MODEL G0459 12" DRUM SANDER OWNER’S MANUAL COPYRIGHT © OCTOBER, 2005 BY GRIZZLY INDUSTRIAL, INC., REVISED MAY, 2007 (BL) WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
Safety Label Placement The safety labels on this machine warn and indicate how to protect the operator or bystander from machine hazards. The machine owner MUST maintain the original label location and readability. If a label is removed or becomes unreadable, REPLACE the label before using the machine. For new labels, contact Grizzly Industrial Inc. at (570) 546-9663 or techsupport@grizzly.com.
Table of Contents INTRODUCTION ............................................................................................................................... 3 Foreword .................................................................................................................................... 3 Contact Info ................................................................................................................................ 3 Machine Data Sheet............................................
SECTION 7: SERVICE ................................................................................................................... 23 Troubleshooting........................................................................................................................ 23 Gauge Blocks ........................................................................................................................... 26 V-Belt Service ................................................................................
INTRODUCTION Foreword Contact Info We are proud to offer the Model G0459 12" Drum Sander. This machine is part of a growing Grizzly family of fine woodworking machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation and proof of Grizzly’s commitment to customer satisfaction. If you have any comments regarding this manual, please write to us at the address below: We are pleased to provide this manual with the Model G0459.
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Identification A C B D E J F H I G Figure 1. Front view, Model G0459. A. B. C. D. E. F. G. H. I. J.
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 which are 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.
Safety Instructions for Machinery 7. ONLY ALLOW TRAINED AND PROPERLY SUPERVISED PERSONNEL TO OPERATE MACHINERY. Make sure operation instructions are safe and clearly understood. 8. KEEP CHILDREN AND VISITORS AWAY. Keep all children and visitors a safe distance from the work area. 9. MAKE WORKSHOP CHILD PROOF. Use padlocks, master switches, and remove start switch keys. 10. NEVER LEAVE WHEN MACHINE IS RUNNING.
Additional Safety for Drum Sanders 1. 2. FEEDING STOCK. DO NOT allow anyone to stand directly in front of this sander when feeding your stock. Never sand more than one piece of stock at a time. 6. DUST COLLECTION SYSTEM. Never operate the sander without an adequate dust collection system in place and running. DO NOT jam the workpiece into the machine during operation. Firmly grasp the workpiece in both hands and ease it into the machine using light pressure. 7. BE ATTENTIVE.
SECTION 2: CIRCUIT REQUIREMENTS 110V Operation Electrocution or fire could result if this machine is not grounded correctly or if your electrical configuration does not comply with local and state codes. Ensure compliance by checking with a qualified electrician! Serious personal injury could occur if you connect the machine to the power source before you have completed the set up process. DO NOT connect the machine to the power source until instructed to do so.
SECTION 3: SET UP Set Up Safety 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 set up process! The Model G0459 is a heavy machine (146 lbs. shipping weight). DO NOT over-exert yourself while unpacking or moving your machine—get assistance.
Inventory Site Considerations After all the parts have been removed from the two boxes, you should have the following items: Box 1: (Figure 3) Qty A. Drum Sander .............................................. 1 B. Crank Handle ............................................. 1 C. 21⁄2" Dust Port ............................................. 1 D. 3mm Hex Wrench ...................................... 1 Floor Load Refer to the Machine Data Sheet for the weight and footprint specifications of your machine.
Placing Sander The Model G0459 is a heavy machine (139 lbs.). DO NOT over-exert yourself while unpacking or moving your machine— get assistance. To place the sander in a permanent location: 1. With an assistant's help, lift the sander out of the box and move it to your predetermined location. Mounting Components and Hardware Needed: Qty Lag Bolts 5 ⁄ 16-18 x 40 (Not Included) ..................4 Flat Washers 5 ⁄ 16 (Not Included) ........................4 To mount the drum sander to a bench top: 1.
Installing Crank Handle Components and Hardware Needed: Qty Crank Handle .................................................... 1 The crank handle is installed on the front right lift screw shaft, and is held in place with two set screws already threaded into the handle. To mount the handwheel: 1. Place the crank handle over the shaft shown in Figure 6 and, using a 3mm hex wrench, secure the handle with the two set screws.
Test Run Now that the machine is connected to the power source, it is important to perform a test run to make sure all the controls are working properly. Before starting the sander, 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 issues associated with this machine.
SECTION 4: OPERATIONS Operation Safety Switch/Lockout The ON/OFF switch can be locked-out to prevent unauthorized use. 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. To turn the switch ON and OFF: 1. 2. 3. To turn the sander ON, flip the switch up. To turn the sander OFF, press the switch down.
Depth of Cut Variable Speed The optimum depth of cut will vary based on the type of wood, feed rate, and sandpaper grit. Under most sanding conditions, the depth should not exceed 0.006" (0.15 mm) (approx. 1⁄4 turn of the handwheel). Each full turn of the crank handle raises the conveyor table approximately 0.027" (0.69 mm). Attempts to remove too much material can cause jamming, wood burning, rapid paper wear or tearing, poor finish, belt slippage, and motor damage.
Sanding DO NOT sand more than one board at a time. Minor variations in thickness can cause one board to be propelled by the rapidly spinning sanding drum and ejected from the machine. NEVER stand directly in front of the outfeed area of the machine. Failure to do so could result in severe personal injury. Sanding Tips • Replace the sandpaper with a higher grit to achieve a finer finish. • Raise the table with a maximum of 1⁄4 turn of the crank handle until the workpiece is the desired thickness.
Choosing Sandpaper 4. There are many types of sanding belts to choose from. We recommend Aluminum Oxide for general workshop environments. Below is a chart that groups abrasives into different classes, and shows which grits fall into each class. Grit Class 36 Extra Coarse Rough sawn boards, thickness sanding, and glue removal. ������� Usage 60 Coarse Thickness sanding and glue removal. 80–100 Medium Removing planer marks and initial finish sanding.
SECTION 5: ACCESSORIES Aluminum Oxide Sanding Rolls, 3" x 50' H4422—60 Grit: Use for thickness sanding and glue removal. H4779—80 Grit: Use for removing planer marks and initial finish sanding. H4423—100 Grit: Use for removing planer marks and initial finish sanding. H4780—120 Grit: Use for finish sanding. H4424—150 Grit: Use for finish sanding.
G3119—4" x 21⁄2" Adapter Made with Anti-Static Additive! Made in USA. G3124—Wire Hose Clamps - 21⁄2" G3123—Flexible Hose - 21⁄2" x 10' Everything you need to hook your sander up to a dust collector. G7313—Tool Table Get that bench-top tool off your bench and put it on this sturdy SHOP FOX® stand instead! Flared legs and adjustable rubber feet ensure stability and reduce machine vibration. Butcher block finish table top measures 13" x 23" and is 301⁄ 2" from the floor. Bottom measures 32" x 22". 700 lb.
SECTION 6: MAINTENANCE Lubrication Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious personal injury. Schedule The chain should be lubricated periodically with a light machine oil. Motor bearings need no lubrication. Use only adequate lubrication. Too much lubricant will attract dirt and sawdust and will clog the chain mechanism. Pillow Block Bearing: Must be lubricated every 20 hours of operation. Use a high-quality, lithiumbased grease.
Table Lift Screws: These should be lubricated with lithium grease every six months. Clean the table lift screws (Figure 21) and rub lithium grease onto the threads. Move the table up or down to spread the grease thoroughly over the threads. Failure to routinely inspect your drum sander for damage and wear could result in unsatisfactory work results, premature component or machinery failure, or operator injury. We recommend you create a checklist for routine inspection and maintenance.
SECTION 7: SERVICE This section is provided for your convenience—it is not a substitute for the Grizzly Service Department. If you need help troubleshooting, you need replacement parts, or you are unsure of how to perform the procedures in this section, then feel free to call our Technical Support at (570) 546-9663. Troubleshooting Motor & Electrical Symptom Possible Cause Possible Solution Machine does not 1. Plug or receptacle is at fault or wired incor- 1.
Sanding Operations Symptom Possible Cause Machine stalls or 1. Dust collection ducting is at fault. is underpowered. 2. Low power supply voltage. 3. Belt is slipping. 4. Motor connection is wired incorrectly. 5. Plug or receptacle is at fault. 6. Pulley or sprocket is slipping on shaft. 7. Motor bearings are at fault. 8. Machine is undersized for the task. 9. Motor has overheated. 10.Centrifugal switch is at fault. 11.Motor is at fault. Possible Solution 1.
Symptom Possible Cause Possible Solution Short V-belt lifes- 1. Pulleys not aligned correctly. pan. 2. Improperly tensioned. 1. Align pulleys (Page 27). 2. Properly tension V-belts (Page 26). Conveyor slips 1. Conveyor is too loose. under load. 2. Too much load. 1. Tension conveyor (Page 28). 2. Decrease load. Conveyor tracks 1. Conveyor tracking is incorrect. to one side; conveyor hits the roller cover. 1. Track the conveyor so it runs straight (Page 28). Workpiece pulls 1.
Gauge Blocks V-Belt Service Tools Needed: Qty 6' Long 2x4 ........................................................ 1 Miter Saw (or Circular Saw) .............................. 1 Jointer ................................................................ 1 Table Saw ......................................................... 1 Tools Needed: Qty Hex Wrench 6mm.............................................. 1 Wrench 12mm ................................................... 1 Straightedge ..........................
Pulley Alignment To adjust V-belt tension: 1. DISCONNECT POWER TO THE SANDER! 2. Open the rear panel. 3. Loosen the motor mount bolts and raise or lower the motor bracket, as shown in Figure 25, to loosen or tighten the V-belt. 4. Tighten the motor mount bolts and replace the rear panel. Tighten V-Belts Motor Plate Bracket Loosen V-Belts Pulley alignment is another important factor in power transmission and belt life.
Conveyor Tensioning & Tracking 2. —If the conveyor starts tracking to one side, immediately turn the drum sander OFF and perform the tracking instructions. Tools Needed: Qty Wrench 19mm ................................................... 1 Phillips Head Screwdriver #2 ............................ 1 Tracking Tensioning The conveyor may slightly stretch with continued use and will eventually need to be tensioned. This is most obvious if the conveyor starts slipping on the rollers.
Drum Adjustments 1. DISCONNECT POWER TO THE SANDER! 2. Open the top cover. Tools Needed: Qty Hex Wrench 4mm.............................................. 1 Wrench 19mm ................................................... 1 Wrench 10mm ................................................... 1 Socket 14mm .................................................... 1 Measuring Tape ................................................ 1 Gauge Blocks (see Page 26) ............................ 2 Feeler Gauge Set ...........
6. Lower the table one full turn of the crank handle. Wait until the chain starts moving before starting to count the crank handle rotation. 7. Starting at one end, place a 0.002" feeler gauge between the sanding drum and the gauge block. (The feeler gauge should slide with moderate resistance, without forcing the drum to roll.) 8. Repeat Step 7 at the other end of the drum.
Pressure Roller Height Tools Needed: Qty Wrenches/Sockets 10mm ................................. 1 Gauge Blocks (see Page 26) ............................ 2 Factory Setting: Distance Below Sanding Drum ..... 0.080" (2mm) The pressure rollers are factory set at 0.080" (2mm) below the bottom of the sanding drum and are fully adjustable either up/down with the four lower adjustment bolts (Figure 33). After the adjustment has been made, always lock the jam nuts against the bottom to prevent them from moving.
5. Turn the crank handle three full rotations (counting from the point of actual table movement so handwheel freeplay does not affect your count) to lower the table so the gauge blocks are below the pressure rollers, as shown in Figure 35. Figure 36. Pressure rollers set correct distance below bottom of sanding drum. 9. Scale Pointer Calibration Figure 35. Gauge blocks below pressure rollers. Note: You may open the side covers to gain better access for the following adjustments. This is not required. 6.
Table Lift Screws Tools Needed: Qty Hex Wrench 6mm.............................................. 1 Wrench/Socket 12mm ....................................... 1 Chalk, Correction Fluid, or Paint ....................... 1 Phillips Head Screwdriver #2 ............................ 1 Flat Head Screwdriver ....................................... 1 The table lift screws are connected by a chain and driven by the crank handle.
Conveyor Belt Replacement Tools Needed: Qty Hex Wrench 6mm.............................................. 1 Wrench/Socket 19mm ....................................... 1 Wrenches/Sockets 14mm ................................. 2 Wrench/Socket 12mm ....................................... 1 Wrench 10mm ................................................... 1 Phillips Head Screwdriver #2 ............................ 1 Measuring Tape ................................................ 1 Gauge Blocks (see Page 26) ......
6. Remove the rear pressure roller (4 hex bolts and 4 flat washers) along with the brackets, compression springs, and spring plates shown in Figure 41. 9. Remove the sanding drum (4 lock nuts and 4 flat washers) and V-belt (Figure 43). Spring Plate Compression Spring Bracket NEW PHOTO Figure 41. Rear pressure roller components. 7. Remove the rear panel. 8.
11. Mark the top of the table lift screws with arrows (all pointing in same direction) and mark the screws with liquid correction fluid above the mounting bracket (Figure 45). Later, when you reassemble the conveyor table, you can use these marks to reset the table height close to the current position. 15. Disconnect the conveyor feed motor wires from the circuit board. 16. Remove the scale pointer.
18. Lay the conveyor table on a flat surface. 19. Loosen the rear left (Figure 49) roller bracket (2 cap screws) enough so the conveyor motor chain is slack. Rear Left Roller Bracket Rear Lift Screw Front Right Sprocket Mounting Bracket Figure 50. Conveyor belt removed from table. Conveyor Motor Chain Conveyor Motor Figure 49. Rear left roller bracket loosened. 27. Measure the distance between the front right table lift screw sprocket and the mounting bracket.
34. Before reinstalling the gear box cover, try raising and lowering the conveyor table with the crank handle. If the worm wheel and worm gear teeth (see Figure 51) are not engaged, the crank handle will only raise the table. If this happens, loosen the crank handle mounting bolts, and move the worm gear around until the teeth mesh with the worm wheel, then secure the crank handle. 35. Reinstall and secure the brace. 36. Try moving the conveyor table up and down. 37.
Electrical Components Feed Motor Wires Feed Motor Capacitor Black Black Drum Motor Black Red Ground (Green) Black Wires from Circuit Board Wires from Switch White Motor Wiring Drum Motor Wires Switch Box Power Cord Black (L1) Red Circuit Board Feed Motor Wires Variable Speed Control Variable Speed Wires Variable Speed Control, Circuit Board G0459 12" Drum Sander Ground (Green) Red (Neutral) Switch Black Switch Box Wiring -39-
Wiring Diagram ���������� ��������� ����� ��� ���������� ����� ����� ���� ������ ����� ����� ����� �������� ����� ����� ����� ����� ������ ����� ��� ����� ����� ������������ ����� ��������� ����� ������� ����� ��������� ��� ����� ������ ������������� ������ ����� ����� ���� ���� ����� wiring diagram -40- G0459 12" Drum Sander
Frame Parts Breakdown 29 12-1 12-2 14 12 29 13 29 14-1 211 10 15 8-7 104 101 117 118 103 119 114 115 8-7 29 8-1 109 107 11 29 108 119 113 112 6 8-6 5-1 5 8-4 8-3 8-5 8-7 8-1 8-7 8-1 8-2 6 8-6 7-1 6 8-6 6 8-6 7-2 7-1 29 4 7-2 17 17 20 18 20-3 20-4 32 20-1 46 54 29 56 57-2 57 5 5-1 30-1 59 209 4 1 100 28 209-1 G0459 12" Drum Sander 40 34 2224 40 34 57 20-5 31 19 24 21 20-6 20-2 29 44 45 22 24 20-7 16 9 23 29 30-2 30-3 57-1 33 -41-
Drum and Conveyor Parts Breakdown 23 86 89 89-1 90 89-1 89 26 85 88 25 86 85 81 89 89-1 90 89-1 89 25 74 73 17 94 42 82 23 70 27 88 71 88 73 74 74 73 70 86 88 73 74 98 85 81 82 86 85 27 92-1 52 92 66 79 80 77 57 57 50-1 74 50-2 35 58 60 61 69 65-1 35 64 51 51 74 61 60 57 38 58 35 64 49-1 51-1 60 61 65 102 64 -42- 64 61 60 51-1 58 36 74 58 50-1 58 57 6 50-2 39 37 49 43 74 6 37 49 G0459 12" Drum Sander
Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 2 3 4 5 5-1 6 7-1 7-2 8-1 8-2 8-3 8-4 8-5 8-6 8-7 9 10 11 12 12-1 12-2 13 14 14-1 15 16 17 18 19 20 20-1 20-2 20-3 20-4 20-5 20-6 20-7 21 22 23 24 25 26 27 28 29 30-1 30-2 30-3 31 32 33 P0459001 PN02 PW07 P0459004 P0459005 PSB09 P0459006 P0459007-1 P0459007-2 P0459008-1 P0459008-2 P0459008-3 P0459008-4 PK06M P0459008-6 PW01 P0459009 P0459010 P0459011 P0459012 PS41 PN12 P0459013 P0459014 P0459014-1 P0459015 P0459016 PSS03 P0459018 PK110 P04590
Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 100 101 102 103 104 107 108 109 112 P0459100 P0459101 PLN02 P0459103 P0459104 P0459107 PB19 P0459109 P0459112 DUST SCOOP WORM GEAR SHAFT BRACKET LOCK NUT 1/4-20 SHAFT MOUNT WORM GEAR BUSHING HEX BOLT 1/4-20 X 1/2 COLLAR GEAR COVER 113 114 115 117 118 119 209 209-1 211 P0459113 P0459114 PN08 PW07 PB03 PSS11 G9987 P0459209-1 P0459211 CRANK HANDLE HANDLE HEX NUT 3/8-16 FLAT WASHER 5/16 HEX BOLT 5/16-18 X 1 SETSCREW 1/4-20 X 1/4 GRIZZLY NAMEPLA
Safety Label Placement and Parts List Safety Label Placement The safety labels on this machine warn and indicate how to protect the operator or bystander from machine hazards. The machine owner MUST maintain the original label location and readability. If a label is removed or becomes unreadable, REPLACE the label before using the machine. For new labels, contact Grizzly Industrial Inc. at (570) 546-9663 or techsupport@grizzly.com.
WARRANTY AND 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.
WARRANTY CARD Name _____________________________________________________________________________ Street _____________________________________________________________________________ City _______________________ State _________________________ Zip _____________________ Phone # ____________________ Email ________________________ Invoice # _________________ Model # ____________________ Order # _______________________ Serial # __________________ The following information is given on a voluntary basis.
FOLD ALONG DOTTED LINE Place Stamp Here GRIZZLY INDUSTRIAL, INC. P.O.
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