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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.
Identification Figure 1. Model g9860/g9860zX identification. a. outfeed table b. Fence c. Cutterhead guard D. Fence Controls (refer to Fence controls on page 25 for detailed information) E. Control panel (refer to control panel on page 24 for detailed information). infeed table G.
Model Specification comparison G9860 G9860ZX G9953 G9953ZX G9953ZXF Motor hp Motor voltage 220V 220V 220V 220V 220V/440V Motor phase single single single single 3-phase Table ⁄ "W x ⁄ "W x ⁄ "W x Dimension ⁄ "W x 80"l ⁄ "W x 80"l ⁄...
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 impor- tance of the safety messages.
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DISCONNECTING POWER SUPPLY. GUARDS & COVERS. NEVER STAND ON MACHINE. APPROVED OPERATION. STABLE MACHINE. DANGEROUS ENVIRONMENTS. AWKWARD POSITIONS. ONLY USE AS INTENDED. UNATTENDED OPERATION. USE RECOMMENDED ACCESSORIES. MAINTAIN WITH CARE. CHILDREN & BYSTANDERS. CHECK DAMAGED PARTS. REMOVE ADJUSTING TOOLS. MAINTAIN POWER CORDS. SECURING WORKPIECE.
additional Safety Instructions for Jointers JOINTER KIcKbacK. "Kickback" is when the KIcKbacK ZONE. the "kickback zone" is the workpiece is thrown off the jointer table by the path that is in line with the tables. Never stand or force of the cutterhead. always use push blocks allow others to stand in this area during opera- and safety glasses to reduce the likelihood of tion.
SEcTION 2: pOWER SuppLy availability circuit Information For your own safety and protection of property, consult a qualified electrician if Electrocution, fire, you are unsure about wiring practices or equipment damage may electrical codes in your area. occur if machine is not correctly grounded and connected to the power Note: The circuit requirements listed in this man-...
Model G9953ZXF Grounding Requirements 440v conversion to operate your jointer with 440V power, you must: 1) replace the magnetic switch contactor, 2) NOTICE replace the overload relay, 3) replace the power lamp and oN button light bulbs, 4) re-wire the No adapter is available or should be used motor, and 5) have an electrician hardwire the with this machine.
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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 load dial from the panel, then replace the light bulb. LOAD re-install the lamp assembly, move the lock latch to the right to secure it.
SEcTION 3: SETup Needed for Setup This machine presents serious injury hazards read through the entire SETup section to under- to untrained users. Read stand the procedures and items required to cor- through this entire manu- rectly move, place, and assemble your machine. al to become familiar with the controls and opera- the following are needed to complete the setup...
Site considerations Mounting to Shop Floor Floor Load refer to the Model Specification comparison although not required, we recommend that you chart on page 5 for the weight and footprint speci- mount your new machine to the floor. Because fications of your machine. some residential floors this is an optional step and floor materials may may require additional reinforcement to support vary, floor mounting hardware is not included.
Moving & using Machine Mounts using machine mounts, shown in Figure 14, gives assembling Jointer the advantage of fast leveling and vibration reduc- tion. the large size of the foot pads distributes the weight of the machine to reduce strain on the floor.
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Note: Before the jointer was shipped from the NOTICE factory, the infeed table was fully raised and the stop bolt was threaded up against the bot- Make sure the straps do not touch the con- tom of it to safely secure it during transit. trol panel pedestal in the next step.
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Installing Fence (G9860/G960ZX) to secure the fence assembly, thread the t-slot nut onto the bottom of the lock shaft so remove the motor access panel on the back that nut fits up into the slot of the fence sup- of the machine. port, as shown in Figure 20.
adjusting cutterhead Setting Outfeed Guard Tension 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. The cutterhead guard is a critical safety feature of this jointer. you MuST install and if the outfeed table is set too low, the workpiece verify its operation before using the jointer! will have increased snipe.
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Note: On the knife-style cutterhead models, place the straightedge on the center of the outfeed table and over the cutterhead, rotate the knurled knob on the cutterhead lock then use the cutterhead pulley to rotate the pin underneath the back of the fence assem- cutterhead until the cutter edge is at the top- bly until it pops in toward the cutterhead.
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loosen the outfeed table lock and rotate the loosen the jam nut and adjust the outfeed handwheel until the cutter edge just touches stop bolt underneath the table so that it just the straightedge when at tdC, then tighten touches the bottom of the tables, as shown in Figure 25, then re-tighten the jam nut.
Dust collection 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 DO NOT operate your jointer without an ade- of verifying the following: 1) the motor powers quate dust collection system.
— 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 com- ing from the power source. if not already done, use the stop button to turn the machine OFF.
SEcTION 4: OpERaTIONS basic controls To reduce the risk of serious injury when using refer to Figures 29–33 and the following descrip- this machine, read and tions to become familiar with the functions of the understand this entire control panel, table controls, and fence controls. manual before beginning any operations.
stock inspection Stock Inspection & Scrape all glue off the workpiece before • jointing. glue deposits on the workpiece, Requirements hard or soft, will gum up the cutterhead and produce poor results. Remove foreign objects from • Follow these rules when choosing and joint- workpiece.
Edge Joint on the Jointer: the concave edge of the workpiece is jointed flat with the jointer (see Figure 38). before turning the jointer ON, make sure the outfeed table height is properly set (refer to page 19 for detailed instructions) to avoid workpiece kickback and to ensure good results.
Surface planning To surface plane the workpiece on the joint- disCoNNECt JoiNtEr FroM poWEr! the purpose of surface planing on the jointer is to make one face of the workpiece flat (see Figures Make sure you read and follow the Safety 40–41).
Edge Jointing To edge joint on the jointer: disCoNNECt JoiNtEr FroM poWEr! the purpose of edge jointing is to produce a Make sure you read and follow the Safety finished, flat-edged workpiece surface that is suit- Instructions beginning on page 6 and the able for joinery or finishing (see Figures 42–43).
bevel cutting To bevel cut on the jointer: disCoNNECt JoiNtEr FroM poWEr! the purpose of bevel cutting on the jointer is to Make sure you read and follow the Safety cut a specific angle of the workpiece edge (see Instructions beginning on page 6 and the Figures 44–45.
aCCEssoriEs SEcTION 5: accESSORIES h9815—power Twist v-belt - ⁄ " x 48" h7288—12" Dispoz-a-blade System ® ® (Includes 4 holders & Knife Inserts) smooth running with less vibration and noise than solid belts. the power twist V-belt can h5143—12" cobalt Dispoz-a-blade Knife ®...
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T20501—Face Shield crown protector 4" G5562—SLIpIT 1 Qt. Gel ® T20502—Face Shield crown protector 7" G5563—SLIpIT 12 oz Spray ® T20503—Face Shield Window G2871—boeshield T-9 12 oz Spray ® G2870—boeshield T-9 4 oz Spray T20452—"Kirova" anti-Reflective S. Glasses ® h3788—G96 Gun Treatment 12 oz Spray T20451—"Kirova"...
SEcTION 6: MaINTENaNcE cleaning & protecting always disconnect power to the machine before performing maintenance. Failure to do this may use a brush and shop vacuum to remove chips result in serious person- and debris from the jointer. Wipe the tables clean al injury.
Lubrication cutterhead bearing blocks Lubricant Frequency Nlgi #2 or Equivalent Every 40 hours other than lubrication points covered in this sec- of operation pump tion, all other bearings are internally lubricated and sealed at the factory. simply leave them the cutterhead bearing blocks are located on alone unless they need to be replaced.
v-belts 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. V-belts will wear and stretch with extended use. Maintaining proper tension of V-belts and making Note: The V-belts are properly tensioned sure they are in good condition will increase the ⁄...
SEcTION 7: SERvIcE review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel- ops. 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.
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Operations symptom possible Cause possible solution tables are 1. table lock is engaged. 1. loosen the table lock. hard to adjust. 2. adjust table stop bolts (page 46). 2. table stop bolts blocking movement. Excessive 1. outfeed table is set too low. 1.
Infeed Table Stop Tools Needed t-handle Wrench w/t-20 torx Bit ..... 1 bolt precision straightedge ........1 To rotate or replace a spiral cutterhead insert: the infeed table has a stop bolt that can be set to limit the how much the infeed table can be low- disCoNNECt JoiNtEr FroM poWEr! ered (see Figure 57).
position the straightedge on the outfeed table While carefully holding the insert in position, and over the insert to make sure that it is insert the bit into the torx screw and press installed correctly and at the same height as the operation lever to seat the insert.
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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.
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12. rotate all of the gib bolts counterclockwise Carefully remove the knife and gib. just enough so the gib holds the knife in if the knife is dull or damaged, replace it with place. a new one. 13. repeat Steps 11–12 on the other end of the cutterhead, then repeat Steps 4–12 with the Clean the knife, gib, and inside the cutterhead slot to remove all the pitch or sawdust.
Setting Fence Stops 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 the fence stops simplify the task of setting the secure the setting.
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Models G9953, G9953ZX, G9953ZXF To set the 45° fence stop: Tools Needed disCoNNECt JoiNtEr FroM poWEr! Machinist's square ..........1 Bevel square ............. 1 loosen the tilt lock and the 45° stop jam nut, Wrench 10mm ........... 1 then back off the stop bolt (see Figure 67). To set the 90°...
adjusting Table Tools Needed precision straightedge 6'l ........ 1 parallelism Feeler gauge ⁄ " (1.3mm) ........ 1 phillips screwdriver ........... 1 hex Wrench 4mm ..........1 hex Wrench 13mm ..........1 the tables of your jointer Must be parallel with Wrench or socket 13mm ........
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Make sure the precision straightedge and the if the outfeed table surface is not at the right table surface are free of debris, then place height, use the handwheel to bring the table the straightedge on the back of the outfeed to the correct height above the cutterhead, table and across the cutterhead.
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11. When the outfeed table height is correct loosen the cap screw in the center of the outfeed table adjustment bolt three full and parallel to the cutterhead, re-tighten the turns, then loosen the set screw that is adjustment bolt cap screw and set screw (see Figure 71), then make sure the table lock is directly underneath the adjustment bolt (see Figure 71).
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repeat Steps 4–5 until the infeed table is With the use of a magnet or an assistant, make sure that the straightedge stays flat completely parallel to the outfeed table, which against the full length of its contact with the will also make it parallel to the cutterhead.
WIRE/COMPONENT DAMAGE. MOTOR WIRING. MODIFICATIONS. CAPACITORS/INVERTERS. WIRE CONNECTIONS. CIRCUIT REQUIREMENTS. EXPERIENCING DIFFICULTIES. 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 (Mfg. since 9/11)
G9860 & G9860ZX Wiring Diagram Electrical Pedestal WARNING! SHOCK HAZARD! Disconnect power before working on wiring. Control Panel Motor 220VAC NEMA 6-20 Plug (As Recommended) -49- READ ELECTRICAL SAFETY Extreme series Jointer (Mfg. since 9/11) ON PAGE 48!
SEcTION 9: paRTS G9860/G9860ZX cabinet breakdown & parts List M IN PART # DESCRIPTION PART # DESCRIPTION P9860001 BASE PS68M PHLP HD SCR M6-1 X 10 P9860003 INFEED TABLE SUPPORT PS68M PHLP HD SCR M6-1 X 10 P9860004 INFEED TABLE LIFTING ARM PW04M FLAT WASHER 10MM P9860005...
g9860 cutterhead G9860/G9860ZX cutterhead & Motor breakdown -54- Extreme series Jointer (Mfg. since 9/11)
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G9860 cutterhead & Motor parts List PART # DESCRIPTION PART # DESCRIPTION 101-1 H2404 JOINTER PAL CARBIDE JIG PSS09M SET SCREW M8-1.25 X 20 P9860101 CUTTERHEAD 3 KNIVE V1.08.02 P9860118 SPECIAL HEX NUT M17-1.5 101A P9860101A CUTTERHEAD 4 KNIFE V2.03.05 P9860121 JACK SCREW M6-1 X 16 P9860102...
G9860/G9860ZX Fence breakdown Model G9860 -56- Extreme series Jointer (Mfg. since 9/11)
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G9860 Fence parts List REF PART # DESCRIPTION REF PART # DESCRIPTION P9860002 FENCE SEAT PSB16M CAP SCREW M4-.7 X 16 P9860018 KEY 10 X 8 X 300 PSS04M SET SCREW M6-1 X 12 18-1 PRP49M ROLL PIN 5 X 25 PSS29M SET SCREW M6-1 X 35 P9860019...
G9860/G9860ZX handwheel breakdown & parts List REF PART # DESCRIPTION REF PART # DESCRIPTION P9860501 LIFT ROD BRACKET PSB47M CAP SCREW M10-1.5 X 40 P9860502 HANDWHEEL PN02M HEX NUT M10-1.5 P9860503 BEVEL GEAR PSS23M SET SCREW M4-.7 X 10 P9860504 SLEEVE P9860516 GREASE FITTING...
G9953/G9953ZX/G9953ZXF cabinet breakdown & parts List REF PART # DESCRIPTION REF PART # DESCRIPTION P9953001 BASE PSB64M CAP SCREW M10-1.5 X 25 P9860003 INFEED TABLE SUPPORT P9860014 ON BUTTON P9860005 OUTFEED TABLE SUPPORT P9860015 STOP BUTTON P9860004 INFEED TABLE LIFTING ARM P9860016 POWER LAMP P9860010...
G9953/G9953ZX/G9953ZXF Fence breakdown -63- Extreme series Jointer (Mfg. since 9/11)
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G9953/G9953ZX/G9953ZXF Fence parts List REF PART # DESCRIPTION REF PART # DESCRIPTION P9953201 TUBE ROD BRACKET PSS01M SET SCREW M6-1 X 10 P9953202 CONNECTOR LEFT PSS03M SET SCREW M6-1 X 8 P9953203 CONNECTOR RIGHT PB26M HEX BOLT M8-1.25 X 30 P9953204 BASE PLATE PW01M...
G9953/G9953ZX/G9953ZXF Table breakdown -65- Extreme series Jointer (Mfg. since 9/11)
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G9953/G9953ZX/G9953ZXF Table parts List REF PART # DESCRIPTION REF PART # DESCRIPTION P9953007 OUTFEED TABLE REAR HOUSING PSS16M SET SCREW M8-1.25 X 10 P9953009 INFEED TABLE REAR HOUSING PSB01M CAP SCREW M6-1 X 16 P9953010 FRONT TABLE COVER PS14M PHLP HD SCR M6-1 X 12 PW01M FLAT WASHER 8MM P9953308...
G9953/G9953ZX/G9953ZXF handwheel breakdown & parts List REF PART # DESCRIPTION REF PART # DESCRIPTION P9860501 LIFT ROD BRACKET PSB47M CAP SCREW M10-1.5 X 40 P9860502 HANDWHEEL PN02M HEX NUT M10-1.5 P9860503 BEVEL GEAR PSS23M SET SCREW M4-.7 X 10 P9860504 SLEEVE P9860516 GREASE FITTING...
G9953/G9953ZX/G9953ZXF Motor breakdown Model G9953 & G9953ZX Model G9953ZXF G9953/G9953ZX Motor parts List REF PART # DESCRIPTION REF PART # DESCRIPTION P9953701 MOTOR 5 HP 220V 1PH PB31M HEX BOLT M10-1.5 X 40 701-1 P9953701-1 MOTOR FAN COVER PN02M HEX NUT M10-1.5 701-2 P9953701-2 MOTOR FAN PW06M...
MuST maintain the original location and readability of the labels on the machine. If any label is removed or becomes unreadable, REpLacE that label before using the machine again. contact Grizzly at (800) 523-4777 or www.grizzly.com to order new labels. -69-...
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-70- Extreme series Jointer (Mfg. since 9/11)
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WARRANTY CARD The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop better products and services. Of course, all information is strictly confidential. Note: We never use names more than 3 times. _____________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________...
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Buy Direct and Save with Grizzly – Trusted, Proven and a Great Value! ® ~Since 1983~ Visit Our Website Today For Current Specials! ORDER 24 HOURS A DAY! 1-800-523-4777...