Paul Joynes
04-27-2012, 11:11 PM
I spent 1.5 hours last night changing my DJ-20 over to a Byrd Shelix cutter head. While the process went fine, I found the instructions from Byrd to be woefully inadequate. I hope that these lessons from my experience will help others when it comes time to install this piece into their jointer.
Parts Required
Bearing, 6004zz (shielded), item 58 in drawing
Bearing, 6005zz (shielded), item 67 in drawing
Byrd cutter head
Tools Required
Retaining ring pliers (internal retaining ring type)
M8 fastener 20-30mm long
Dead blow mallet
Metric allen key set
14 gauge wire 36 inches long
Gear puller, 3" capacity, even number of fingers
3/8" dowel or similar sized scrap wood
230736
Procedure
Remove blade guard from jointer (items 72 through 79)
Remove cutter guard from jointer (items 51 & 52)
Remove fence assembly from jointer (items 1 through 48)
Remove motor cover from the base of the jointer
Remove the belt cover from in front of the pulley
Now that you have access to the belt, rotate it off of the pulley so that the cutter head is able to rotate freely.
Using the 14 gauge wire, form a hook that is able to be lowered between the cutter head (item 61) and the operator side bearing housing (item 57). This wire will be used to cradle the operator side of the cutter head during removal so that it does not fall down the dust chute. Pull the wire up so that approximately 12 inches of wire is on each side of the cutter head.
Remove the socket head cap screws (item 55 & 56) from the fence side bearing housing (item 68).
Using a dead blow mallet and 3/8" dowel, place the dowel against the operator side of the cutter head and drive the cutter head assembly (items 58 through 71) from the operator side bearing housing (item 57). As the bearing nears its release from the operator side bearing housing, support the operator side of the cutter head assembly using the wire installed in step 7.
Remove the cutter head assembly from the jointer and set aside.
Remove the operator side bearing housing (items 55 through 57) and set aside.
Remove the pulley (items 62 and 69 through 71) from the cutter head assembly.
Install the M8 fastener into the tapped end of the cutter head. Place the fingers of the gear puller around the bearing housing (item 68) and press the cutter head out of the bearing housing by advancing the gear puller's jack screw against the M8 fastener.
Using the retaining ring pliers, remove the retaining ring from the bearing housing, press out the bearing and replace it with bearing 6005zz. Reinstall the retaining ring.
Press the 6004zz bearing onto the stubby end of the Byrd cutter head. My bench vise has a 15" opening capacity so there was no issue with pressing bearings onto the cutter head. If you do this using the dead blow mallet, you will have to be careful to ensure the part is square to the cutter head.
Press the fence side bearing housing onto the Byrd cutter head. Reinstall the pulley onto the new cutter head.
Cradle the operator side of the Byrd cutter head using the 14 gauge wire and re-insert the cutter head assembly back into the jointer from the fence side.
Fasten the fence side bearing housing in place using the socket head cap screws that were removed earlier. Support the operator side of the assembly using the wire mentioned in step 17.
Line the operator side bearing housing (item 57) up with the 6004zz bearing and tap in place using a dead blow mallet. Fasten the bearing housing to the jointer using the socket head cap screws that were removed earlier.
Place the drive belt back onto the motor and cutter head pulleys.
Reinstall the jointer fence and all guards that were initially removed.
Parts Required
Bearing, 6004zz (shielded), item 58 in drawing
Bearing, 6005zz (shielded), item 67 in drawing
Byrd cutter head
Tools Required
Retaining ring pliers (internal retaining ring type)
M8 fastener 20-30mm long
Dead blow mallet
Metric allen key set
14 gauge wire 36 inches long
Gear puller, 3" capacity, even number of fingers
3/8" dowel or similar sized scrap wood
230736
Procedure
Remove blade guard from jointer (items 72 through 79)
Remove cutter guard from jointer (items 51 & 52)
Remove fence assembly from jointer (items 1 through 48)
Remove motor cover from the base of the jointer
Remove the belt cover from in front of the pulley
Now that you have access to the belt, rotate it off of the pulley so that the cutter head is able to rotate freely.
Using the 14 gauge wire, form a hook that is able to be lowered between the cutter head (item 61) and the operator side bearing housing (item 57). This wire will be used to cradle the operator side of the cutter head during removal so that it does not fall down the dust chute. Pull the wire up so that approximately 12 inches of wire is on each side of the cutter head.
Remove the socket head cap screws (item 55 & 56) from the fence side bearing housing (item 68).
Using a dead blow mallet and 3/8" dowel, place the dowel against the operator side of the cutter head and drive the cutter head assembly (items 58 through 71) from the operator side bearing housing (item 57). As the bearing nears its release from the operator side bearing housing, support the operator side of the cutter head assembly using the wire installed in step 7.
Remove the cutter head assembly from the jointer and set aside.
Remove the operator side bearing housing (items 55 through 57) and set aside.
Remove the pulley (items 62 and 69 through 71) from the cutter head assembly.
Install the M8 fastener into the tapped end of the cutter head. Place the fingers of the gear puller around the bearing housing (item 68) and press the cutter head out of the bearing housing by advancing the gear puller's jack screw against the M8 fastener.
Using the retaining ring pliers, remove the retaining ring from the bearing housing, press out the bearing and replace it with bearing 6005zz. Reinstall the retaining ring.
Press the 6004zz bearing onto the stubby end of the Byrd cutter head. My bench vise has a 15" opening capacity so there was no issue with pressing bearings onto the cutter head. If you do this using the dead blow mallet, you will have to be careful to ensure the part is square to the cutter head.
Press the fence side bearing housing onto the Byrd cutter head. Reinstall the pulley onto the new cutter head.
Cradle the operator side of the Byrd cutter head using the 14 gauge wire and re-insert the cutter head assembly back into the jointer from the fence side.
Fasten the fence side bearing housing in place using the socket head cap screws that were removed earlier. Support the operator side of the assembly using the wire mentioned in step 17.
Line the operator side bearing housing (item 57) up with the 6004zz bearing and tap in place using a dead blow mallet. Fasten the bearing housing to the jointer using the socket head cap screws that were removed earlier.
Place the drive belt back onto the motor and cutter head pulleys.
Reinstall the jointer fence and all guards that were initially removed.