How to remove pulley from 22-560 planer?
Thanks for the help w/ my previous post, guys. Quick recap-22-560 Planer was smoking and making bad sounds. Wasn’t certain what it was. Advice was a potential issue with cutterhead pulley which is driven by the rubber belt.
The advice was spot on. The pulley had developed a “wobble” which in turn forced the belt into the plastic cover/shroud. Generated enough heat to actuall melt the belt right into this plastic cover. It finally seized the entire planer up. Thankfully, I got it shutdown quickly and no damage was done to the motor.
Anyhow, I need to get this pulley off and get it replaced w/ a new one from Delta. But, for the life of me, I cannot get this thing off. I thought about calling Delta Tech but they weren’t a ton of help in the beginning. I guess I’m really looking for someone who has faced this specific issue-and it sounds like there have been a few of us.
I’d really appreciate any help. I flipped it on the other day and the motor sounds great so I’d like to get some more use out of this lil’ planer.
Replies
you may have to purchase a gear/pulley puller .
Eric in Cowtown
Most local rental places have all different sizes any types. You could rent one fo a half day.
Wood,
This may be an obvious question, but have you taken off the damaged belt first before trying to remove the pulley?
The two links below will have new pulleys for you without the Delta Factory price.
http://www.toolpartsdirect.com/cgi-bin/schematic.cgi/delta/22-560
http://www.surpluscenter.com/sort.asp?UID=2006041412142073&catname=powerTrans&keyword=PPP1
Dan Kornfeld, Owner/President - Odyssey Wood Design, Inc.
thanks JC.
No, I am certainly not immune to needing to be asked the basics. Yes, I have the belt off. The nut that I thought was what secured the pulley to the cutterhead is off also. That pulley wobbles all over but will NOT come off that cutterhead. I quit last night because I was starting to rough up the threads on the cutterhead from my frustration. Whats most frustrating is that I fired up the planer to listen for anything bad coming from the motor...nothing. Still sounds brand new. SO, I am left with a planer that I can' t use because I can't figure out how to get a darn pulley off and replaced.
Thanks for the parts sites. I could have sworn that I had checked out the first site and their price was actually higher than Delta's direct price but I could be mistaken. I will take a closer look when/if I can ever get this pulley off.
thanks
woodk2,
When I had the same problem with my Delta I poured over the on-line blueprints/specs...and then asked myself a question...."Do I really want to take the risk of trying to fix a planer that overheats...will I trust that it's fixed?"
The parts diagram shows only a small key and the nut holding the pulley in place. Being the pulley is wobbling around but still stuck, my guess would be that the key has worked itself into the pulley and become jammed somehow.
At this point things don't look good because the shaft of the cutter head may be chewed up and pulling off the pulley with a gear puller may do further damage, but there isn't any alternative.
Most auto service stations have gear pullers but it is well worth buying a cheap set from some outfit like Harbor Freight if you expect to work on machinery. There is no substitute for having a puller when you have to separate a pulley and the shaft it is mounted on.
John W.
John, thanks. I really think you nailed it. I do see something that looks like the remnants of a key type washer. Only now, it looks like it has become part of the pulley. Almost fused together.
Man, I'm wondering if I am getting over my head. What is a pulley puller and how in the world do they work? I'm willing to give it a shot if I can figure out how to use the tool w/out damaging the planer more.
thanks again for the help.
Wood, I am not familiar with that specific machine but it now sounds as though the pulley is beyond re-use, and all grub screws etc have been loosened , so you might as well cut it off with a hack saw, rather than using a puller which you don't have-and which may damage the shaft. I assume there is a key or woodruff which is now jamming it, and you are not able to knock it through?Philip Marcou
A "puller", for gears or pulleys or whatever, is essentially two pivoting arms with hooks on the ends attached to a cross bar. A threaded screw passes through the center of the cross bar. Generally there is a square head on the outboard end of the screw and a point on the inboard (hook) end of the screw.The hooks are placed over the edge of the pulley and the screw is tightened with an adjustable wrench (or socket if it is hex) until the pointed end contacts the center of the pulley shaft. Each turn of the screw applies more removal force on the pulley. It helps to whack the wrench end of the screw with a hammer every now and then. It helps to "shock" the grip between the pulley and the shaft and loosen it.You can, during this process, apply heat to the pulley hub to help it expand - but, you'll need to work fast as the heat will transfer to the shaft and then you're back in the bag.Good luck. It's not as hard as it may sound.Jerry
When I noticed the increase in noise coming from my planer, I took it apart and after several tightenings of the shaft nut, I contacted Delta. They said that this was a common problem. They sent me a new pully and cutter assy. In the meantime, I decided to use the epoxy putty that you get in a stick and hold the pully on with that. It has worked very well and I have not had any problem for over a year. I would try to pull the pully off with a wheel puller. The key is a small woodruf style key that, as others have said, has probably welded itself into the pully. I would then try the epoxy approach. It keeps the parts from having any play between each other and working themselves loose. You should replace the key because I would not trust the epoxy to keep the shaft from rotating. The epoxy is only to take up the clearance and keep the pully from wobbling due to the clearances on the shaft.
Sounds to me like it is time to call their warranty department.
Years ago I had a small; 8" table saw and it started making all kinds of noise. It turned out to be a soft bull gear and the teeth became like half circles. I called Delta and their first question was about its age. They told me I had owned it six years. The man told me that it was only warranted for two years. I told him that Milwaukee has a lifetime guarantee and I did not have more than 10 hours running time on that saw. I told them that the price of everything was more than what it would cost me to put a skill saw underneath. I told them I had a Milwaukee motor I would put underneath if they didn't take care of me. Then the person told me to send in the motor and they would see what they could do. I got it back and it has been working great ever since.
I told them my opinion was that it was a defective part because gear teeth do not round off like half circles.
Sound to me like your planer has a defective pulley or possibly more. A pulley should never come lose or wobble.
Good points.
UPDATE-I got the pulley off tonight. I drilled a bunch of holes into the pulley and got it to wiggle loose completely. So, finally, the pulley is off!
But, you bring up some good points. WHY did the pulley wiggle loose in the first place? Should I go ahead and buy the parts, spend the money and attempt to fix this thing? Sure sounds like I'm not the only one who has dealt with this issue. So, I have to make the decision or not to spend the money on this thing, probably wait a few months for the parts and then see what happens. Hmmm. I gotta sleep on this one.
thanks for the help.
Wait a few month's?
Gee I shouldn't think it would take long to get the pulley. It may be a stock item that you could get at the local hardware, and it shouldn't be all that expensive.
Wood',
Did you find a woodruff key (or the remains of one) and a set screw? It is possible that the set screw backed off enough to let the pulley slip. The drive belt must be perpendicular to the shaft - if not, it's creating an off set tension especially when under load. As you bring this machine back to a fully functioning unit, be sure to check the shaft for run out. If it's bent, you want to find out now, before you send any wood through the machine.
When you order the new pulley, get a well balanced cast iron one. Add some blue Loc-Tite to the set screw before tightening it down.
Give it a go, it should be worth fixing.Dan Kornfeld, Owner/President - Odyssey Wood Design, Inc.
> WHY did the pulley wiggle loose in the first place?Aw heck, don't overthink this. I would hate to see anyone drop a few hundred bucks for what's most likely a cheap and long-lasting fix.When I first got interested in machines, I could never figure out what "the pros do", since I kept coming upon difficult situations where something got totally rusted/broken/twisted/bent/worn in use. As I became more experienced, I realize these problems are universal. Stuff happens.You do gradually amass a collection of tools that makes tough situations easier to deal with. Probably a puller would have slid the pulley/key apart no problem. The pulley would have been destroyed, but it already was.Make sure the shaft isn't worn down or the next pulley will wobble too. Assuming it passes, swap the pulley and key, tighten any set screws or jam nuts, and take pride that you got it back to work!Pete
Pete/all others-thanks again for all the help.
I examined the rod/shaft of the cutterhead and it appears to be in great shape with one concern...there is a cavity where a "key" resides. Some of you have mentioned this key. I did find some remnants of chewed up metal when I finally got the pulley off.
My concern is this...the cavity appears to have some wear. It looks like when it was new/perfect, it was a perfect oblong circle-appearing almost like a router cut mortise only very tiny of course. Well, this cavity appears to have been compromised. It has some wear on the sides. Best example-back to the mortise...you know when you are cutting mortises with your router and it goes off track in one of your passes? That is a good analogy to what I have.
My concern remains...I am ready to order my parts and attempt the repair. I'm just real worried about this little cavity where this "key" fits. Seems like the keys function would be to keep the pulley aligned/on the shaft correctly. If it has indeed been compromised, I may be going through this again in a few months.
I know I just gotta do whatever and see what happens...just keeping you guys in the loop. Maybe this thread will help others down the road. After doing some searches, I am a bit concerned about what planer to buy next if I do end up going down that path. Seems like this is not entirely unusual for the Delta benchtop class planers.
thanks again.
You're agonizing way too much over this. Parts on machines wear out. Order the damn pulley, fix your planer, and get back to woodworking.Clay Foster
http://www.home.earthlink.net/~claypen
I guess the point of my "overthinking this" is the fact that "ordering the parts and fixing the damn thing" may not be posible without ordering a $90 cutterhead. If that is what it takes, I would rather just invest in a newer planer/different brand as I have now discovered that Delta seems to have an issue with this pulley. Heck, I even saw a post on Amazon where a guy had similar problems.
I agree you shouldn't buy the cutterhead. The key and pulley should be cheap enough though. Pete
Pete-I'm into it for $40 right now(ordered the parts this a.m.) I needed the belt guard, key, pulley, and belt. A cutterhead takes it to $120-$130. I learned alot from you guys and am appreciative. It wasn't my intent to drag it on....My biggest concern at this stage is that the hole where the KEY resides has been compromised enough that it doesn't keep the pulley from spinning on the cutterhead shaft. Oh well, its worth a shot. thanks again.
OK, that part wasn't clear from your previous posts. Wear in the keyway can be acceptable, but if the pulley can spin even with the key installed, that's not workable. There is a flavor of loctite to secure unthreaded shaft assemblies, but I wouldn't recommend it in this case as I doubt the clearances are tight enough.
I guess I'm not clear on exactly what this pulley/key configuration is. Is it a woodruff key? The shaft would have what looks like a biscuit slot in it. The only way the pulley could spin with this key is if the shaft had a groove worn all the way around. If not a woodruff key, what is it? What else secures the pulley? I get the impression that there is no set screw; that it's just held in place laterally by a nut. Is this true?
Pete
Pete, some of this is based on previous posts from those who have much more mechanical knowledge than I. So, please cut me some slack if this doesn't come across correctly.
Yes, another poster did tell me that it was indeed a woodruff key.
Here is what I see...the shaft has this slot in it. You called it a biscuit type slot. I described it previously as resembling a router cut mortise type shape...except much much smaller...A small cavity with rounded ends. Again, very small. I know now that the woodruff resides in this hole and hooks up with the pulley to prevent it from spinning on the shaft. Well, this hole has obviously been altered from the pressure of the key on the sides of the hole I would guess. No clue if this was the initial cause of the pulley coming loose and having the mounting hole enlargened on the pulley.
Your question of what holds the pulley on the shaft...appears to be just the nut that goes on the shaft. But that key was so bungled up when I got into it that it certainly had some holding power.
The best description of the hole currently is a poorly cut router mortise, where you go slightly off track and the sides of the mortise are affected. Thats what it looks like. Yes, I am fearful that when I get the new key it will not lock the pulley in place on the shaft. I'm no engineer, but it sure does seem like Delta could have designed this more effectively. Especially considering that I have looked through previous posts on a few different Woodworking forums as well as Amazon. I never found anyone with motor issues. But I found many with belt/pulley issues.
Hopefully I am making sense.
Edited 4/17/2006 3:10 pm ET by Woodk
If the slot is a bit wider than the key, the pulleystill won't be able to spin on the shaft and you should be fine. Make sure the nut is secure to control pulley wobble, as wobble will cause the key to eat into the slot further.
I hate woodruff keys as they have a tendency to die ugly deaths.
Pete
It sounds to me as if the shaft has a "straight" key, not a half-moon, woodruff key - he mentions a slot like a "dado.Same issues. The pulley can't turn unless the entire shaft is shot.Jerry
It looks like the key should be a section out of a circle? That's called a Woodruff key. Its job in this case is to keep the pulley from spinning on the shaft. Alignment will be taken care of by the bore of the pulley on the shaft not the key. You can get woodruff keys in any good hardware store. Make sure you use the same size. Your local Delta services center could get you one too, and even at Delta prices it should be cheap. As others have said, don't sweat this. Technically, the worn keyway may result in reduced life. However, if you tighten down whatever keeps the pulley on (looks to be a locknut), it will likely outlast the rest of the machine. I always use blue loctite (242) on threaded parts that I want to stay tight. You can get that at the hardware store or any auto parts place or big box.Pete
I too have had this pulley problem with my 22-560 planer.
The first time the pulley was wobbly and the belt melted along witrh the belt cover. The nut was loose so I figured that was the heart of the problem. Replaced the pulley, belt, and key after using a puller to get it off. Since the nut was loose, I used loc-tite on it when reassembling. That was about a year ago, and now it just happened again. This time the nut was still stuck to the shaft, but the pulley was loose and wobbly again. Sent an e-mail to Delta, which they acknowleged receipt, but no further word. It appears to me that Delta misengineered this pulley arrangement, and we are stuck with it. The key by the way is not a woodruff type, but just a 3/8 length of 3/16 key stock. It may be possible to have a new keyway cut into the cutterhead shaft by a local machine shop, at 180 degrees from thhe original slot. Use loc-tite on the pulley bore as well as the nut. Good luck!
Sounds like it was designed poorly. Hopefully Delta will make good on it. Thanks for clarifying the key design.Pete
Delta has just notified me they are sending all parts to repair my planer.The sawmillcreek.com forum had a message from someone saying the early models of this 22-560 planer had many instances of this pulley problem. Delta has ackowledged this by sending the parts free of charge even tho it is several years out of warranty. It pays to complain sometimes.
Hen, I had to pay for my parts...but thats fine. I don't feel like going through the process of getting Delta to send them free. Besides, I think they are probably on their way.
Anyhow, my question is this...did Delta Tech give you any insight into preventing this problem in the future? I mean, we are going to put a new pulley, key, etc...on the planer but is it going to happen again?
Just curious if they gave an insight into prevention.
Delta said nothing other than that they are sending the parts. However I think I will use loc-tite on the pulley and the nut when I reassemble. I know from the recent instance that loc-tite on the nut only did not work. The nut was still tight, but the pulley was loose.
I would give them a call and press the issue. Eventually you will get results if each time you talk with someone and ask to speak with their supervisor. Be persisitent with each person who says they cannot help. If you do not get immediate results tell them about the posting on this borad and that you are aware of others who have had the same problem. Be careful to write down the name of each person you speak with. Seldom have I not had results even when the warrranty is up. Two things I always do: Be courteous and tell them what you expect to have done for you. For several years when I was in retail and I knew the problem was with the customer and if I asked them what they wanted me to do they did not know. If I had never had a problem and the company never told us about a problem and the custoemr could not convince me or it was clear there was a problem which was not ours then I refused to accomodate the person. For example: if an engine seized and there was brand new oil in it and the engine was several months old. I knew they had run the engine out of oil and then added a lot of new oil to make it look like it had not run out of oil. Many companies will honor their warranty even past the time period. I saw a company honor a warranty on an engine that seized and we did not know why. The customer was a regular custoemr and it was past the warranty period. One time I had a problem with a Rockwell tool. It was four years past the warranty and I was persistant. I told them I believed it was a flaw in their work and it was nothing on my part which contributed. I explained to them how hears do not wear with half circles on the teeth if I had never greased it. At first they refused. When they did I asked them if they expected me to buy another company's product to replace it? They did not like that. So they asked me to send it in and they would see what they would do. They did far more than I asked. They gave me a completely brand new motor unit. That tool is still going strong. I knew it was a bad gear and because of my persisitence it got me what I wanted and what I felt was the right thing to do. Years ago I had a similar thing happen with a Milwaukee product. That tool was six years old at the time. In those days there was not a time limited warranty. I took my tool into a repair cenetr and they told me there would not be a problem and when I would get it back. Milwaukee repaired my tool better than I expected and I am still using it about 20 years later. The big difference between the companies is how they handled my problem.
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