MODEL G5394 STROKE SANDER OWNER'S MANUAL

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1 MODEL G5394 STROKE SANDER OWNER'S MANUAL WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

3 Table of Contents INTRODUCTION... 2 SECTION 1: SAFETY... 6 SECTION 2: CIRCUIT REQUIREMENTS... 9 SECTION 3: SETUP SECTION 4: OPERATIONS SECTION 5: ACCESSORIES SECTION 6: MAINTENANCE SECTION 7: SERVICE SECTION 8: WIRING SECTION 9: PARTS WARRANTY AND RETURNS... 45

4 INTRODUCTION Manual Accuracy Functional Overview your machine may not exactly match the manual Contact Info

5 Identification Figure 1.. A. B. C. D. E. F. G. H. I. J. K. L.

6 MODEL G5394 STROKE SANDER MACHINE DATA SHEET Product Dimensions: Shipping Dimensions: Electrical: Motor: Main Specifications: Machine Data Sheet Table Information Model G0679 Page 1 of 2

7 Belt Information Platen Information Construction Other Related Information Other Specifications: Features: Model G0679 Page 2 of 2

8 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. 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. NOTICE Safety Instructions for Machinery This symbol is used to alert the user to useful information about proper operation of the machine. Safety Instructions for Machinery 1. READ ENTIRE MANUAL BEFORE STARTING. 2. ALWAYS USE ANSI APPROVED SAFETY GLASSES WHEN OPERATING MACHINERY. 3. ALWAYS WEAR A NIOSH APPROVED RESPIRATOR WHEN OPERATING MACHINERY THAT PRODUCES DUST. 4. ALWAYS USE HEARING PROTECTION WHEN OPERATING MACHINERY. 5. WEAR PROPER APPAREL. 6. NEVER OPERATE MACHINERY WHEN TIRED OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL.

9 Safety Instructions for Machinery 7. ONLY ALLOW TRAINED AND PROP- ERLY SUPERVISED PERSONNEL TO OPERATE MACHINERY. 8. KEEP CHILDREN/VISITORS AWAY. 9. UNATTENDED OPERATION. OFF 10. DO NOT USE IN DANGEROUS ENVIRONMENTS. 11. KEEP WORK AREA CLEAN AND WELL LIGHTED. 12. USE A GROUNDED POWER SUPPLY RATED FOR THE MACHINE AMPERAGE. 13. ALWAYS DISCONNECT FROM POWER SOURCE BEFORE SERVICING MACHINERY 14. MAINTAIN MACHINERY WITH CARE. 15. MAKE SURE GUARDS ARE IN PLACE AND WORK CORRECTLY BEFORE USING MACHINERY. 16. REMOVE CHUCK KEYS OR ADJUSTING TOOLS. 17. DAMAGED MACHINERY. 18. DO NOT FORCE MACHINERY. 19. SECURE WORKPIECE. 20. DO NOT OVERREACH. 21. MANY MACHINES CAN EJECT WORKPIECES TOWARD OPERATOR. 22. STABLE MACHINE. 23. CERTAIN DUST MAY BE HAZARDOUS 24. EXPERIENCING DIFFICULTIES.

10 Additional Safety for Stroke Sanders 1. RESPIRATOR AND SAFETY GLASSES. 5. UNATTENDED OPERATION 6. CLOTHING. 2. DUST COLLECTION SYSTEM 3. HAND PROTECTION 4. SANDING CORRECT MATERIAL. 7. REPLACING SANDPAPER 8. MAINTENANCE AND ADJUSTMENTS 9. EXPERIENCING DIFFICULTIES 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.

11 SECTION 2: CIRCUIT REQUIREMENTS 220V Operation Power Connection Device Figure 2 Serious personal injury could occur if you connect the machine to power before completing the setup process. DO NOT connect the machine to the power until instructed later in this manual. Electrocution or fire could result if machine is not grounded and installed in compliance with electrical codes. Compliance MUST be verified by a qualified electrician! Full Load Amperage Draw Extension Cords Figure 2. Power Supply Circuit Requirements If you are unsure about the wiring codes in your area or you plan to connect your machine to a shared circuit, consult a qualified electrician.

12 SECTION 3: SETUP Setup Safety Items 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! This machine and its components are very heavy. Get lifting help or use power lifting equipment such as a forklift to move heavy items. Description Qty Unpacking please immediately call Customer Service at (570) for advice. Otherwise, filing a freight claim can be difficult.

Inventory Frame Components: (Figure 4) Qty C. D. E. F. G. H.

machine or examine the packaging materials carefully.

13 Inventory Frame Components: (Figure 4) Qty C. D. E. F. G. H. 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. SUFFOCATION HAZARD! Immediately discard all plastic bags and packing materials to eliminate choking/suffocation hazards for children and animals. Figure 4. Uprights: (Figure 3) Qty A. B. Wheel Components: (Figure 5) Qty I. J. K. Figure 5. Figure 3.

Table Components: (Figure 6) Qty A. B. C. Hardware/Tools: (Figure 8) Qty F.

Note: Extra fasteners are included with the machine.

14 Table Components: (Figure 6) Qty A. B. C. Hardware/Tools: (Figure 8) Qty F. G. H. I. J. K. L. M. N. O. P. Q. R. S. T. U. Figure 6. Additional Components: (Figure 7) Qty D. E. Figure 8. Note: Extra fasteners are included with the machine. You may be left with extra hardware after assembly is complete. Figure 7.

15 Hardware Recognition Chart

Clean Up Figure 9 For optimum performance, clean all moving parts or sliding contact surfaces.

DO NOT use these products to clean the machinery.

inhaled. Minimize your risk by only using these products in a well ventilated area.

16 Clean Up Figure 9 For optimum performance, clean all moving parts or sliding contact surfaces. 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. Site Considerations Floor Load Machine Data Sheet Placement Location Figure 10 Many cleaning solvents are toxic if inhaled. Minimize your risk by only using these products in a well ventilated area. G2544 Solvent Cleaner & Degreaser H9692 Orange Power Degreaser Figure 10. 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. Figure 9.

17 Assembly To assemble your machine: 1. Figure Figure 12 Figure 11. Foot assembly attachment. 4 Figure 12. Second upright assembly. Figure Step 1 Figure 13. Third cross brace.

18 5 Figure 14 7 Figure 16 6 Figure 14. Top rail attachment. Figure 15. Figure 16. Platen assembly Figure 15. Motor bolt. Figure 17. Table elevation rod. Note: To make sure both sides are set evenly, fully lower both before connecting the table elevation rod.

19 10 Figure Figure 20 Figure 18. Inserting table rods. 11 Figure 19 Figure 20. Idler wheel assembly Figure 19. Attaching table. Figure 21 Figure 21. Belt tracking.

20 15 Figure Steps Figure 24 Figure 22. Idler wheel cover. 16 Figure 23 Figure 24. Gearbox shaft. 19 Figure 25 Figure 23. Knob placement. Figure 25. Handwheel placement.

21 20 Figure Figure 28 Figure 26. Switch box mounting. 21 Figure 27 Figure 28. Attaching handle. Machine Leveling Figure 29 Figure 27. Replacing cover. Figure 29. Machine leveling.

Dust Collection Test Run DO NOT operate the Model G5394 without an adequate dust collection system. This sander creates substantial amounts of wood dust while operating.

22 Dust Collection Test Run DO NOT operate the Model G5394 without an adequate dust collection system. This sander creates substantial amounts of wood dust while operating. Failure to use a dust collection system can result in short and long-term respiratory illness. Required CFM at each 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 the dust collection hoses: 1. Figure 30 TroubleshootingPage 30 To test run the machine: ON 7. OFF Figure

SECTION 4: OPERATIONS To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations.

23 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 and lungs could result from using this machine without proper protective gear. Always wear safety glasses and a respirator when operating this machine. Basic Controls Figures ON/OFF Switch: Table Elevation Handwheel: Table Work Stop: Table Depth Indicator: 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. NOTICE If you have never used this type of machine or equipment before, WE STRONGLY REC- OMMEND that you read books, trade magazines, or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training. Figure 31. Basic controls.

24 Belt Tension Handwheel: Platen Press Handle: Table Movement Handle: Table Movement To move the table vertically: Figure 33 Figure 33. Vertical table movement. Figure 32. Basic controls (continued). Note: Due to the locking nature of the wormdrive gearbox, no lock is needed to prevent vertical table movement. To move the table horizontally: 1.

Always use the workstops and be sure they are in the correct position and secured before using the machine.

25 Workstops Platen Press To rotate the platen press handle: The belt speed on the Model G5394 is 3500 FPM, or nearly 40 MPH. A workpiece ejected at this speed could cause serious personal injury and property damage. Always use the workstops and be sure they are in the correct position and secured before using the machine. 1. Figure 35 To position the workstops: Figure 34 Figure 35. Platen press Figure 34. Table workstop.

3. Figure 36 Figure 37. Installing new belt.

26 Sanding Belt Replacement 6. Figure 37 To replace the sanding belt: Figure 36 Figure 37. Installing new belt Belt Tracking Page 32. Figure 36. Belt covers open

27 Platen Press Movement Basic Operations To perform sanding operations: Figures 38 To move the platen press: 1. Figure 38. Sanding movements ON Note: The proper amount of pressure to apply is dependent on a number of factors, including the grit of sandpaper being used, the type and moisture content of the wood being used, and the condition of the sandpaper. Knowing how much pressure to apply will take practice. OFF 2. To move the table: 1. 2.

SECTION 5: ACCESSORIES T20501 Face Shield Crown Protector 4" T20502 Face

Safety Glasses T20452 "Kirova" Anti-Reflective Glasses T20456 "Dakura"

Surface Cleaners Size Model T20502 T20452 T20503 T20448 T20456 H0736

Figure 40 G5443 6" x 186"; 60 Grit G5444 6" x 186"; 80 Grit G5445 6" x

28 SECTION 5: ACCESSORIES T20501 Face Shield Crown Protector 4" T20502 Face Shield Crown Protector 7" T20503 Face Shield Window T20448 Economy Clear Safety Glasses T20452 "Kirova" Anti-Reflective Glasses T20456 "Dakura" Clear Safety Glasses H0736 Shop Fox Safety Glasses PRO-STICK Abrasive Surface Cleaners Size Model T20502 T20452 T20503 T20448 T20456 H0736 Figure 39. Figure 40 G5443 6" x 186"; 60 Grit G5444 6" x 186"; 80 Grit G5445 6" x 186"; 100 Grit G5446 6" x 186"; 120 Grit G5447 6" x 186"; 150 Grit G5548 6" x 186"; 180 Grit G5549 6" x 186"; 220 Grit Figure 41 Figure 22.

2PK P100 & O Vapor G2752 4" Rolling Floor Sweep G2753 4" Bench Dust Collection Attachment

29 T20514 Small Half-Mask Respirator T20515 Medium Half-Mask Respirator T20516 Large Half-Mask Respirator T20511 Pre-Filter P100 T20539 Cartridge Filter 2PK P100 T20541 Cartridge Filter 2PK P100 & O Vapor G2752 4" Rolling Floor Sweep G2753 4" Bench Dust Collection Attachment G2754 4" Floor Dust Collection Attachment Figure 42. H2443 Universal Adapter Figure 44. Figure 43.

30 SECTION 6: MAINTENANCE Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious personal injury. Schedule Lubrication Table Elevation Ways Figure 45 Daily Check: Weekly Maintenance: Every 500 Hours: Cleaning Figure 45. Table elevation ways. AccessoriesPage 26

31 Table Elevation Chain Figure 46 Table Elevation Gearbox Figure 47 Figure 46. Table elevation chain. Figure 47. Table elevation gearbox.

32 SECTION 7: SERVICE Troubleshooting Motor & Electrical OFF ON Page 35 Page 35

33 Operations Machine vibrates excessively (non-motor related). Page 24 Deep sanding grooves or scores in workpiece. Abrasive grit rubs off the belt easily. Sanding belt surface clogs quickly or burns. Burn marks on workpiece. Glazed sanding surfaces. Belt rubs on machine frame. Page 24 Page 32

34 Table Bearings Belt Tracking Tools Needed Qty Tools Needed Qty To adjust the sanding belt tracking: To adjust the bearing assemblies: Figure Figure Figure 48. Table bearing adjustment (table removed for clarity) Figure 49. Belt tracking adjustment. 4. Steps Steps 4 5

35 Table Elevation Wear Pin Adjustment Tools Needed Qty To adjust the wear pins: Steps Figure 50 Figure 50. Wear pin adjustment.

36 SECTION 8: WIRING Wiring Safety Instructions 1. SHOCK HAZARD. 5. WIRE/COMPONENT DAMAGE. 2. QUALIFIED ELECTRICIAN. 3. WIRE CONNECTIONS. 4. MOTOR WIRING. 6. MODIFICATIONS CAPACITORS. CIRCUIT REQUIREMENTS. Page 9 9. EXPERIENCING DIFFICULTIES. The photos and diagrams included in this section are best viewed in color. You can view these pages in color at

Wiring Diagram View this page in color at www.grizzly.com.

SHOCK HAZARD! Disconnect power before working on wiring.

37 Wiring Diagram View this page in color at PLUG (as recommended) 220 VAC 220V MOTOR WARNING! SHOCK HAZARD! Disconnect power before working on wiring. Figure 51. Switch wiring. Figure 52. Motor wiring. READ ELECTRICAL SAFETY ON PAGE 34!

38 Main Breakdown SECTION 9: PARTS

39 Main Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 101 P LEFT FOOT 134 PLN07 LOCK NUT 5/ P RIGHT FOOT 135 PK157M KEY 7 X 7 X P LEFT AUXILIARY FOOT 136 PB03 HEX BOLT 5/16-18 X P RIGHT AUXILIARY FOOT 138 P CHAIN WHEEL ADAPTER 105 P LEFT PROTECTION COVER 139 P CONNECTING ROD 106 P RIGHT PROTECTION COVER 140 P TRIANGULAR SCREW 1/4-20 X 1/2 107 P SANDER TABLE PROTECTION COVER 142 P SLEEVE COUPLING 108 P SANDER TABLE 143 PCAP121M CAP SCREW M6-1 X 20 (LH) 109 P TOP BEAM 144 P SPECIAL WASHER 110 P BOTTOM BEAM 145 P FOLLOWING WHEEL SUPPORT 111 P DRIVING WHEEL 146 P ADJUSTING SCREW 3/ P FOLLOWING WHEEL 147 P SLEEVE BEARING 16 X 32 X P MOTOR 3HP 220V 1PH P SLEEVE BEARING 14 X 32 X P MOTOR FAN 148 P ADJUSTING SUPPORT P MOTOR FAN COVER 149 P ADJUSTING SCREW 1/2-12 X P CAPACITOR COVER 150 PN06 HEX NUT 1/ PC300F S CAPACITOR 300M 125V 1-7/8 X 3-3/8 151 P ADJUSTING SCREW 1/2-12 X P MOTOR SEAT 152 PSS02 SET SCREW 5/16-18 X 3/8 115 P GEAR BOX 153 P HANDLE 116 P SLEEVE BEARING MOUNT 154 PSS02 SET SCREW 5/16-18 X 3/8 117 P HAND WHEEL SPINDLE 155 P FOLLOWING WHEEL AXLE 118 P HANDWHEEL 156 P ADJUSTING SCREW 1/2-12 X 2-1/2 120 PCAP148M CAP SCREW M X P SANDER BELT 6" X 186" 121 P UNIVERSAL JOINT 158 PLW01 LOCK WASHER 5/ P FIXING RING OF UNIVERSAL JOINT 159 PW05M FLAT WASHER 4MM P FIXING PIN OF UNIVERSAL JOINT 160 PCAP121M CAP SCREW M6-1 X 20 (LH) 122 P CHAIN WHEEL ADAPTER 161 PSS07 SET SCREW 1/4-20 X 1/2 123 PK36M KEY 5 X 5 X PB31 HEX BOLT 1/4-20 X P6204 BALL BEARING 6204ZZ 163 P PLASTIC CUSHION 125 PR09M EXT RETAINING RING 20MM 164 PN05 HEX NUT 1/4" P CHAIN WHEEL 165 PW01 FLAT WASHER 1/2 127 PSS02 SET SCREW 5/16-18 X 3/8 166 PCAP72 CAP SCREW 1/2-13 X P CHAIN WHEEL ADAPTER 167 P MAGNETIC SWITCH ASSEMBLY 129 P BALL BEARING MOUNT P SWITCH CASE 130 PB09 HEX BOLT 5/16-18 X 1/ P OL RELAY SDE RA PB03 HEX BOLT 5/16-18 X P CONTACTOR SDE MA PCAP16 CAP SCREW 3/8-16 X 3/ P PLASTIC COVER SCREW PCAP14 CAP SCREW 3/8-16 X P SWITCH COVER 132 PLN01 LOCK NUT 3/ PLW04 LOCK WASHER 3/8 133 P FOOT CUSHION 169 PFB16 FLANGE BOLT 5/16-18 X 24

40 Table Assembly Breakdown

41 Table Assembly Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 201 P TABLE BRACKET RIGHT 218 P GUIDE ROLLER SEAT P TABLE BRACKET LEFT 219 P ARBOR 202 P COPPER BAR 5/16" X 10MM 220 PR03M EXT RETAINING RING 12MM 203 PN08 HEX NUT 3/8" PN02 HEX NUT 5/16" PB18 HEX BOLT 3/8-16 X PB03 HEX BOLT 5/16-18 X P PLATE 223 P AUXILIARY SLIDE 206 P KEY WHEEL FIXING PLATE 224 P BACK STOP 207 P SET SCREW 8-32 X PB21 HEX BOLT 3/8-16 X 3/4 208 P LOCK WASHER #8 226 P SCALE POINTER 209 PN14 HEX NUT # P WORKTABLE 210 P GRIP 229 PN05 HEX NUT 1/4" P CHAIN 230 PFH16 FLAT HD SCR 1/4-20 X 1 1/4 212 PCAP70 CAP SCREW 5/16-18 X P GUIDE BAR 213 P TABLE BASE RIGHT 232 P SYNTHETIC PLATE (LARGE) 214 PB07 HEX BOLT 5/16-18 X 3/4 233 PCAP16 CAP SCREW 3/8-16 X 3/ PCAP03 CAP SCREW 5/16-18 X P SYNTHETIC PLATE (SMALL) 215 PW07 FLAT WASHER 5/ PW07 FLAT WASHER 5/ P GUIDE ROLLER 236 P TABLE BASE LEFT 217 PB51 HEX BOLT 1/4-20 X 3/8

42 Platen Press Breakdown

43 Platen Press Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 301 PR11M EXT RETAINING RING 25MM 318 P PRESSING PLATE HANDLE 302 PW19M FLAT WASHER 25MM 319 P PLASTIC WASHER 8MM 303 P MIDDLE POST SPRING 3.2 X 35 X PB07 HEX BOLT 5/16-18 X 3/4 304 P MIDDLE POST 321 PW02 FLAT WASHER 3/8 305 PB51 HEX BOLT 1/4-20 X 3/8 322 P BEARING SHAFT 306 PW06 FLAT WASHER 1/4 323 PR31M EXT RETAINING RING 38MM 307 P6001ZZ BALL BEARING 6001ZZ 324 PLN02 LOCK NUT 1/ P BACK BEARING PILLAR 325 P MIDDLE PRESSING PLATE SEAT 309 P FRONT BEARING PILLAR 326 P SPRING 1.3 X 9.6 X P UPPER PRESSING PLATE 327 P LOWER PRESSING PLATE SEAT 311 PLW04 LOCK WASHER 3/8 328 P FIXING PLATE 312 PN08 HEX NUT 3/8" PFS03 FLANGE SCREW X 3/8 313 P DISTANCE SLEEVE 330 P PAD 314 P BEARING SHAFT 331 P GRAPHITE PAD 315 PCAP159M CAP SCREW 1/4-20 X P GUIDE POST 316 P PRESSING PLATE STAND 333 PLW07 LOCK WASHER 1/2 317 P OFFSET SCREW 5/16-18 X 3/4 334 P CAP SCREW 1/2-13 X 3/4

Labels Breakdown & Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 501 P5394501 MACHINE ID LABEL 506 PLABEL-61C BELT DIRECTION LABEL 502 PLABEL-57C GLASSES/RESPIRATOR LABEL 507 P5394507

44 Labels Breakdown & Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 501 P MACHINE ID LABEL 506 PLABEL-61C BELT DIRECTION LABEL 502 PLABEL-57C GLASSES/RESPIRATOR LABEL 507 P MODEL NUMBER LABEL 503 P HAND ABRASION WARNING 508 XLABEL-12 READ MANUAL LABEL 504 PLABEL-63C DISCONNECT WARNING 509 PLABEL-14A ELECTRICITY LABEL 0.7" 505 G9987 GRIZZLY NAMEPLATE Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine 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) or to order new labels.

48 WARRANTY AND RETURNS

49 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!

SECTION 9: PARTS. Main Breakdown -36- Model G5394 (Mfd. Since 11/08)

SECTION 9: PARTS. Main Breakdown -36- Model G5394 (Mfd. Since 11/08) SECTION 9: PARTS Main Breakdown 105 137 136 113-1 113 141 140 113-2 113-3 111 113-4 114 135 143 144 101 121-1 -1 116 147-1 121-2 115 120 121 107 108 164 162 160 158 138 109 127 126 160 158 123 127 123