Harbor Freight Tools 95668 Router User Manual
Contents
1. 52 over the Table Legs 28 Secure the Table 52 using two Short Bolts 152 and washers 65 in the front of the shaper and five Long Hex Bolts 151 and Washer 65 for the rear corners and for the spindle housing See Figure G above and the assembly diagram on page 29 Installing The Fences 1 Using the Philips Head Screws 12 and Washers 13 install each Fence 60 to the Right and Left Fence Bodies 57 59 Make sure the Screwheads are countersunk completely below the surface of the Right and Left Fence Bodies 57 59 See Figure H Installing The Safety Guard Ts Connect the Hold Down Bar 77 to the Hex Post 79 with two Hex Bolts 75 and two Flat Washers 76 See Figure I Connect the Hold Down Bar 77 to the Ring Guard 85 with two Philips Head screws 78 and two Hex Nuts 84 See Figure I Position the Hold Down Bar 77 and Ring Guard 85 on the Housing Bracket 87 and install the Hex Post 79 on the Mounting Bracket 82 See Figure I FIGURE FIGURE H HOLD DOWN BAR RING GUARD T7 RIGHT FENCE BODY 85 not Shown PHILIPS HEAD SCREWS 78 57 HEX NUTS 84 o LEFT FENCE BODY 59 HOUSING BRACKET M E PHILIPS HEAD SCREWS 12 MOUNTING BRACKET WASHERS 13 82 7 A Installing The Spindle 1 Prior to installation make sure to remove any oil grease dirt and debris from the Spindle 105 Draw Bar 121 and Spindle Housing 110 surfaces before install2. Arbo Wrench 146 mot shown oe Pes b eda p 29 4 132 1 A a 5 ar 133 a ce eng 134 FR Ws e NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 95668 For technical questions please call 1 800 444 3353 PAGE 29 LIMITED 1 YEAR 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that for a period of ninety days from date of purchase that the engine motor the belts if so equipped and the blades if so equipped are free of defects in materials and workmanship Harbor Freight Tools also warrants to the original purchaser for a period of one year from date of purchase that all other parts and components of the product are free from defects in materials and workmanship 90 days if used by a professional contractor or if used as rental equipment This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages
3. Wood Shaper 3 Do not force the Wood Shaper This tool will do the work better and safer at the speed and capacity for which it was designed 4 A WARNING Keep hands and fingers away from the cutting area Use a push stick not included when necessary 9 Never leave the Wood Shaper unattended when it is plugged into an electrical outlet Always unplug the unit from its electrical outlet before leaving 6 Industrial applications must follow OSHA guidelines T Never stand on the Wood Shaper Serious injury could result if the unit is tipped 8 Always unplug the Wood Shaper from its power supply source before performing any inspection maintenance or cleaning procedures 9 Keep all guards in place and in proper working order 10 Never place your hands within 12 inches of the Cutters Never pass your hands directly over or in front of the Cutter As one hand approaches the 12 inch radius point move it in an arc motion away from the Cutter to the outfeed side and reposition that hand more than 12 inches beyond the Cutter 11 Do not shape stock shorter than 12 inches without special fixtures or jigs not included Where practical shape longer stock and cut to size SKU 95668 For technical questions please call 1 800 444 3353 PAGE 5 12 13 14 195 16 17 18 19 20 21 22 23 24 25 Keep the Cutters on the underside of the workpiece whenever possible This provides a dist
4. or respirator and hearing protection must be used for appropriate conditions SKU 95668 For technical questions please call 1 800 444 3353 PAGE 19 Start Up 1 Once assembly is complete and all adjustments have been made the Wood Shaper is ready for start up Always pay attention to any unusual noises and vibrations on every start up as well as making sure the Wood Shaper operates as intended Make sure the Fences 60 any accessories jigs Spindle Cutter or Router Bit Collet Nut 102 being used are tight and no loose items are on the Work Table 52 Make sure the Forward Reverse Switch 144 is set to the correct direction for the Cutter installed Plug the Wood Shaper s Power Cord 22 into the nearest 110 volt grounded electrical outlet Then start the Wood Shaper by flipping the Power Switch 5 to the ON position Once the machine is running listen for any unusual noises The Wood Shaper should run smoothly with little or no vibrations AA WARNING If there is an unusual noise or vibration shut off the machine immediately DO NOT use the Wood Shaper any further until the problem s is corrected If the problem s continues and cannot be easily identified have a qualified service technician check out the machine To Set Up The Wooden Fences For Straight Shaping 1 Because the Wood Shaper s Fences 60 are independently adjustable you can set up the machine to cut part or all of the workpie
5. the Collet Nut 102 See Figure O 6 Rotate the assembly by hand making sure the Collet 103 104 and bit rotate freely on center T A WARNING When using a Router Bit 103 104 operate the Wood Shaper only in a counterclockwise direction Router Bits are designed to cut in the counterclockwise direction only DO NOT operate the Wood Shaper in the clock wise direction If this warning is ignored the workpiece can kickback The Collet Nut 102 can loosen and throw the Router Bit causing severe injury i PINDLE HOUSING 11 not included r W __COLLET NUT a 102 COLLET 103 ori SPINDLE HOUSING FLAT EDGE FIGURE O ADJUSTMENTS INSTRUCTIONS 1 A CAUTION Always make sure the Power Switch 5 of the Wood Shaper is in its OFF position and the unit is unplugged from its electrical outlet prior to performing any adjustment procedures Fence Positioning 1 The two Fences 60 are independently adjustable to allow for different SKU 95668 For technical questions please call 1 800 444 3353 PAGE 13 shaping tasks The Fences 60 can be set at different positions to remove material from the entire edge of the wood stock or set at the same position to shape part of the edge Loosen the Lock Handle 61 See Figure P Adjust the position of the Fence 60 by turning the Knob 64 See Figure P Once the Fence 60 is in the desired position re tighten the Lock Handle 61 See Figure P FIGURE P
6. x 20 Philips Head Screw M6 1 x 12 Half Collar Adjusting Shaft Flat Washer 1 2 Hex Nut M12 1 75 o Hex Bolt M8 1 25 x 12 Hex Nut M8 1 25 Hex Nut M8 1 25 Flat Washer 3 8 _ 2 o1 0 3 4 5 6 7 Hold Down Bar 8 9 2 Philips Head Screw M4 0 7 x 10 Hex Post Hex Nut M8 1 25 Flat Washer 3 8 Mounting Bracket Hand Knob Hex Nut M4 0 7 Ring Guard Hex Bolt M8 1 25 x 30 Housing Bracket Clamp Sleeve Left Stuff Ring Roll Pin 3 x 20mm Lock Bar Hand Knob Roll Pin 3 x 20mm Lock Nut Hex Bolt M12 1 75 x 30 Upper Spindle Nut Safety Washer Rub Collar 1 2 x 1 3 16 x 3 16 Rub Collar 1 2 x 1 3 16 x 1 4 Rub Collar 1 2 x 1 3 16 x 3 8 Cutter Spindle Collet Nut Collet Collet Spindle Key 4 x 4 x 20mm Interior Retaining Ring 47mm Wave Washer 45mm Ball Bearing Spindle Housing Ball Bearing Sleeve Ball Bearing r f T T ca rg T 7 T T 00 ti Flat Washer 3 8 2 2 2 2 2 00 00 Table Leg i N Hex Bolt M8 1 25 x 25 i 00 Hex Bolt M12 1 75 x 30 i NO Lock Washer 12mm OO Table Support Miter Block Flat Washer 1 4 2 Philios Head Screw M4 0 7 x 6 3 5 O 9 9 9 0 94 Self Tapping Screw 3 5 x 12mm 9 Support Pole T7 Stud Bolt Anti Kickback Pin 4 4 4 100 4 A 101 102 44A 103 104 105 4 4 a7 Poner Mo 4 Self Tapping Screw M
7. 3 x 15 107 i 108 109 110 111 112 53A 113 Spindle Pulle Carriage Bolt M6 1 x 35 114 Lower Spindle Nut 10 12 13 14 16 18 19 0 2 3 6 T 8 0 1 4 5 v 8 9 0 1 2 3 5 6 a 8 0 1 2 3 3 3 3 3 3 3 5 5 5 Hex Bolt M8 1 25 x 12 Ql z NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 95668 For technical questions please call 1 800 444 3353 PAGE 27 PARTS LIST CONT Part Description Part Description S Flat Washer 1 2 Motor Mount Plate Flat Washer 3 8 Hex Nut M8 1 25 Hex Bolt M8 1 25 x 12 Lock Washer 12mm Flat Washer 3 8 Lock Washer 8mm Flat Washer 1 4 him Philips Head Screw M6 1 x 12 Forward Reverse Switch Switch Bracket Arbor Wrench Tap Screw M3 5 x 12 Right Fence Lid Left Fence Lid 1 2 Spacer Carriage Bolt M8 1 25 x 40 Long Hex Bolt M12 x 1 75 x 40 Lock Washer 8mm Short Hex Bolts M12 x 1 75 x 30 Flat Washer 3 8 WIRING DIAGRAM 4 DANGER Disconnect power from machine before performing any electri cal service Failure to do this will result in a shock hazard leading to injury ition E E ETE T CAPACITOR REAR VIEW OF SWITCH REAR VIEW OF SWITCH REV 07j SKU 95668 For technical questions please call 1 800 444 3353 PAGE 28 ASSEMBLY DIAGRAM
8. FENCE 60 LOCK HANDLE 61 Fence Alignment 1 To align the Fences 60 so they are parallel with each other use a straight edge that is long enough to span the entire length of the two Fences 60 See Figure Q If the Fences 60 are not parallel place shims not included between the back of the Fence and the face of the Right or Left Fence Body 57 59 See Figure Q FENCE 60 Y e n FENCE te 60 STRAIGHT EDGE NOT INCLUDED SKU 95668 For technical questions please call 1 800 444 3353 PAGE 14 Table Inserts 1 Table Inserts 53 53A are used to reduce wood chips falling into the machine which could cause flying debris Using the smallest Table Insert also covers any unused portion of the bit below the surface of the Work Table 52 See Figure R 2 Position and snap in the Table Insert 53 53A you wish to use See Figure R 3 Make sure the Table Insert 53 53A is seated and flush with the Work Table 52 surface See Figure R 53 53A Belt Adjustment 1 The Wood Shaper uses a Belt 123 on two Pulleys 113 127 to compensate for different Belt positions as the Spindle 105 height is adjusted To adjust the V Belt Loosen the two Hex Head Screws 134 Slide the Motor 129 position to increase or decrease V Belt 123 tension so that the Belt is snug with about 1 4 deflection when pressed lightly with your finger Then retighten the Hex Head Screws S
9. LCENTRAL MACHINERY INDUSTRIAL SHAPER ROUTER Model SET UP AND OPERATING INSTRUCTIONS Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2007 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools Diagrams within this manual may not be drawn proportionally Due to continuing improve ments actual product may differ slightly from the product described herein Tools required for assembly and service may not be included For technical questions or replacement parts please call 1 800 444 3353 Revised Manual 10d PRODUCT SPECIFICATIONS Electrical Requirements 110 VAC 60 Hz 10 54 Amps With Load Motor Size 1 HP Single Phase Motor RPM 3450 Spindle Speed 11 000 Power Cord Length 70 Power Cord Specifications SUT 16 AWG x 3C Plug Type 3 Prong Grounded 4 and 2 included 9 16 L x 11 3 4 Wide x 2 3 4 High Qty 2 26 1 8 Long x 27 1 2 Wide x 36 1 2 High SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts list and assembly diagram Keep your invoice with this manual Write the invoice number on the
10. ance guard for the operator Unplug the Wood Shaper and always rotate the Spindle by hand to test any new setup to ensure proper Cutter clearance before starting the Wood Shaper When shaping contoured work and using a Rub Collar never start shaping at a corner See the Rub Collar section further on in this manual The danger of kickback is increased when the stock has knots holes or foreign objects in it Always run warped stock through a jointer before you run it through the Wood Shaper Keep any unused portion of the Cutter below the Table surface Never attempt to remove too much material in one pass Several light passes are safer and give a cleaner finish In most applications it is recommended to use a push stick not included as a Safety device In other situations using a push stick can be dangerous If the push stick comes in contact with the Cutter on the end grain it can be violently propelled from your hand potentially causing serious injury It is recommended to use some type of fixture jig or hold down device as a safer alternative Always make sure the Cutter is positioned in the correct direction before starting the Wood Shaper and always feed against the rotation of the Cutter Always use the Overhead Guard when the Fence is not in place Never operate the Wood Shaper without the second Lock Nut in place over the Spindle Nut Turn off the Wood Shaper and allow the unit to stop on its own if
11. be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing the risk of electric shock See 3 Prong Plug and Outlet 2 The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool The green wire in the cord must be the only wire connected to the tool s grounding system and must never be attached to an electrically live terminal See 3 Prong Plug and Outlet i The tool must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the following illustration See 3 Prong Plug and Outlet THIS PRODUCT USESA mae olle O VE SI 3 Prong Plug and Outlet Outlets for 2 Prong Plug Double Insulated Tools Tools with Two Prong Plugs i Tools marked Double Insulated do not require grounding They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories Inc the Canadian Standard Association and the National Electrical Code See Outlets for 2 Prong Plug Zz Double insulated tools may be used in either of the 120 volt outlets shown in the preceding illustration See Outlets for 2 Prong Plug Symbology Double Insulated Volts A
12. ce edge A WARNING DO NOT use the Miter Gauge 45 in conjunction with the Fences 60 The Fences may not be parallel to the miter slot and binding of the workpiece could result To set up the Fences 60 for cutting material from the whole edge of the workpiece follow the steps below Loosen the Lock Handle 61 See Figure DD next page Turn the Hand Knob 68 and adjust the infeed Fence 60 until the workpiece contacts the Cutter at the desired location See Figure DD next page SKU 95668 For technical questions please call 1 800 444 3353 PAGE 20 10 Ti Tighten the Lock Handle 61 to lock the infeed Fence 60 in position See Figure DD 60 Bee OUTFEED SIDE 60 INFEED SIDE HAND KNOB 68 Adjust the outfeed Fence 60 so that it is located as far back from the front of the Work Table 52 as possible See Figure DD Turn on the Wood Shaper Using a piece of scrap wood advance the workpiece 8 into the Cutter and turn off the machine DO NOT remove the workpiece from the infeed Fence 60 See Figure DD Once the Cutter has come to a complete stop adjust the outfeed Fence 60 so that it just touches the newly cut edge of the workpiece Always follow the direction of feed as shown below See Figure EE GUARD NOT SHOWN FOR CLARITY y_ INPUT FEED Wy URGE lt q DIRECTION OF FEED OUTPUT FEED FIGURE EE Check to make sure all Aluminum Fence Lock Handles 61 are ti
13. come into contact with the Cutter 4 Make handles for safety and control 5 Use materials that will move easily across the Work Table 52 surface and Rub Collar 98 99 100 6 Remember to consider the Cutter and Rub Collar 98 99 100 diameter when making the pattern T Install hold down clamps not included at three sides of the pattern assembly or screw the pattern assembly to the back side of the workpiece PUSH BLOCK NOT INCLUDED SCRAP WOOD iil t 2 FIGURE KK SKU 95668 For technical questions please call 1 800 444 3353 PAGE 24 INSPECTION MAINTENANCE AND CLEANING 1 CAUTION Always make sure the Power Switch 5 of the Wood Shaper is in its OFF position and the unit is unplugged from its electrical outlet prior to performing any inspection maintenance or cleaning procedures 2 Before each use inspect the general condition of the Wood Shaper Check for misalignment or binding of moving parts cracked or broken parts damaged electrical wiring and any other condition that may affect the safe operation of the machine If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment 3 To clean use compressed air to blow off any wood shavings dirt and debris Use a clean cloth and mild detergent to wipe off exterior of machine Do not use solvents Do not introduce liquids to any electrical part of the unit 4 To store keep the machi
14. ding the Spindle 105 at the top with the provided Arbor Wrench 146 See Figures W and X 4 Check to make sure the Cutter not included will rotate in the correct direction FIGURE W A FIGURE X AREOR WRENCH SAFETY WASHER 97 UPPER SPINDLE NUT I l 96 UPPER SPINDLE NUT gp 96 Setting Spindle Height ils Correct Spindle 105 height is crucial to most shaping applications Make sure to use a piece of scrap wood to confirm the correct Spindle height before cutting expensive lumber 2 Loosen the Spindle Hand Knob 92 located on the side of the Wood Shaper See Figure Y next page 3 Move the Spindle Height Knob 120 to the right to raise the Spindle 105 or to SKU 95668 For technical questions please call 1 800 444 3353 PAGE 17 the left to lower the Spindle 105 See Figure Z 4 Retighten the Spindle Hand Knob 92 on the side of the Wood Shaper DO NOT overtighten the Knob Only a small amount of tension is needed to keep the Spindle 105 from moving during operation See Figure Y FIGURE Y _ FIGURE Z re SPINDLE HAND KNOB 92 SPINDLE HEIGHT KNOB 120 Rub Collars 1 When shaping workpieces that have irregular shapes Rub Collars 98 99 100 are a necessity Some examples of when you would use a Rub Collar are raising arched or tombstone door panels round table tops or any other cut that needs to have its depth of cut limited PA There are three set up position
15. e cut on the corner of the workpiece as kickback could occur Once the cut is started the workpiece should be pulled away from the Taper Pin 56 See Figures HH FIGURE HH TAPER PIN 56 ROTATION i a Th i r i RUB COLLAR 98 99 100 SKU 95668 For technical questions please call 1 800 444 3353 PAGE 23 Pattern Shaping 1 Sometimes the location of the Taper Pin 56 holes on the Work Table 52 will not always be in the safest position You can clamp a piece of scrap wood to the Work Table so the edge of the scrap wood can be used as the starting support See Figure JJ 2 The use of patterns templates allows identical parts to be cut with speed and accuracy Shaping with a pattern begins by attaching a prefabricated template to the rough workpiece The edge of the template rides against a Rub Collar 98 99 100 on the Spindle 105 as the Cutter cuts the matching profile on the workpiece edge Also you can incorporate extra features into the template assembly such as toggle clamps not included to hold the workpiece or you can use custom guards for safety and protection See Figure KK CAUTION Make sure to design jigs and fixtures so screws and clamps DO NOT contact the Cutter and the workpiece is held securely to the jig The jig must be stable on the Work Table 52 3 To make a template design the assembly so that cutting will occur underneath the workpiece Make sure screws or clamps will not
16. ee Figure S FIGURE SKU 95668 For technical questions please call 1 800 444 3353 PAGE 15 Cutter Direction 1 The Wood Shaper is capable of operating in two directions by the use of the Forward Reverse Switch 144 It is very important that the workpiece be fed against the direction of the Cutter rotation Cutter not included See Figure T 2 When the Forward Reverse Switch 144 is pointing to the FWD position the Spindle 105 and Cutter rotate counterclockwise See Figure T 3 When the Forward Reverse Switch 144 is pointing to the REV position the Spindle 105 and Cutter rotate clockwise See Figure T 4 Always try to operate the Wood Shaper so the wood is cut from the underside Underside cutting is much safer for the operator because when the wood is cut on the top side the Cutter can lift and grab the wood and cause possible injury to the operator FIGURE T Cutter Installation L Slide the Cutter not included onto the Spindle 105 making sure the rotation is correct for the specific application SKU 95668 For technical questions please call 1 800 444 3353 PAGE 16 2 Place the required spacers also called Rub Collars 98 99 100 onto the Spindle 105 See Figure V SPINDLE 105 RUB COLLARS 98 99 100 CUTTER _ NOT INCLUDED 3 Install the Safety Washer 97 and Upper Spindle Nut 96 securely Tighten the Upper Spindle Nut with an open end wrench while hol
17. ent such as those dust masks that are specially designed to filter out microscopic particles California Health amp Safety Code 25249 5 et seq AA WARNING People with pacemakers should consult their physician s before using this product Operation of electrical equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker WARNING The warnings precautions and instructions discussed in this manual cannot cover all possible conditions and situations that may occur The operator must understand that common sense and caution are factors which cannot be built into this product but must be supplied by the operator SAVE THESE INSTRUCTIONS GROUNDING Improperly connecting the grounding wire can result in AWARNING Pn _ j electric shock Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Do not modify the power cord plug provided with the tool Never remove the grounding prong from the plug Do not use the tool if the power cord or plug is damaged If damaged have it repaired by a service facility before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician SKU 95668 For technical questions please call 1 800 444 3353 PAGE 7 Grounded Tools Tools with Three Prong Plugs 1 Tools marked with Grounding Required have a three wire cord and three prong grounding plug The plug must
18. er Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded Do not expose power tools to rain or wet conditions Water entering power equipment will increase the risk of electric shock Do not abuse the Power Cord Never use the Power Cord to pull the Plug from an outlet Keep the Power Cord away from heat oil sharp edges or moving parts Replace damaged Power Cords immediately Damaged Power Cords increase the risk of electric shock PERSONAL SAFETY Stay alert Watch what you are doing and use common sense when operating the Wood Shaper Do not use the tool while tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Use the right product for the job Do not attempt to force small equipment to do the work of larger industrial equipment There are certain applications for which this product was designed It will do the job better and safer at the rate and capacity for which it was designed Do not modify this product and do not use this product for a purpose for which it was not designed Avoid accidental starting Be sure the P
19. ght before proceeding to finish the cut See Figure DD SKU 95668 For technical questions please call 1 800 444 3353 PAGE 21 To Set Up The Aluminum Fences For Partial Edge Removal 1 WARNING ALWAYS use the aid of a jig not included when shaping small or narrow workpieces A jig will reduce the chance of your hands coming into contact with the Cutter 2 Loosen the Lock Handle 61 See Figure DD 3 Turn the Hand Knob 68 and adjust the infeed Fence 60 until the workpiece contacts the Cutter at the desired location See Figure DD 4 Retighten the Lock Handle 61 to lock the infeed Fence 60 in position See Figure DD 5 Adjust the outfeed Fence 60 so that it comes into alignment with the infeed Aluminum Fence 60 See Figure FF 6 Place a straight edge against the infeed and outfeed Aluminum Fences 60 to check alignment Once they are both in alignment make sure the Lock Handle 61 is tightened rA Always feed the wood against the rotation of the Cutter Also examine the grain on the side edge of the board Whenever possible run the board so the Cutter is cutting with the grain See Figure GG GUARD NOT SHOWN FOR CLARITY GUARD NOT SHOWN FOR CLARITY OUTPUT FEED CREEK lt DIRECTION OF FEED DIRECTION OF FEED FIGURE FF FIGURE GG Freehand Shaping 1 Freehand shaping is shaping without the aid of the Miter Gauge 45 or Aluminum Fences 60 The most dangerous part
20. high resistance 2 The V Belt is slipping 1 The Stand of the Wood Shaper is unstable and wobbles 2 The Spindle or Cutter is loose or out of alignment 3 The Wood Shaper has a loose Motor or Spindle Cartridge 1 Defective Forward Reverse Switch 1 Defective Power Switch For technical questions please call 1 800 444 3353 1 Make sure machine is plugged into a working 110 volt grounded electrical outlet 1 Make sure machine is plugged into a working 110 volt grounded electrical outlet 2 Adjust V Belt tighter or replace Belt 1 Stabilize the Stand on the floor 2 Reinstall the Spindle and or Cutter 3 Have a qualified service technician check Motor and or Spindle Cartridge 1 Immediately turn off machine and unplug it from its electrical outlet Do not operate machine until a qualified service technician repairs or replaces Forward Reverse Switch 1 Immediately unplug machine from its electrical outlet Do not operate machine until a qualified service technician repairs or replaces Power Switch PAGE 26 PARTS LIST Part Description Part Description _ 2 Teba 6 Fene Flat Washer 3 8 Knob M8 1 25 Flat Washer 5mm Lock Washer 1 2 _Flat Washer 5mm _ _ Hex Nut M4 0 7 Hex Bolt M12 1 75 x 20 i 4 Carriage Bolt M8 1 25 x 12 67 Adjusting Screw Stud 63 6 T 65 1 1 1 Hand Knob Roll Pin 3
21. ing the Spindle See Figures J and K REV 07j SKU 95668 For technical questions please call 1 800 444 3353 PAGE 11 2 Thread one end of the Draw Bar 121 into the bottom end of the Spindle 105 approximately 10 to 15 turns until tight See Figure J 9 Insert the Spindle Draw Bar assembly into the Spindle Housing 110 from the top side of the Work Table 52 See Figure K 4 Thread the tapered Draw Bar Hex Nut 122 onto the end of the Draw Bar 121 under the Work Table 52 making sure the tapered side of the Hex Nut is facing upward See Figure L 3 Place a wrench not included on the top end of the Spindle 105 6 Using an open end wrench not included tighten the Draw Bar Hex Nut 122 while holding the Spindle 105 securely DO NOT over tighten the Draw Bar Hex Nut See Figure M FIGURE J FIGURE K SPINDLE 105 DRAW BAR 121 REV 07j SKU 95668 For technical questions please call 1 800 444 3353 PAGE 12 Router Bit Assembly 1 Prior to installation make sure to remove any oil grease dirt and debris from the Collet 103 104 Draw Bar 121 and Spindle Housing 110 surfaces before installing a Router Bit 2 Remove the Spindle 105 as shown on page 12 of this manual See Figures K L and M 3 Insert the Collet 103 104 into the Spindle Housing 110 See Figure N 4 Install the Router Bit not included on Hold the flat edge on the Spindle Housing 110 and tighten
22. inside of the front cover Keep this manual and invoice in a safe and dry place for future reference GENERAL SAFETY RULES A WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS WORK AREA 1 Keep your work area clean and well lit Cluttered benches and dark areas invite accidents 2 Do not operate the Wood Shaper in explosive atmospheres such as in the presence of flammable liquids gases or dust Power equipment creates sparks which may ignite the dust or fumes 3 Keep bystanders children and visitors away while operating power equipment Distractions can cause you to lose control Protect others in the work REV 10d SKU 95668 For technical questions please call 1 800 444 3353 PAGE 2 4 area from debris such as chips and sparks Provide barriers or shields as needed Children and visitors should never be in the work area ELECTRICAL SAFETY Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded If the tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the us
23. loor or the weight of the Wood Shaper may damage the Spindle See Figure G Place the Stand assembly on the Wood Shaper and attach it with the Carriage Bolts 9 3 8 Flat Washers 10 and Hex Nuts 11 Then have an assistant help you turn the Wood Shaper unit upright See Figure G Level the Wood Shaper with a carpenter s level If necessary move the Stand slightly until it is level Then tighten all Bolts and Nuts on the Stand FIGURE G STAND ASSEMBLY WORK TABLE 52 Optional Table Spacer Installation Ts Your shaper comes with a Table Spacer Installation Kit that will enable you to make shallow cuts and utilize the upper blade area of most router bits with shanderd length shanks This is an optional feature that is not required for most applications Unplug the shaper power cord Remove the four table corner Hex Bolts 66 then remove the three Spindle Housing Hex Bolts 95 Lift the Table 52 off of the stand assembly See Figure G above and the assembly diagram on page 29 Locate the package included with your shaper that contains all the hardware for installing the spacers There should be five M12 Long Bolts 151 two M12 Short Bolts 152 and seven 1 2 Spacers 150 Position one spacer over each of the four corner bolt holes and one over each of the three spindle housing bolt holes REV 07j SKU 95668 For technical questions please call 1 800 444 3353 PAGE 10 Carefully place the Table
24. lternating Current Underwriters Laboratories Inc ae Revolutions per Minute SKU 95668 For technical questions please call 1 800 444 3353 PAGE 8 UNPACKING When unpacking check to make sure all the parts shown on the Parts Lists on pages 27 and 28 are included If any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible ASSEMBLY INSTRUCTIONS 1 CAUTION Always make sure the Power Switch 5 of the Wood Shaper is In its OFF position and the unit is unplugged from its electrical outlet prior to performing any assembly procedures Stand Assembly 2 Lay one Side Panel 1 on the floor and attach the Tie Bars 2 with the Carriage Bolts 9 3 8 Flat Washers 10 and Hex Nuts 11 Do not fully tighten the Bolts and Nuts at this time See Figures D and E Attach the second Side Panel 1 to the assembly See Figures D and E FIGURE D SIDE PANEL 1 CARRIAGE BOLTS 9 3 8 FLAT WASHERS 10 HEX NUTS 11 SIDE PANEL 1 TIE BAR 2 TIE BAR e e RUBBER FEET 2 a 3 4 Attach the four Rubber Feet 3 to the bottom of the Side Panels 1 See Figure F FIGURE E FIGURE F SKU 95668 For technical questions please call 1 800 444 3353 PAGE 9 Place the Wood Shaper s Work Table 52 upside down on two sturdy blocks that are at least 3 1 2 off the floor Make sure the Spindle 105 DOES NOT touch the f
25. ne in a clean dry safe location out of reach of children and other unauthorized people 5 AA CAUTION All maintenance service or repairs not mentioned in this manual must only be performed by a qualified service technician PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO REV 07j SKU 95668 For technical questions please call 1 800 444 3353 PAGE 25 SKU 95668 TROUBLESHOOTING The Wood Shaper does not start or the circuit breaker trips The Wood Shaper runs Slow The Wood Shaper vibrates The Spindle is loose Or the Cutter chatters The Forward Reverse Switch does not operate properly The Power Switch does not turn off Machine 1 Electrical supply circuit has low voltage or high resistance 1 Electrical supply circuit has low voltage or
26. of shaping freehand is beginning the cut where the Cutter first contacts the workpiece Often the workpiece will tend to jerk or kickback catching the operator off guard SKU 95668 For technical questions please call 1 800 444 3353 PAGE 22 2 To reduce this tendency use a Taper Pin 56 The Taper Pin allows you to anchor and slowly pivot the workpiece into the Cutter as the cut is started Thus shaping freehand is more stable and safer See Figures HH WARNING ALWAYS use an auxiliary jig not included and extreme care when shaping with the Fences 60 removed Freehand shaping often requires you to remove the Fences resulting in reduced protection from the Cutter 3 To set up the Wood Shaper for freehand shaping remove the Fences 60 from the machine 4 Insert the Taper Pin 56 in the best suited hole on the Work Table 52 so you can feed the workpiece into and against the rotation of the Cutter See Figures HH 5 Install the Cutter so it will cut in the correct direction Then adjust the Spindle 105 height 6 Install the Ring Guard 85 DO NOT use the Wood Shaper without the Ring Guard installed ra Use a supplemental hold down jig not included or you can use rubberized handle push blocks not included to support or guide the workpiece and protect your hands 8 Place the workpiece against the Taper Pin 56 See Figures HH 9 Slowly pivot and feed the workpiece into the Cutter Avoid starting th
27. ower Switch is off before plugging SKU 95668 For technical questions please call 1 800 444 3353 PAGE 3 in Plugging in power equipment with the Power Switch on invites accidents J Remove adjusting keys or wrenches before turning the power tool on A wrench or a key that is left attached to a rotating part of the Wood Shaper may result in personal injury 6 Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the Wood Shaper in unexpected situations eye goggles Dust mask or respirator and hearing protection must be T Use safety equipment Always wear ANSI approved safety impact used for appropriate conditions TOOL USE AND CARE 1 Do not force the Wood Shaper Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed Pee Do not use the Wood Shaper if the Power Switch does not turn it on or off Any tool that cannot be controlled with the Power Switch is dangerous and must be replaced 3 Disconnect the Power Cord Plug from the power source before making any adjustments changing accessories or storing the Wood Shaper Such preventive safety measures reduce the risk of starting the tool accidentally 4 Store idle tools and equipment out of reach of children and other untrained persons Tools and equipment are dangerous in the hands of untrained users 5 Maintain this product with ca
28. re Keep the Wood Shaper and its Table clean and in proper working order Properly maintained tools and equipment are easier to control Do not use damaged tools and equipment Tag damaged tools and equipment Do not use until repaired 6 Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the Wood Shaper s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools T Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one product may become hazardous when used on another product SKU 95668 For technical questions please call 1 800 444 3353 PAGE 4 1 Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury 2 When servicing a tool use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury SPECIFIC SAFETY RULES 1 Maintain labels and nameplates on the Wood Shaper These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement 2 Avoid unintentional starting Make sure you are prepared to begin work before turning on the
29. s for Rub Collars 98 99 100 A Above the Cutter This set up is the safest and produces a most consistent result The only drawback is that the cut is on the underside of the workpiece out of view of the operator However if the workpiece lifts off the Work Table 52 you simply run it through a second time to finish the cut See Figure AA RUB COLLAR 98 99 100 FIGURE AA SKU 95668 For technical questions please call 1 800 444 3353 PAGE 18 B Between two Cutters This set up has the advantage of making two profile cuts in a single pass Although there is a Rub Collar 98 99 100 beneath a Cutter this set up is safer than the previous set up Any lifting of the workpiece will still cause the Cutter to make an uneven cut Asecond pass will correct the profile on the bottom edge but the top profile will still have the gouge from lifting the workpiece into the Cutter See Figure BB RUB COLLAR 98 99 100 BETWEEN FIGURE BB C Below the Cutter This set up allows the cut to be viewed by the operator However it is also the most dangerous Any slight lifting of the workpiece will cause the Cutter to make too deep of a cut There is also increased risk of kickback It is NOT recommended to shape with a Rub Collar below the Cutter See Figure CC RUB COLLAR 98 99 100 tee FIGURE CC OPERATING INSTRUCTIONS 1 Use safety equipment Always wear ANSl approved safety impact eye goggles Dust mask
30. so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspection verifies the defect we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return repaired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 REV 07 SKU 95668 For technical questions please call 1 800 444 3353 PAGE 30
31. the workpiece is to be backed out of an uncompleted cut Never attempt to remove material stuck in the moving parts of the Wood Shaper while it is plugged in and running Make sure the Table is clear with the exception of the workpiece to be shaped The Wood Shaper is designed for shaping wood workpieces only Do not attempt to use the Wood Shaper to cut metal or other nonwood materials SKU 95668 For technical questions please call 1 800 444 3353 PAGE 6 26 27 28 29 Use the right tool for the job Do not attempt to force a small tool or attachment to do the work of a larger industrial tool There are certain applications for which this tool was designed It will do the job better and more safely at the rate for which it was intended Do not modify this tool and do not use this tool for a purpose for which it was not intended A WARNING Some dust created by power sanding sawing grinding drilling and other construction activities contain chemicals known to the State of California to cause cancer birth defects or other reproductive harm Some examples of these chemicals are lead from lead based paints crystalline silica from bricks and cement or other masonry products arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipm
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