INDUSTRIAL SHAPER/ROUTER Model 95668 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.
PRODUCT SPECIFICATIONS Electrical Requirements Spindle Diameter Spindle Thread Spindle Travel Router Collets Maximum Cutting Diameter Table Size Footprint Miter Guide Fence Dimensions Overall Dimensions Gross Weight 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: SJT 16 AWG x 3C Plug Type: 3 Prong / Grounded 1/2” 12mm x 1.
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 1. 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.
in. Plugging in power equipment with the Power Switch on, invites accidents. 5. 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. 7. Use safety equipment.
SERVICE 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.
12. Keep the Cutters on the underside of the workpiece whenever possible. This provides a distance guard for the operator. 13. 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. 14. 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.
26. 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. 27.
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 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.
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.
5. 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 floor or the weight of the Wood Shaper may damage the Spindle. (See Figure G.) 6. 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.) 7.
3. Carefully place the Table (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).
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.) 3. 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.) 5.
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). 5.
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. 2. Loosen the Lock Handle (61). (See Figure P.) 3. Adjust the position of the Fence (60) by turning the Knob (64). (See Figure P.) 4. Once the Fence (60) is in the desired position, re-tighten the Lock Handle (61). (See Figure P.) FIGURE P FENCE (60) FENCE (60) LOCK HANDLE (61) KNOB (64) Fence Alignment: 1.
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.
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.
2. Place the required spacers, also called Rub Collars (98, 99, 100), onto the Spindle (105). (See Figure V.) SPINDLE (105) FIGURE V 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 holding the Spindle (105) at the top with the provided Arbor Wrench (146). (See Figures W and X.) 4.
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 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.
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. A second 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.
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. 2. 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). 3.
6. Tighten the Lock Handle (61) to lock the infeed Fence (60) in position. (See Figure DD.) FENCE (60) INFEED SIDE FENCE (60) OUTFEED SIDE FIGURE DD LOCK HANDLE (61) HAND KNOB (68) 7. 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.) 8. Turn on the Wood Shaper. 9. 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).
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.
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.
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.
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.
TROUBLESHOOTING Problem The Wood Shaper does not start or the circuit breaker trips. Possible Reason 1. Electrical supply circuit has low voltage or high resistance. The Wood Shaper runs slow. 1. Electrical supply circuit has low voltage or high resistance. 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. SKU 95668 2. The V-Belt is slipping. 1.
PARTS LIST Part # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Description Side Panel Tie Bar Rubber Foot Philips Head Screw (M4-0.7x25) Power Switch Switch Lamella Flat Washer (5mm) Hex Nut (M4-0.7) Carriage Bolt (M8-1.25 x 12) Flat Washer (3/8”) Hex Nut (M8-1.25) Philips Head Screw (M5-0.8 x 12) Exterior Tooth Washer (5mm) Hex Nut (M5-0.8) Shelf Electricity Label 18 19 20 21 22 23 Hex Nut (M8-1.
PARTS LIST (CONT.) Part # 119 120 121 122 123 124 125 126 127 128 129 129-1 129-2 129-3 129-4 129-5 130 131 Description Stud Knob Draw Bar (M8-1.0) Draw Bar Hex Nut (M8-1.0) Belt (690 x 10mm) Hex Bolt (M8-1.25 x 12) Flat Washer (3/8”) Belt Guard Motor Pulley Set Screw (M6-1 x 10) Motor Start Capacitor Capacitor Cover Wiring Box Motor Fan Motor Fan Cover Key (5 x 5 x 22mm) Carriage Bolt (M8-1.
ASSEMBLY DIAGRAM NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts.
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.