 P9860517 KEY 5 X 5 X 15 506 P9860506 GEAR SHAFT 518 P9860518 LOCK WASHER 8MM 507 P9860507 LI FT CO NNECTOR 519 P9860519 HEX BOLT M8-1.25 X 25 508 P9860508 SPECIAL EXT RETAINER RING 520 P9860520 HEX BOLT 3/ 8-16 X 2 509 P9860509 EXT RETA I NING RING 22 MM 521 P9860521 HEX NUT 3/8"-16 510 P9860510 SPECIAL FLAT WASHER D12 X 8MM 522 P9860522 SPECIAL NUT M25-1.5 511 P9860511 LOCK KNOB M10-1.5 X 20MM 523 P9860523 SET SCREW M6-1 X 6 512 P9860512 HANDWHEEL KNOB 3/8"-16

Extreme Series Jointer (Mfd. Since 10/20)

-59-

G9953ZX/ZXF Cabinet

REF P ART # DE SCRIP TION REF P ART # DES CRIP TI ON

6V2

13V2

G9953ZXF 440V

Conversion Kit

40V3*

39V2*

* = These parts vary by model.

Pay close attention to

part number when ordering.

1 P9953ZX001 BASE 21 P9953ZX021 FLAT WASHER 10MM 2 P9953ZX002 I NFEED TABLE SUPPORT 22 P9953ZX022 CAP SCREW M10-1.5 X 25 3 P9953ZX003 OUTFEED TABLE SUPPORT 23 P9953ZX023 ON B UTTON 4 P9953ZX004 I NFEED TABLE LIFTING ARM 24 P9953ZX024 STOP BUTTON 5 P9953ZX005 OUTFEED TABLE LIFTING ARM 25 P9953ZX025 POWER LAMP 6V2 P9953ZX006V2 DUST HOOD 5" V2.10.20 26 P9953ZX026 PHLP HD SCR M6-1 X 12 8 P9953ZX008 TABLE HEIGHT SPINDLE 27 P9953ZX027 CONTROL PANEL 13V2 P9953ZX013V2 DUST CHUTE 5" V2.10.20 28 P9953ZX028 CONTROL PANEL PEDESTAL 14 P9953ZX014 MOTOR ACCESS COVER 39V2 P9953ZX039V2 CONTACTOR TECO CU-18 220V V2.05.08 15 P9953ZX015 PHLP HD SCR M6-1 X 10 39V2 P9953ZXF039V2 CONTACTOR TECO CU-18 440V V2.05.08 16 P9953ZX016 PHLP HD SCR M6-1 X 12 40V3 P9953ZX040V3 OL RELAY TECO RHU-10 15-20A V3.01.11 19 P9953ZX019 STOP COLLAR 40V3 P9953ZXF040V3 OL RELAY TECO RHU-10 15-20A V3.01. 11 20 P9953ZX020 SET SCREW M8-1.25 X 8 42 P9953ZXF042 440V CONVERSION KIT

-60-

Extreme Series Jointer (Mfd. Since 10/20)

G9953ZX/ZXF Cutterhead

107

117

120

REF P ART # DES CRIPTION REF PART # DESCRIP TION

122

121

123

110

112

119

111

124

108

109

118

117

105

125

103

903

901

118

902

125

104

102

106

119

102 P9953ZX102 BEARING HOUSI NG FRONT 118 P9953ZX118 HEX BOLT M10-1. 5 X 30 103 P9953ZX103 BEARING HOUSING REAR 119 P9953ZX119 CAP SCREW M5-.8 X 16 104 P9953ZX104 BALL BEARING 6206ZZ 120 P9953ZX120 CUTTERHEAD REAR COVER 105 P9953ZX105 BALL BEARING 6208ZZ 121 P9953ZX121 PHLP HD SCR M4-.7 X 15 106 P9953ZX106 BEARING END CAP 122 P9953ZX122 STAR KNOB 107 P9953ZX107 BRAKE NUT M30-1.5 123 P9953ZX123 HEX NUT M5-. 8 108 P9953ZX108 BEARING CAP 124 P9953ZX124 SET SCREW M8-1.25 X 20 109 P9953ZX109 SPANNER NUT M40-1.5P 125 P9953ZX125 GRE ASE FI TTI NG 110 P9953ZX110 CUTTERHEAD PULLEY 901 P9953ZX901 FLAT HD TORX T20 M6-1 X 15 111 P9953ZX111 CUTTERHEAD STOP PLATE 902 P9953ZX902 INDEXABLE INSERT 14 X 14 X 2 112 P9953ZX112 END CAP 903 P9953ZX903 SPI RAL CUTTERHEAD BODY 117 P9953ZX117 LOCK WASHER 10MM

Extreme Series Jointer (Mfd. Since 10/20)

-61-

239

G9953ZX/ZXF Fence

219

220

234

225

243

241

224

242

245

237

246

232

244

235

238

236

226

230

223

217

222

231

228

221

229

233

209

210

235

207

206

202

204

209

-62-

218

241

240

203

214

213

212

215

226

218

211

205

208

Extreme Series Jointer (Mfd. Since 10/20)

201

216

217

208

G9953ZX/ZXF Fence Parts List

REF PART # DESCRIP TION REF P ART # DESCRI PTION

201 P9953ZX201 TUBE ROD BRACKET 224 P9953ZX224 HEX BOLT M8-1.25 X 30 202 P9953ZX202 CONNECTO R LEFT 225 P9953ZX225 FLAT WA SHER 8 MM 203 P9953ZX203 CONNECTO R RI G HT 226 P9953ZX226 HEX NUT M10- 1. 5 204 P9953ZX204 BASE PLATE 228 P9953ZX228 HEX BOLT M8-1.25 X 25 205 P9953ZX205 CAP SCREW M10-1.5 X 60 229 P9953ZX229 CAP SCREW M6-1 x 16 206 P9953ZX206 LOCK WASHER 8MM 230 P9953ZX230 BRACKET 207 P9953ZX207 CAP SCREW M8-1.25 X 50 231 P9953ZX231 ANCHOR RO D 208 P9953ZX208 CAP SCREW M10-1.5 X 25 232 P9953ZX232 PIVOT PIN RIGHT 209 P9953ZX209 FLAT WA SHER 6 MM 233 P9953ZX233 PIVOT PIN LEFT 210 P9953ZX210 CAP SCREW M6-1 X 10 234 P9953ZX234 FENCE ROD 211 P9953ZX211 GEAR SHAFT 235 P9953ZX235 PIVOT ARM 212 P9953ZX212 HANDWHEE L 236 P9953ZX236 FENCE ANGLE SEAT 213 P9953ZX213 FLAT WASHER 3/8 237 P9953ZX237 FE NCE ROD B RACKE T 214 P9953ZX214 HANDLE 3/8-16 238 P9953ZX238 PIVOT ROD 215 P9953ZX215 SET SCREW M8-1.25 X 10 239 P9953ZX239 FENCE 216 P9953ZX216 HEX NUT M8 -1. 25 240 P9953ZX240 FENCE RO D 217 P9953ZX217 SET SCREW M8-1.25 X 25 241 P9953ZX241 CAP SCREW M6-1 X 25 218 P9953ZX218 LOCK LEVER 1/2 X 50MM 242 P9953ZX242 FENCE STOP BLOCK 219 P9953ZX219 KNOB 3/8" 243 P9953ZX243 FLAT WASHER 1/4 220 P9953ZX220 FENCE A DJ US TMENT HANDL E 244 P9953ZX244 FLAT WASHER 5/16 221 P9953ZX221 FLAT WA SHER 6 MM 245 P9953ZX245 HEX NUT M8-1. 25 222 P9953ZX222 SET SCREW M6-1 X 10 246 P9953ZX246 SET SCREW M8-1.25 X 40 223 P9953ZX223 SET SCREW M6-1 X 8

Extreme Series Jointer (Mfd. Since 10/20)

-63-

308

G9953ZX/ZXF Table

313

305

314

310

311

312

316

309

301

317

315

303

307

306

302

-64-

401

402

304

404

314

405

315

403

805

804

802

801

806

807

803

Extreme Series Jointer (Mfd. Since 10/20)

REF PART # DES CRIPTION REF PART # DESCRI PTION

G9953ZX/ZXF Table Parts List

7 P9953ZX007 OUTFEED TABLE REAR HOUSING 305 P9953ZX305 SET SCREW M8-1.25 X 10 9 P9953ZX009 INFEED TABLE REAR HOUSING 306 P9953ZX306 CAP SCREW M6-1 X 16 10 P9953ZX010 FRONT TABLE COVER 307 P9953ZX307 PHLP HD SCR M6-1 X 12 11 P9953ZX011 FLAT WASHER 8MM 308 P9953ZX308 J-ROD (LONG) 12 P9953ZX012 HEX BOLT M8-1.25 X 16 309 P9953ZX309 TENSI ON SPRI NG 18 P9953ZX018 KNOB 3/8-16 X 1-1/2 310 P9953ZX310 HEX NUT M12-1.75 41 P9953ZX041 BRAKE SWITCH 311 P9953ZX311 FLAT WASHER 1/2 43 P9953ZX043 BRAKE PLATE 312 P9953ZX312 FLAT WASHER 3/8 44 P9953ZX044 CAP SCREW M8-1.25 X 35 313 P9953ZX313 INFEED TABLE 45 P9953ZX045 HEX NUT M8-1. 25 314 P9953ZX314 BED PIVOT PIN 46 P9953ZX046 BRAKE BRACKET 315 P9953ZX315 CAP SCREW M10-1.5 X 45 47 P9953ZX047 BRAKE PAD 316 P9953ZX316 J -ROD (SHORT) 48 P9953ZX048 PHLP HD SCR 10-24 X 1/2 317 P9953ZX317 TABLE PIVOT ROD (SHORT) 49 P9953ZX049 FLAT WASHER #10 401 P9953ZX401 CUTTE RHEAD G UARD 50 P9953ZX050 PHLP HD SCR 10-24 X 3/8 402 P9953ZX402 CAP SCREW M6-1 X 25 51 P9953ZX051 CAP SCREW M8-1.25 X 16 403 P9953ZX403 SPRI NG SHAFT HOUS I NG 52 P9953ZX052 HEX NUT M4-. 7 404 P9953ZX404 SPRING SHAFT 53 P9953ZX053 SET SCREW M4-.7 X 65 405 P9953ZX405 CAP SCREW M12-1.75 X 20 54 P9953ZX054 HEX BOLT M6-1 X 45 801 P9953ZX801 HANDLE HUB 55 P9953ZX055 HEX NUT M6-1 802 P9953ZX802 SHAFT 56 P9953ZX056 TENSION SP RI NG 803 P9953ZX803 CAP SCREW M5-.8 X 15 301 P9953ZX301 OUTFEED TABLE 804 P9953ZX804 HANDLE 302 P9953ZX302 NOISE DAMPER 805 P9953ZX805 HEX NUT 5/16"-24 303 P9953ZX303 COVER 806 P9953ZX806 FLAT WASHER 5 MM 304 P9953ZX304 TABLE PIVOT ROD (LONG) 807 P9953ZX807 LOCK WASHER 5MM

Extreme Series Jointer (Mfd. Since 10/20)

-65-

G9953ZX/ZXF Handwheel

520

REF PART # DES CRIPTION REF P ART # DESCRIP TION

522

523

513

507

515

503

505

508

506

501

516

502

517

522

523

514

504

509

510

511

518

519

521

512

501 P9953ZX501 LI FT ROD BRA CKET 513 P9953ZX513 CAP SCREW M10-1.5 X 40 502 P9953ZX502 HANDWHEEL 514 P9953ZX514 HEX NUT M10-1. 5 503 P9953ZX503 BEVEL GEAR 515 P9953ZX515 SET SCREW M4-.7 X 10 504 P9953ZX504 SLEEVE 516 P9953ZX516 GREASE FI TTI NG 505 P9953ZX505 LI FT ROD 517 P9953ZX517 KEY 5 X 5 X 15 506 P9953ZX506 GEAR SHAFT 518 P9953ZX518 LOCK WASHER 8MM 507 P9953ZX507 LI FT CONNECTO R 519 P9953ZX519 HEX BOLT M8-1.25 X 25 508 P9953ZX508 SPECIAL EXT RETAINER RING 520 P9953ZX520 HEX BOLT 3/8-16 X 2 509 P9953ZX509 EXT RETAI NI NG RI NG 22MM 521 P9953ZX521 HEX NUT 3/8"-16 510 P9953ZX510 SPECIAL FLAT WASHER D12 X 8MM 522 P9953ZX522 SPECIAL NUT M25-1.5 511 P9953ZX511 LOCK KNOB M10-1.5 X 20MM 523 P9953ZX523 SET SCREW M6-1 X 6 512 P9953ZX512 HANDWHEEL KNOB 3/8"-16

-66-

Extreme Series Jointer (Mfd. Since 10/20)

G9953ZX/ZXF Motor

REF PART # DESCRI PTION REF PART # DES CRIPTION

REF PART # DES CRIPTION REF PART # DESCRI PTION

Model G9953ZX

701-1

701-5

701-2

701-1

701-3

701-4

707

706

704

703

711

710

702

701

709

701-2

Model G9953ZXF

701-3

708

705

G9953ZX Motor Parts List

701 P9953ZX701 MOTOR 5 HP 220V 1PH 704 P9953ZX704 HEX BOLT M10-1.5 X 40 701-1 P9953ZX701-1 MOTOR FA N COVE R 705 P9953ZX705 HEX NUT M10-1 . 5 701-2 P9953ZX701-2 MOTOR FA N 706 P9953ZX706 FLAT WASHER 12MM 701-3 P9953ZX701-3 MOTOR WI RI NG J UNCTI ON BOX 707 P9953ZX707 HEX BOLT M12-1.75 X 25 701-4 P9953ZX701-4 S CAP. 800MFD 250V 2-7/8 X 3-1/4 708 P9953ZX708 KEY 7 X 7 X 65 701-5 P9953ZX701-5 R CAP. 30M 350V 3 X 2 709 P9953ZX709 SET SCREW M8-1.25 X 20 702 P9953ZX702 MOTOR PULLEY 710 P9953ZX710 MOTOR MOUNT PLA TE 703 P9953ZX703 LOCK WASHER 10MM 711 P9953ZX711 V-BELT A50

G9953ZXF Motor Parts List

701 P9953ZXF701 MOTOR 5 HP 220V 3PH 705 P9953ZXF705 HEX NUT M10-1. 5 701-1 P9953ZXF701-1 MO TOR FAN CO VER 706 P9953ZXF706 FLAT WASHER 12MM 701-2 P9953ZXF701-2 MO TOR FAN 707 P9953ZXF707 HEX BOLT M12-1.75 X 40 701-3 P9953ZXF701-3 MO TOR WI RI NG J UNCTION BOX 708 P9953ZXF708 KEY 7 X 7 X 65 702 P9953ZXF702 MOTOR PULLEY 709 P9953ZXF709 SET SCREW M8-1.25 X 20 703 P9953ZXF703 LOCK WASHER 10MM 710 P9953ZXF710 MOTOR MOUNT PLATE 704 P9953ZXF704 HEX BOLT M10-1.5 X 40 711 P9953ZXF711 V-BELT A50

Extreme Series Jointer (Mfd. Since 10/20)

-67-

720

REF PART # DESCRIP TI ON REF P ART # DESCRI PTION

Labels & Cosmetics

714

713

712

718

715

716

712 P9860712 EXTREME SERIES NAMEPLATE 717 P9860717 G RI ZZL Y GRE EN TOUCH- UP PA I NT 713 P9860713 EYE HAZARD LABEL 718 P9860718 GRI ZZLY PUTTY TO UCH-UP P AI NT 714 P9860714 MACHINE ID LABEL (G9860) 719* P9860719 MODEL NO. LABEL (G9860) 714 P9860ZX714 MACHINE ID LABEL (G9860ZX) 719* P9860ZX719 MODEL NO. LABEL (G9860ZX) 714 P9953ZX714 MACHINE ID LABEL (G9953ZX) 719* P9953ZX719 MODEL NO. LABEL (G9953ZX) 714 P9953ZXF714 MACHINE ID LABEL (G9953ZXF) 719* P9953ZXF719 MODEL NO. LABEL (G9953ZXF) 715 P9860715 PUSH BLOCK WARNI NG 720 P9860720 HANDWHEEL UP/DOWN LABEL 716 P9860716 GRIZZLY NAMEPLATE-LARGE * Not Shown

717

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.

-68-

Extreme Series Jointer (Mfd. Since 10/20)

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.

warranty-card

registration page

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

, or you can scan the QR code below to be automatically directed to our warranty

. Enter all applicable information for the product.

WARRANTY

Grizzly G9860 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

Manual Accuracy

Contact Info

Machine Description

Identification

Model Specification Comparison

SECTION 1: SAFETY

Safety Instructions for Machinery

Additional Safety Instructions for Jointers

SECTION 2: POWER SUPPLY

SECTION 3: SETUP

Needed for Setup

Unpacking

Inventory

Clean Up

Site Considerations

Dust Collection

Test Run

SECTION 4: OPERATIONS

Basic Controls

Squaring Stock

Surface Planning

Edge Jointing

Bevel Cutting

SECTION 5: ACCESSORIES

SECTION 6: MAINTENANCE

Schedule

Lubrication

V-Belts

SECTION 7: SERVICE

Troubleshooting

Rotating/Replacing

Cutterhead Inserts

Setting Fence Stops

SECTION 8: WIRING

Wiring Safety Instructions

G9860 & G9860ZX Wiring Diagram

G9953ZX Wiring Diagram

G9953ZXF 220V Wiring Diagram

G9953ZXF 440V Wiring Diagram

SECTION 9: PARTS

G9860/ZX Cabinet

G9860/ZX Cutterhead & Motor

G9860/ZX Fence

G9860 /ZX Table

G9860/ZX Handwheel

G9953ZX/ZXF Cabinet

G9953ZX/ZXF Cutterhead

G9953ZX/ZXF Fence

G9953ZX/ZXF Table

G9953ZX/ZXF Handwheel

G9953ZX/ZXF Motor

Labels & Cosmetics

WARRANTY & RETURNS