Model D4500/D4501 6" & 8" Indexable Insert Spiral Cutterheads Instruction Sheet

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Kerry Parks
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Model D4500/D4501 6" & 8" Indexable Insert Spiral Cutterheads Instruction Sheet Phone #: (360) 734-3482 Online Tech Support: tech-support@shopfox.

1 Model D4500/D4501 6" & 8" Indexable Insert Spiral Cutterheads Instruction Sheet Phone #: (360) Online Tech Support: Web: Introduction These indexable-insert spiral cutterheads are designed to replace both straight-knife and spiral cutterheads from Shop Fox and many other brands of 6" and 8" jointers. The Model D4500 6" cutterhead fits Shop Fox jointer Model W1679. The Model D4501 8" cutterhead fits Shop Fox jointer Model W1684. The total procedure for changing the cutterhead and setting up the jointer takes approximately one hour. The job consists of removing the old cutterhead, installing and shimming the new spiral cutterhead, and readjusting the outfeed table even with the knife edges at TDC (top dead center). These instructions make reference to many procedures detailed in your owner's manual. Call Technical Support at (360) if you need additional help. Inventory (Figure 1) A. Spiral Cutterhead...1 B. Torx Drivers T20 1 4"...5 C. T-Handle Socket Driver...1 D. Hex Nuts E. Flat Washers 10mm...2 F. Lock Washers 10mm...2 G. Bearing Block Studs 3/8-24 x H. Flat Head Torx Screws T20 M6-1 x I. Spare Cutterhead Inserts 14 x 14 x Cutterhead knives and inserts are razor sharp! Always wear heavy gloves when handling cutterheads, and avoid contact with cutters whenever possible. Failure to comply can result in serious personal injury! I A H G Figure 1. Model D4500/D4501 inventory. B F E D C Installation Refer to Figure 1 and the Parts Breakdown in your owner's manual to aid you during installation. Tools Needed Qty Wrench 8mm...1 Wrench 14mm...1 Precision Straightedge...1 Feeler Gauge Set...1 Pair of Heavy Leather Gloves...1 #16992MN COPYRIGHT DECEMBER, 2014 BY WOODSTOCK INTERNATIONAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC. Printed in Taiwan

To install spiral cutterhead, do these steps: 1. DISCONNECT JOINTER FROM POWER SOURCE! 2. Remove jointer fence and cutterhead guard. 3. Remove V-belts from pulleys. 4.

Figure 2. Jointer disassembly Steps 1 4. 5. Remove nut from bearing block stud, as shown in Figure 3, and repeat on other side. Figure 3. Removing nut from bearing block stud. 6.

Note: Your cutterhead may have paper shims stuck to bearing block or part of casting where bearing block rests.

2 To install spiral cutterhead, do these steps: 1. DISCONNECT JOINTER FROM POWER SOURCE! 2. Remove jointer fence and cutterhead guard. 3. Remove V-belts from pulleys. 4. Lower both beds to make enough room for cutterhead to come out, as shown in Figure 2. Note: When lowering, make sure fence support does not come into contact with cutterhead pulley. Figure 2. Jointer disassembly Steps Remove nut from bearing block stud, as shown in Figure 3, and repeat on other side. Figure 3. Removing nut from bearing block stud. 6. Wearing heavy leather gloves, carefully remove cutterhead from casting (see Figure 4). Note: Your cutterhead may have paper shims stuck to bearing block or part of casting where bearing block rests. If you see these, carefully pull them off and set them aside for later use, or keep them with your cutterhead in event that you reinstall it later. Also, mark side of cutterhead where they were used, so future install will go smoothly. Your new cutterhead may or may not need these shims. Bearing Block Bearing Block Stud Figure 4. Cutterhead removed. -2-

7. Install included bearing block studs into spiral cutterhead bearing blocks, and install cutterhead (see Figure 5). 8. Tighten spiral cutterhead, and ensure both pulley set screws are tight.

3 7. Install included bearing block studs into spiral cutterhead bearing blocks, and install cutterhead (see Figure 5). 8. Tighten spiral cutterhead, and ensure both pulley set screws are tight. Figure 5. Spiral cutterhead installed. 9. Using straightedge and feeler gauge set, verify cutterhead is parallel with outfeed table, as shown in Figure 6. With straightedge in position, raise or lower outfeed table until cutterhead body (not carbide insert) just touches straightedge. Straightedge Outfeed Table Figure 6. Checking cutterhead parallelism. 10. Move straightedge to other side (see Figure 7) to determine if one end of cutterhead body is higher/ lower than the other. Place feeler gauge between cutterhead body and straightedge (see Figure 8) to determine height difference. Black Lines Represent Straightedge Positions From Overhead View If cutterhead is even or within 0.004" with outfeed table from one side to the other, skip to Step 13. If cutterhead is over 0.004" from one side to other, go to Step Lift spiral cutterhead slightly and place a shim beneath bearing block. Figure 7. Position of straightedges in relation to cutterhead body. Note: Use shims from your old cutterhead if available. If not available, newspaper is approximately 0.003" thick and will work for shimming. (We don't recommend shimming more than 0.004" on either side, as this may affect how bearing block seats in casting.) 12. Repeat Steps 7 10 and adjust if necessary. Straightedge Outfeed Table 0.004" Feeler Gauge(s) -3- Figure 8. Using feeler gauge to measure height of cutterhead.

4 13. Use straightedge to adjust outfeed table even with edge of cutterhead knives at TDC (see Figures 9 & 10). This is a routine procedure that is covered in more detail in owner's manual that came with your jointer. Top Dead Center 14. Re-install fence. 15. Install cutterhead guard back over cutterhead, making sure that spring tension in guard is properly set so guard springs back over cutterhead when it is pulled back and released. Figure 9. Cutterhead at TDC (Top Dead Center). 16. Re-adjust infeed table. Insert Service D4500 Number of Inserts D4501 Number of Inserts Each insert can be rotated to reveal any one of its four cutting edges. Therefore, if one cutting edge becomes dull or damaged, simply rotate it clockwise 90 to reveal a fresh cutting edge (see Figure 11). In addition, each insert has a reference dot on one corner. As the insert is rotated, the reference dot location can be used as an indicator of which edges are used and which are new. The insert must be replaced when all four edges are dull. Figure 10. Setting outfeed table height. To install or adjust a carbide cutter, do these steps: 1. DISCONNECT JOINTER FROM POWER SOURCE! 2. Remove any sawdust from head of carbide insert Torx screw. 3. Remove Torx screw. Rotate or replace carbide insert. 4. Lubricate Torx screw threads with light machine oil. Figure 11. Rotating indexable carbide inserts. 5. Torque Torx screw to inch/pounds. -4-

5 Parts Breakdown & List D4500 Parts REF PART # DESCRIPTION REF PART # DESCRIPTION 1 XD SPIRAL CUTTERHEAD 6" 9 XD KEY 5 X 5 X 30 2 XD INDEXABLE INSERT 14 x 14 x 2 (SET OF 10) 10 XD BALL BEARING RS 3 XD FLAT HD TORX T20 M6-1 X XD BALL BEARING BLOCK 4 XD HEX NUT ⅜ XD PULLEY 5 XD LOCK WASHER 10MM 13 XD SET SCREW ¼-20 X ⅜ 6 XD BEARING BLOCK STUD 3/8-24 X 4 14 XD T-HANDLE DRIVER 1/4" 7 XD BALL BEARING BLOCK 15 XD TORX BIT T20 X 1/4" 8 XD BALL BEARING RS 16 XD FLAT WASHER 10MM D4501 Parts REF PART # DESCRIPTION REF PART # DESCRIPTION 1 XD SPIRAL CUTTERHEAD 8" 9 XD KEY 5 X 5 X 35 2 XD INDEXABLE INSERT 14 x 14 x 2 (SET OF 10) 10 XD BALL BEARING RS 3 XD FLAT HD TORX T20 M6-1 X XD BALL BEARING BLOCK 4 XD HEX NUT ⅜ XD PULLEY 5 XD LOCK WASHER 10MM 13 XD SET SCREW X ⅜ 6 XD BEARING BLOCK STUD 3/8-24 X 4 14 XD T-HANDLE DRIVER 1/4" 7 XD BALL BEARING BLOCK 15 XD TORX BIT T20 8 XD BALL BEARING RS 16 XD FLAT WASHER 10MM -5-

MODEL T " SPIRAL CUTTERHEAD INSTALLATION INSTRUCTIONS

MODEL T SPIRAL CUTTERHEAD INSTALLATION INSTRUCTIONS MODEL T27449 8" SPIRAL CUTTERHEAD INSTALLATION INSTRUCTIONS The Model T27449 indexable insert spiral cutterhead is designed to replace the straightknife cutterhead on the Grizzly jointer Model G0490W/G0490XW