How to Replace the Roller on a DeWALT Planer

There are two feed rollers in your planer -- an infeed roller and an outfeed roller. The rollers feed the stock through the planer, and hold it firmly against the table, so you get a nice, smooth finish. The roller is made of rubber on a steel shaft. Over time, the rubber will harden, reducing its ability to grip the wood, which will cause it to slip. The steel shaft is supported on either end by bushings. After years of use, the bushings will fail. Sometimes, a failed bushing will also score the roller's shaft.

Let's get started.

REMOVING THE ROLLER   1. Remove the side covers.

a. Remove the two screws securing the left (side) cover to the planer.

b. Pivot the upper portion of the side cover toward the planer and lift the side cover until its bottom portion clears the rail on the frame.

c. Remove the left (side) cover from the planer.

d. Repeat this step to remove the right (side) cover from the planer.

  2. Raise the cutter head.

a. Use the crank handle to raise the planer's cutter head to its highest position.

  3. Tilt the planer.

a. Carefully tilt (and lay) the planer on its front.

  4. Remove the chain cover.

a. Use a short (stubby) Phillip’s screwdriver to remove the two screws securing the chain cover to the housing.

b. Remove the chain cover from the unit.

  5. Remove the chains and sprockets.

a. Use snap-ring pliers to remove the retaining rings from the outer two sprockets.

b. Slowly and simultaneously slide the two outer sprockets (and the outer chain) away from the roller assemblies.

c. Use snap-ring pliers to remove the retaining rings from the two inner sprockets.

d. Slowly and simultaneously slide the two inner sprockets (and the inner chain) away from the roller assemblies.

e. Remove the spacer from the shaft of the infeed roller.

  6. Remove the roller.

a. Remove the screws securing the (chain-side) retaining bracket to the planer.

b. Remove the (chain-side) retaining bracket from the planer.

c. Remove the screws securing the (belt-side) retaining bracket to the planer.

d. Remove the (belt-side) retaining bracket from the planer.

e. Remove the roller from the planer.

TRANSFERRING COMPONENTS FROM THE OLD ROLLER TO THE NEW

  7. Transfer the bushings and washers.

a. Remove the two bushings from the old roller.

b. Remove the two felt washers from the old roller.

c. Install the two felt washers onto the new roller.

d. Install the bushings on to the new roller.

INSTALLING THE NEW ROLLER

  8. Installing the new roller.

a. Install the new roller onto the planer.

b. Note: While the retaining brackets appear similar, there is a distinct difference between the two: one of the brackets contains elongated mounting holes; one contains round mounting holes. The bracket with the elongated mounting holes should be installed on the belt-side of the planer.

c. Install the (chain-side) bracket.

d. Slide (and hold) the roller assembly toward the (chain-side) bracket until the roller bushing contacts the inside of the bracket.

e. Secure the (chain-side) bracket with the two screws.

f. Install the (belt-side) bracket.

g. Install (and partially tighten) the screws on the (belt-side) bracket.

h. Press the (belt-side) bracket toward the roller until the inside of the bracket contacts the roller bushing; hold the bracket against the roller bushing.

i. Secure the (belt-side) bracket with the two screws.

REASSEMBLING THE UNIT

  9. Reinstall the inner chain.

a. Install the spacer onto the shaft of the infeed roller.

b. Install the chain onto the two inner sprockets. Both hub stems should face the same direction (toward the rollers). The left-hand sprocket (the one that attaches to the outfeed roller) contains the shorter hub. The sprocket that attaches to the motor contains the taller hub.

c. Align the hub key of the right-hand sprocket (the one that attaches to the motor) with keyway on the roller and press the sprocket partially onto the roller shaft.

d. Align the left-hand sprocket with the shaft of the outfeed roller and rotate the outfeed roller until the hub key (on the sprocket) aligns with the keyway on the roller shaft.

e. Press the both sprockets firmly onto the roller shafts.

f. Secure the two (inner) sprockets with the retaining rings.

  10. Reinstall the outer chain.

a. Install the chain onto the two outer sprockets. Both hub stems should face the same direction (toward the rollers).

b. Align the hub key of the left-hand sprocket (the one that attaches to the outfeed roller) with keyway on the roller shaft and press the sprocket partially onto the shaft.

c. Align the right-hand sprocket with the shaft of the infeed roller and rotate the infeed roller until the hub key (on the sprocket) aligns with the keyway on the roller shaft.

d. Press both sprockets firmly onto the roller shafts.

e. Secure the two (outer) sprockets with the retaining rings.

  11. Reinstall the chain cover.

a. Install the chain cover.

b. Secure the chain cover with the two screws.

  12. Reinstall the side covers.

a. Install the top portion of the left (side) cover.

b. Lift the side cover until the bottom portion clears the rail on the frame.

c. Press the side cover down until the bottom portion seats behind the frame rail.

d. Secure the left (side) cover with the two screws.

e. Repeat this step to install the right (side) cover.