Grizzly G9862, G9968 Instruction Manual

COPYRIGHT © MARCH, 2002 BY GRIZZLY INDUSTRIAL, INC.

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

PRINTED IN TAIWAN

INDUSTRIAL SHAPER

MODEL G9862/G9968

INSTRUCTION MANUAL

Model G9968

Model G9862

WARNING

Some dust created by power sanding, sawing, grind­ing, drilling, and other construction activities contains
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, cement, and
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 equipment, such
as those dust masks that are specially designed to fil­ter out microscopic particles.

Table Of Contents

PAGE

1. SAFETY

SAFETY RULES FOR ALL TOOLS ......................................................................2-3

ADDITIONAL SAFETY INSTRUCTIONS FOR SHAPERS ......................................4

2. CIRCUIT REQUIREMENTS ............................................................................................5

220V OPERATION ....................................................................................................5

440V OPERATION ....................................................................................................5

GROUNDING ............................................................................................................6

EXTENSION CORDS ................................................................................................6

3. GENERAL INFORMATION ............................................................................................7

COMMENTARY ........................................................................................................7

UNPACKING..............................................................................................................8

PIECE INVENTORY ..................................................................................................8

HARDWARE RECOGNITION CHART ......................................................................9

CLEAN UP ..............................................................................................................10

SITE CONSIDERATIONS ......................................................................................11

4. ASSEMBLY ..................................................................................................................12

BEGINNING ASSEMBLY ........................................................................................12

GUARD COVER ......................................................................................................12

FENCE GUARD ......................................................................................................13

UPPER HOLD-DOWNS ..........................................................................................13

5. ADJUSTMENTS............................................................................................................14

SPEED CHANGES..................................................................................................14

FENCE ADJUSTMENT ..........................................................................................15

ALIGNING THE FENCE ..........................................................................................15

TABLE INSERTS ....................................................................................................16

HOLD-DOWNS ........................................................................................................16

CUTTER INSTALLATION........................................................................................17

FOOT BRAKE..........................................................................................................18

TEST RUN ..............................................................................................................18

6. OPERATION..................................................................................................................19

SWITCH ..................................................................................................................19

REVERSE SWITCH ................................................................................................20

SPINDLE HEIGHT ..................................................................................................21

STRAIGHT SHAPING ........................................................................................21-22

RUB COLLARS ......................................................................................................23

TABLE EXTENSION................................................................................................24

PATTERN WORK & JIGS ..................................................................................24-25

FREEHAND SHAPING............................................................................................26

SHAPER ACCESSORIES ......................................................................................26

7. MAINTENANCE ............................................................................................................27

GENERAL................................................................................................................27

TABLE......................................................................................................................27

LUBRICATION ........................................................................................................27

V-BELT ....................................................................................................................27

SCHEDULE ............................................................................................................27

MAINTENANCE NOTES ........................................................................................28

WIRING DIAGRAMS ..........................................................................................29-30

8. CLOSURE ....................................................................................................................31

MACHINE DATA ................................................................................................32-33

PARTS BREAKDOWN AND PARTS LISTS ......................................................34-41

WARRANTY AND RETURNS ................................................................................42

-2- G9862/G9968 Shaper

Safety Instructions For Power Tools

SECTION 1: SAFETY

5. KEEP CHILDREN AND VISITORS
AWAY. All children and visitors should be

kept a safe distance from work area.

6. MAKE WORKSHOP CHILD PROOF with

padlocks, master switches, or by removing
starter keys.

7. NEVER FORCE TOOL. It will do the job

better and safer at the rate for which it was
designed.

8. USE RIGHT TOOL. Do not force tool or

attachment to do a job for which it was not
designed.

1. KEEP GUARDS IN PLACE and in working

order.

2. REMOVE ADJUSTING KEYS AND
WRENCHES. Form habit of checking to

see that keys and adjusting wrenches are
removed from tool before turning on.

3. KEEP WORK AREA CLEAN. Cluttered

areas and benches invite accidents.

4. NEVER USE IN DANGEROUS ENVI­RONMENT. Do not use power tools in

damp or wet locations, or where any flam­mable or noxious fumes may exist. Keep
work area well lighted.

For Your Own Safety Read Instruction

Manual Before Operating This Equipment

Indicates an imminently hazardous situation which, if not
avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not
avoided, COULD

result in death or serious injury.

Indicates a potentially hazardous situation which, if not
avoided, MAY

result in minor or moderate injury. It may also

be used to alert against unsafe practices.
This symbol is used to alert the user to useful information

about proper operation of the equipment.

The purpose of safety symbols is to attract your attention to possible hazardous conditions.
This manual uses a series of symbols and signal words which are intended to convey the level
of importance of the safety messages. The progression of symbols is described below.
Remember that safety messages by themselves do not eliminate danger and are not a substi­tute for proper accident prevention measures.

NOTICE

G9862/G9968 Shaper -3-

9. USE PROPER EXTENSION CORD. Make

sure your extension cord is in good condi­tion. Conductor size should be in accor­dance with the chart below. The amperage
rating should be listed on the motor or tool
nameplate. An undersized cord will cause a
drop in line voltage resulting in loss of
power and overheating. Your extension
cord must also contain a ground wire and
plug pin. Always repair or replace exten­sion cords if they become damaged.

Minimum Gauge for Extension Cords

10. WEAR PROPER APPAREL. Do not wear

loose clothing, gloves, neckties, rings,
bracelets, or other jewelry which may get
caught in moving parts. Non-slip footwear
is recommended. Wear protective hair cov­ering to contain long hair.

11. ALWAYS USE SAFETY GLASSES. Also

use face or dust mask if cutting operation is
dusty. Everyday eyeglasses only have
impact resistant lenses, they are NOT safe­ty glasses.

12. SECURE WORK. Use clamps or a vise to

hold work when practical. It’s safer than
using your hand and frees both hands to
operate tool.

13. NEVER OVERREACH. Keep proper foot-

ing and balance at all times.

LENGTH

AMP RATING 25ft 50ft 100ft

0-6 18 16 16
7-10 18 16 14
11-12 16 16 14
13-16 14 12 12
17-20 12 12 10
21-30 10 10 No

Safety Instructions For Power Tools

14. MAINTAIN TOOLS WITH CARE. Keep

tools sharp and clean for best and safest
performance. Follow instructions for lubri­cating and changing accessories.

15. DISCONNECT TOOLS before servicing

and changing accessories, such as blades,
bits, cutters, and the like.

16. REDUCE THE RISK OF UNINTENTION­AL STARTING. Make sure switch is in off

position before plugging in.

17. USE RECOMMENDED ACCESSORIES.

Consult the owner’s manual for recom­mended accessories. The use of improper
accessories may cause risk of injury.

18. CHECK DAMAGED PARTS. Before fur-

ther use of the tool, a guard or other part
that is damaged should be carefully
checked to determine that it will operate
properly and perform its intended function.
Check for alignment of moving parts, bind­ing of moving parts, breakage of parts,
mounting, and any other conditions that
may affect its operation. A guard or other
part that is damaged should be properly
repaired or replaced.

19. NEVER LEAVE TOOL RUNNING UNAT­TENDED. TURN POWER OFF. Do not

leave tool until it comes to a complete stop.

20. NEVER USE UNDER THE INFLUENCE of

alcohol or drugs, or when tired.

21. NEVER ALLOW UNSUPERVISED OR
UNTRAINED PERSONNEL TO OPER­ATE THE MACHINE. Make sure any

instructions you give in regards to the
operation of the machine are approved,
correct, safe, and clearly understood.

-4- G9862/G9968 Shaper

1. NEVER ALLOW YOUR HANDS to come

within 12 inches of a spinning cutter. Never
pass your hands directly over or in front of
a spinning cutter.

2. BLIND CUT WHENEVER POSSIBLE. This

keeps the knives on the underside of the
workpiece and provides a distance guard
for the operator.

3. WHEN SHAPING CONTOURED WORK

and using a rub collar, NEVER start out at a
corner. See the “Rub Collar” instructions
further on in the manual for more details on
the proper procedure.

4. WITH THE MACHINE UNPLUGGED,

always rotate the spindle by hand with any
new setup to ensure proper cutter clear­ance before starting the machine.

5. DO NOT SHAPE STOCK SHORTER than

12 inches without special work holding fix­tures or jigs. Where practical, shape longer
stock and cut to size.

6. NEVER ATTEMPT to remove too much

material in one pass. You are far more like­ly to enjoy safer and higher quality results if
you allow the cutter to remove material in
multiple passes.

7. THE DANGER OF kickback is increased

when the stock has knots, holes, or foreign
objects in it. Warped stock should be run
through a jointer before attempting to run it
through a shaper.

8. KEEP THE UNUSED PORTION of the cut-

ter below the table surface.

9. THE USE OF PUSH STICKS as safety

devices in some applications is smart; in
others it can be quite dangerous. If the push
stick comes in contact with the cutter on the
end grain, it can fly out of your hand like a
bullet—potentially causing serious injury.
We recommend using some type of fixture,
jig, or hold-down device as a safer alterna­tive. Use a guard or other type of protective
device at all times.

10. NEVER FORCE MATERIALS through the

shaper. Let the cutters do the work.
Excessive force is likely to result in poor cut­ting results and will cause dangerous kick­back conditions.

11. ALWAYS ensure that the cutters or bits, the

fence, and the spindle elevator knob have
been tightened properly before beginning
any operation.

12. ALWAYS feed the work toward the cutters

in the direction opposite of the cutter rota­tion. Also, using and maintaining a sharp
cutterhead will greatly reduce the chance of
kickback.

13. IF AT ANY TIME YOU ARE EXPERIENC­ING DIFFICULTIES PERFORMING THE
INTENDED OPERATION, STOP USING
THE SHAPER! Then contact our service

department or ask a qualified expert how
the operation should be performed.

Additional Safety Instructions For Shapers

Like all power tools, there is danger asso­ciated with shapers. Accidents are fre­quently caused by lack of familiarity or fail­ure to pay attention. Use this tool with
respect and caution to lessen the possibil­ity of operator injury. If normal safety pre­cautions are overlooked or ignored, serious
personal injury may occur.

No list of safety guidelines can be complete.
Every shop environment is different. Always
consider safety first, as it applies to your
individual working conditions. Use this and
other machinery with caution and respect.
Failure to do so could result in serious per­sonal injury, damage to equipment or poor
work results.

G9862/G9968 Shaper -5-

SECTION 2: CIRCUIT REQUIREMENTS

Model G9862

The Model G9862 Shaper is prewired with a 5
H.P. single-phase motor. Under normal use, the
motor draws approximately 30 amps at 220V. We
recommend using a 30 amp circuit. This includes
the appropriate wiring and circuit breaker. If fre­quent circuit failure occurs when using the
shaper, contact our service department.

The shaper must be connected to its own dedi­cated 30A circuit. It should not share a circuit with
any other machine. A standard 2-pole breaker is
necessary for use with the shaper.

We recommend using a NEMA-style L6-30 plug

and outlet similar to that in Figure 1. You may

also “hard-wire” the shaper directly to your panel,
provided you place a disconnect near the
machine. Check the electrical codes in your area
for specifics on wiring requirements.

Figure 1. Recommended plug configuration for

220V, three-phase operation.

Model G9968

The Model G9968 Shaper is prewired with a 71⁄2
H.P. three-phase motor. Under normal use, the
motor draws approximately 20 amps at 220V. We
recommend using a 20 amp circuit. This includes
the appropriate wiring and circuit breaker. If fre­quent circuit failure occurs when using the
shaper, contact our service department.

The shaper must be connected to its own dedi­cated 20A circuit. It should not share a circuit with
any other machine. A standard 3-pole breaker is
necessary for use with the shaper.

We recommend using a NEMA-style L15-30 plug

and outlet similar to that in Figure 1. You may

also “hard-wire” the shaper directly to your panel,
provided you place a disconnect near the
machine. Check the electrical codes in your area
for specifics on wiring requirements.

Figure 1. Recommended plug configuration for

220V, three-phase operation.

-6- G9862/G9968 Shaper

Grounding

In the event of an electrical short, grounding
reduces the risk of electric shock by providing a
path of least resistance to disperse electric cur­rent.

Extension Cords

We do not recommend the use of extension
cords on 220V or 440V equipment. It is much bet­ter to arrange the placement of your equipment
and the installed wiring to eliminate the need for
extension cords. Should it be necessary to use
an extension make sure the cord is rated Hard
Service (grade S) or better. Refer to the chart in

Section 1: Safety to determine the minimum

gauge for the extension cord. The extension cord
must also contain a ground wire and plug pin.
Always repair or replace extension cords when
they become worn or damaged.

This equipment must be
grounded. Verify that any
existing electrical outlet
and circuit you intend to
plug into is actually
grounded. Under no cir­cumstances should the
grounding pin from any
three-pronged plug be
removed. Serious injury
may occur.

440V Operation

The Model G9968 Shaper is furnished with a 71⁄2
H.P. three-phase motor that can be wired to
440V. Under normal use, the motor draws
approximately 10 amps at 440V. We recommend
using a 10 amp circuit. This includes the appro­priate wiring and circuit breaker. If frequent circuit
failures occur when using the shaper, contact our
service department.

The shaper must be connected to its own dedi­cated 10A circuit. It should not share a circuit with
any other machine. A standard 3-pole breaker is
necessary for 440V use.

We recommend using a NEMA-style L20-30 plug

and outlet similar to that in Figure 2. You may

also “hard-wire” the shaper directly to your panel,
provided you place a disconnect near the
machine. Check the electrical codes in your area
for specifics on wiring requirements.

Figure 2. Recommended plug configuration for

440V, three-phase operation.

This tool is equipped with an electric cord that has
an equipment-grounding conductor which must
be properly connected to a grounding plug. The
plug must be plugged into a matching outlet that
is properly installed and grounded in accordance
with all local codes and ordinances.

Improper connections of the electrical-grounding
conductor can result in the risk of electric shock.
The conductor with green or green and yellow
striped insulation is the electrical-grounding con­ductor. If repair or replacement of the electric
cord or plug is necessary, do not connect the
equipment grounding conductor to a live terminal.

G9862/G9968 Shaper -7-

SECTION 3: GENERAL INFORMATION

Grizzly Industrial, Inc. is proud to offer the Model
G9862/G9968 Shaper. This shaper is part of
Grizzly’s growing family of fine woodworking and
metalworking machinery. When used according
to the guidelines stated in this manual, you can
expect years of trouble-free, enjoyable operation.

The Model G9862 and the Model G9968 are the
same machine with the exception of the motor
size/phase difference and the absence/presence
of table extension wings. Thse shapers are
intended for heavy-duty professional use and
feature a 1

1

⁄4" spindle. The Model G9862 offers a
5 H.P., 220V, Single-Phase motor. The Model
G9968 offers a 7

1

⁄2 H.P., 220V, three-phase
motor. Both machines feature magnetic power
switching, a Forward/Reverse switch and are
capable of operating at 5500, 7500 and 10,000
R.P.M. The current Grizzly catalog contains
many different profiles of cutterheads available
for the Model G9862/G9968, as well as power­feeders.

We are also pleased to provide this manual with
the Model G9862/G9968. It was written to guide
you through assembly, review safety considera­tions, and cover general operating procedures. It
represents our latest effort to produce the best
documentation possible. If you have any criti­cisms that you feel we should address in our next
printing, please write to us at the address below:

Grizzly Industrial, Inc.

C

⁄O Technical Documentation

P.O. Box 2069

Bellingham, WA 98227

Commentary

Most important, we stand behind our machines.
We have an excellent service department at your
disposal should the need arise. If you have any
service questions or parts requests, please call or
write to us at the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone:[phone]

Fax:[phone]
E-Mail: [e-mail]
Web Site: http://www.grizzly.com

The specifications, drawings, and photographs
illustrated in this manual represent the Model
G9862/G9968 as supplied when the manual was
prepared. However, owing to Grizzly’s policy of
continuous improvement, changes may be made
at any time with no obligation on the part of
Grizzly. Whenever possible, though, we send
manual updates to all owners of a particular tool
or machine. Should you receive one, we urge you
to insert the new information with the old and
keep it for reference.

Read the manual before
assembly and operation.
Become familiar with
the machine and its
operation before begin­ning any work. Serious
personal injury may
result if safety or opera­tional information is not
understood or followed.

-8- G9862/G9968 Shaper

Unpacking

The shaper base unit (shown in Figure 3) and
hardware (shown in Figure 4) is shipped from the

manufacturer in a carefully packed carton. If you
discover the machine is damaged after you have
signed for delivery, and the truck and driver are
gone, you will need to file a freight claim with the
carrier. Save the containers and all packing mate­rials for possible inspection by the carrier or its
agent. Without the packing materials, filing a

freight claim can be difficult. If you need assis-

tance determining whether you need to file a
freight claim, or with the procedure to file one,
please contact our Customer Service.

Piece Inventory

After all the parts have been removed from the

carton, you should have:

Part Qty

• Shaper Unit 1

• Fence Guard Attachment 1

• Cutter Guard 1

• Star Knobs

3

⁄8"-1" 2

• Star Knobs

3

⁄8"-7⁄8"2

• Washers

3

⁄8"4

• Combo Wrench 27/24mm 1

• Combo Wrench 21/19mm 1

• Combo Wrench 19/17mm 1

• Combo Wrench 14/12mm 1

• Combo Wrench 12/10mm 1

• Allen

®

Wrench 12mm 1

• Hold-Downs w/Bars & Knobs 2

• Table Hold-Downs (G9862) 2

• Miter Gauge (G9862) 1

In the event that any nonproprietary parts are
missing (e.g. a nut or a washer), we would be
glad to replace them, or, for the sake of expedi­ency, replacements can be obtained at your local
hardware store.

When you are completely satisfied with the con­dition of your shipment, you should inventory its
parts.

Figure 4. Model

G9968

Hardware. (Model

G9862 miter gauge and hold-down assemblies

not shown.)

Figure 3. Model G9968 base unit w/wings.

The Model G9862/G9968
is a heavy machine, 1600
lbs. shipping weight. DO
NOT over-exert yourself
while unpacking or mov­ing your machine—use
power equipment to move
the machine. Serious per­sonal injury may occur if
safe moving methods are
not followed.

G9862/G9968 Shaper -9-

Hardware Recognition Chart

Use this chart to match up
hardware pieces during the
assembly process!

-10- G9862/G9968 Shaper

Clean Up

The unpainted surfaces are coated with a waxy
oil to protect them from corrosion during ship­ment. Remove this protective coating with a sol­vent cleaner or citrus-based degreaser such as
Grizzly’s G7895 Degreaser. To clean thoroughly,
some parts may need to be removed. Avoid chlo­rine-based solvents as they may damage painted
surfaces should they come in contact. Always fol­low the manufacturer’s instructions when using
any type of cleaning product.

Do not use gasoline or
other petroleum-based
solvents to clean with.
They have low flash
points which make them
extremely flammable. A
risk of explosion and
burning exists if these
products are used.
Serious personal injury
may occur.

Do not smoke while using
solvents. A risk of explo­sion or fire exists and may
result in serious personal
injury.

Many of the solvents
commonly used to clean
machinery can be toxic
when inhaled or ingest­ed. Always work in well­ventilated areas far from
potential ignition sources
when dealing with sol­vents. Use care when dis­posing of waste rags and
towels to be sure they do
not create fire or environ­mental hazards.

Figure 5. Components removed for cleaning.

In order to thoroughly clean the waxy oil from the
shaper, the guard assembly needs to be removed

as shown in Figure 5. Also, the fence halves and

other components can be cleaned easier if they
are removed from the mounting brackets.

After all the waxy oil has been removed from the
shaper table, the guard assembly, the fence
halves, the rub collars and the spindle, lightly oil
all of the parts (especially the mating surfaces)
with a protective lubricant. Replace each piece in
the same manner as it was removed. If desired,
the rub collars can be set aside until you are
ready to install a cutter.

G9862/G9968 Shaper -11-

Site Considerations

FLOOR LOAD

Your Model G9862/G9968 Shaper represents a
very large weight load in a moderate sized foot­print. Most commercial shop floors will be ade­quate for the 1600 lb. weight of the Model
G9862/G9968. Some floors may require addition­al support. Contact an architect or structural engi­neer if you have any question about the ability of
your floor to handle the weight.

WORKING CLEARANCES

Working clearances can be thought of as the dis­tances between machines and obstacles that
allow safe operation of every machine without
limitation. Consider existing and anticipated
machine needs, size of material to be processed
through each machine, and space for auxiliary
stands and/or work tables. Also consider the rel­ative position of each machine to one another for
efficient material handling. Be sure to allow your­self sufficient room to safely run your machines in
any foreseeable operation.

Make your shop “child safe.”
Ensure that your workplace
is inaccessible to children by
closing and locking all
entrances when you are
away. Never allow visitors in
your shop when assembling,
adjusting or operating equip­ment.

LIGHTING AND OUTLETS

Lighting should be bright enough to eliminate
shadow and prevent eye strain. Electrical circuits
should be dedicated or large enough to handle
combined motor amp loads. Outlets should be
located near each machine so power or exten­sion cords are not obstructing high-traffic areas.
Be sure to observe local electrical codes for prop­er installation of new lighting, outlets or circuits.

Make sure floor structure is
capable of supporting the
combined weight of the
machine parts and people.

-12- G9862/G9968 Shaper

SECTION 4: ASSEMBLY

Beginning Assembly

Most of your Model G9862/G9968 Shaper has
been assembled at the factory, but some parts
must be assembled or installed after delivery. We
have organized the assembly process into steps.
Please follow along in the order presented in this
section.

Guard Cover

Figure 6. Installing the cutter guard.

Keep loose clothing out
of the way of machinery
and keep hair pulled
back.

Wear safety glasses dur­ing the entire assembly
process. Failure to com­ply may result in serious
personal injury.

Disconnect power to the
machine when perform­ing any maintenance or
assembly. Failure to do
this may result in serious
personal injury.

To install the guard cover:

1. Place the guard cover on the guard assem-

bly.

2. Thread the (2)

3

⁄8"-16 x 7⁄8" star knobs through

the guard cover and into the holes in the

guard assembly as shown in Figure 6.

Some metal parts may
have sharp edges on
them after they are
formed. Please examine
the edges of all metal
parts before handling
them. Failure to do so
could result in injury.

3. Adjust to the desired position and tighten the

knobs.

G9862/G9968 Shaper -13-

Fence Guard

The Model G9862/G9968 comes with a fence
guard to reduce operator exposure to the spin­ning cutter. To install the fence guard:

1. Place the fence guard against the face of the

guard assembly and thread the (2)

3

⁄8"-16 x

1" star knobs through the guard and into their

respective holes as shown in Figure 7.

2. Adjust the height of the fence guard as need-

ed to keep the clearance above the cutter to
a minimum.

Figure 7. Mounting clearance guard.

Upper Hold-Downs

The upper hold-downs are meant to be mounted
across from those hold-downs already installed
on the table. To install the hold downs:

1. Insert the upper hold-down shafts into the

holes on the guard assembly as shown in

Figure 8.

2. Tighten the shaft bolt to lock the shaft into

place.

3. Position the upper hold-downs where

desired and tighten the hold-down knobs
that secure the hold-down bars into place.

Figure 8. Mounting hold-downs.

Shaft Bolt

Hold-Down Knobs