Grizzly G9862, G9968 Instruction Manual

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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

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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.

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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

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

⁄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.

⁄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:(570) 546-9663

Fax:(800) 438-5901 E-Mail: techsupport@grizzly.com 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

⁄8"-1" 2

• Star Knobs

⁄8"-7⁄8"2

• Washers

⁄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)

⁄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)

⁄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

-14- G9862/G9968 Shaper

Speed Changes

The Model G9862/G9968 Shaper is equipped with three groove pulleys that control the speed of the spindle. To change spindle speeds:

1. Unplug the machine.

2. Turn the belt tensioning lever (shown in Figure 9) counterclockwise to loosen the

adjustment bracket.

3. Pull the motor toward the spindle pulley to

loosen the V-belt.

Figure 10. Spindle speed adjustment.

5. Align the belt along the appropriate pulley

groove.

6. Swing the motor away from the spindle pul-

ley so the belt is tight.

7. Tighten the belt tensioning lever.

8. Spin the pulley to ensure proper tracking.

SECTION 5: ADJUSTMENTS

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

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

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

Figure 9. Belt tensioning lever.

4. Select the desired speed. There are three

speeds for the spindle: 5500, 7500 and

10,000 R.P.M. Figure 10 shows the belt

position for each available speed.

G9862/G9968 Shaper -15-

Figure 11. Fence controls.

Fence Adjustment

The fence is a two-piece adjusting system. Each fence is independently adjustable to compensate for different cutting thicknesses and special shaping applications. Each fence moves toward the front and back of the shaper and to the left and right. To adjust the front-to-back controls of the

fence, see the control location in Figure 11 and

follow the instructions below:

1. Loosen the fence lock handle.

2. Turn the fence adjustment knob until the

fence is set to the desired position.

3. Tighten the fence lock handle.

More detailed information concerning these fence adjustments is covered in the “Straight Shaping” instructions.

To change the fence spindle opening (move the fence pieces left or right) use the lateral move-

ment lock handle shown in Figure 11 to move the

fence. Always be sure to adjust the fences so there is as little clearance around the cutter as possible. Narrow clearance around the cutter provides more support and not as much operator exposure to the cutter.

Microadjustment

Fence Lock Handles

Fence Adjustment Knob

Figure 12. Aligning fences with straightedge.

Aligning The Fence

The following procedure ensures that the fence pieces are properly aligned.

1. Check that the fence pieces are tightly

secured to the fence housing.

2. Adjust one or both fence halves so they are

in close alignment. Micro-adjust and check the alignment with a straightedge as shown

in Figure 12.

3. If the fences are not coplanar with each

other, correct the appropriate fence by placing shim stock or paper between the back of the fence and the fence housing.

Lateral Movement

Lock Handle

-16- G9862/G9968 Shaper

Table Inserts

The Model G9862/G9968 is supplied with two

inserts (shown in Figure 13). Use the smallest

opening that a particular cutter will allow. This offers more support for the workpiece and reduces the amount of chips that can fall into the machine. The correct spindle opening also allows any unused portion of the cutter to remain below the table surface, thus, increasing operator protection. The table inserts have been machined flush with the surface of the table.

Figure 13. Table inserts

(guard removed for clarity).

Figure 14. Hold-downs in place.

Hold-Downs

Hold-downs are used to hold the workpiece flat on the table and snug against the fence as shown

in Figure 14.

Periodically check the knob that secures the holddown bar to the guard to make sure that it remains tight.

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

G9862/G9968 Shaper -17-

Cutter Installation

Your shaper operates at speeds of 5500, 7500 and 10,000 R.P.M. 3

⁄2" or larger cutters must be operated at the slowest speed. Always use the largest spindle size possible. “Stacking” two bushings inside each other in order to use a cutter two sizes bigger than the spindle will result in a malfunction of cutter operation, which may damage your equipment. To install a cutter:

1. Unplug the shaper.

2. Place the Allen

wrench over the spindle cap screw, and place a combo wrench on the spindle nut.

3. Loosen the spindle nut. Figure 15. Tightening spindle nuts.

4. Install the cutterhead onto the spindle. Use

spacers or collars so the configuration suits your particular task. Refer to the “Rub Collar” instructions in this manual for ideas on the safest setup.

5. Thread the spindle nut onto the spindle and

thread the spindle cap screw back into its hole.

6. Tighten the nut and the cap screw as shown in Figure 15. Use a wrench on the notches

at the top of the spindle for leverage.

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

-18- G9862/G9968 Shaper

Once assembly is complete and adjustments are done to your satisfaction, you are ready to start the machine.

Turn on the power supply at the main panel.

Press the START button. Make sure that your finger is poised on the STOP button, just in case

there’s a problem. The shaper should run smoothly with little or no vibration or rubbing noises. Strange or unnatural noises should be investigated and corrected before operating the machine further.

Run the Model G9862/G9968 for a short time to ensure that the moving parts are working properly with no excessive vibration. If any problem develops, correct it before attempting to use the machine.

If you cannot locate the source of unusual noises or cannot fix any problems that arise, immediately contact our service department for help.

Test Run

Foot Brake

The Model G9862/G9968 comes with a foot brake to stop or slow the cutter immediately after use. To ensure proper function and wear, this brake should be inspected and/or adjusted. To inspect the foot brake:

1. Locate the brake pad shown in Figure 16.

Figure 17. Brake pedal.

Figure 16. Brake pad.

2. Press the brake pedal (shown in Figure 17)

to visually inspect how the brake pad hits the spindle pulley.

The flat surfaces of the brake pad and the underside of the pulley should meet evenly for proper wear. If these surfaces do not meet evenly, then you need to adjust the bracket that mounts the foot brake.

To adjust the brake pad bracket:

1. Locate the two mounting bolts that mount the

bracket to the spindle seat assembly.

2. Loosen the two bolts with the 17mm wrench

provided with the shaper.

3. Slide the bracket in the desired direction

then tighten the bolts enough to inspect the brake pad function. If the brake pad meets the spindle pulley evenly, as described before, then snug the mounting bolts tight. If the brake pad still does not meet the under-

side of the spindle evenly, then repeat steps 1-3.

G9862/G9968 Shaper -19-

SECTION 6: OPERATIONS

Figure 18. ON/OFF switches.

Switch

Your shaper is equipped with a START/STOP

switch as shown in Figure 18. Always feed the

workpiece against the rotation of the cutter. Whenever possible, mount the cutter so the board is milled on the bottom side. This method does a better job, and it is safer for the operator.

Always check the direction of cutter rotation before beginning any shaping operation.

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

Wear safety glasses during all operations on the shaper. Failure to comply may result in serious personal injury.

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

Always wear a dust mask when operating the shaper. Using this machine produces sawdust which may cause allergic reactions or respiratory problems.

NOTICE

The following section was designed to give instructions on the basic operations of this shaper. However, it is in no way comprehensive of every shaper application. There are many different jigs that can be built to increase safety, accuracy, and types of cuts. WE STRONGLY RECOMMEND that you read books, trade magazines, or get formal training to maximize the potential of your shaper.

-20- G9862/G9968 Shaper

Figure 18A. Forward/reverse switch.

Reverse Switch

Your shaper is equipped with a FORWARD/REVERSE switch as shown in

Figure 18A. In many instances, it will be neces-

sary to flip the cutter over and reverse cutter rotation. Whenever possible, mount the cutter so the board is milled on the bottom side. This does a better job, and it is safer for the operator.

Always check the direction of cutter rotation before beginning any shaping operation.

NOTICE

This machine was designed to be started and stopped with the START/STOP buttons—not the reversing switch.

G9862/G9968 Shaper -21-

The fence assembly is a two-piece, independently adjustable system. When removing material from the whole face of your workpiece, the outfeed fence can be adjusted to provide support for the workpiece as it passes over the cutter, or it can be set in-line for partial face removal.

If removing material from the whole face, observe the following steps:

1. Loosen the locking handles shown in Figure 20 that hold the fences in place.

Straight Shaping

Figure 20. Location of fence locking handles.

Spindle Height

To adjust the cutter height:

1. Loosen the spindle lock knob shown in Figure 19.

2. Move the spindle up or down with the hand-

wheel until the desired position is obtained.

3. Lock the spindle into position.

Figure 19. Spindle height adjustment wheel and

spindle lock.

The lock knob keeps the spindle in a fixed position during shaper operation. Do not over-tighten the lock knob. A snug fit is all that is needed to keep the spindle from moving during shaper use.

NOTICE

2. Adjust the infeed fence by turning the adjust-

ment knobs (shown in Figure 20) until the

workpiece contacts the cutter in the desired location.

3. Lock the infeed fence in position with the

locking handle. Use a test piece to determine the best setting.

Read the entire manual before making any cuts with your shaper. Serious personal injury may result if safety or operational information is not understood or followed.

Spindle Lock

Fence Lock Handles

Adjustment Knob

-22- G9862/G9968 Shaper

4. Set the right and left cast iron fences to bare-

ly clear the cutter. This allows the maximum support possible. Remember to tighten down the fence before starting the shaper.

5. When removing the entire face of the work-

piece, a test sample of the desired cut should be advanced about 8'' then stopped.

6. Once the shaper is turned off and the cutter

has come to a complete stop, adjust the outfeed fence to support the new profiled edge

as shown in Figure 21.

Figure 21. Fence adjusted to support workpiece.

If the face of the workpiece will only be partially removed, observe the following steps:

1. Adjust the infeed fence to approximately the

desired depth of cut. Lock the infeed fence.

2. Use a straightedge to adjust the outfeed

fence to the same plane as the infeed fence. Lock the outfeed fence.

3. Set the right and left cast iron fence ends so

they barely clear the cutter. This allows the maximum support possible for the workpiece. Remember to tighten down the fence before starting the shaper.

4. Run a test piece through the shaper as shown in Figure 22.

Figure 22. Fence adjustment for blind cuts.

5. Always cut the end grain first (as shown in Figure 23) when putting an edge around the

perimeter of your workpiece.

Figure 23. Sequence for multiple cuts.

G9862/G9968 Shaper -23-

Figure 25. Rub collar installed above cutter.

Figure 26. Rub collar between two cutters.

3. Between two cutters: Using a rub collar

between two cutters, as in Figure 26, has

the distinct advantage of performing two cuts at once or eliminating the need to change cutters for two different operations. Notice that part of the edge is left uncut. The uncut portion rides on the rub collar.

2. Above the cutter (preferred method— safer): When the rub collar is used above

the cutter as seen in Figure 25, the cut can-

not be seen. This offers some advantage: the stock is not affected by slight variations in thickness and accidental lifting will not damage the workpiece. If lifting occurs, simply correct the mistake by repeating the operation.

Figure 24. Rub collar installed below cutter.

Rub Collars

Rub collars are used when shaping curved or irregular workpieces, such as arched doors or round table tops. Rub collars also limit the depth of your cut.

There are two types of rub collars—solid and ballbearing. We recommend against the use of solid rub collars. Grizzly carries an extensive line of ball bearing rub collars designed for use with Grizzly shapers. See the current catalog for listings.

It is possible to use the rub collars in any of the following positions:

1. Rub collar below the cutter: When the rub

collar is used below the cutter as shown in

Figure 24, the progress of the cut can be

observed. However, any unintentional movement may lift the workpiece into the cutter, damaging your work and possibly kicking the workpiece back toward you with great force. We do not recommend this position.

Whenever the cutterhead is above the workpiece, or you can see it spinning during use, you must take extreme caution to keep your hands away from the cutterhead. Failure to do so may cause serious personal injury.

-24- G9862/G9968 Shaper

Table Extension

The table extension can support stock 36" away from the spindle. To adjust the table extension:

1. Loosen the star knobs (shown in Figure 27)

located on the underside of both sides of the shaper.

Figure 27. Table extension knobs.

2. Slide the table extension to the desired width

of needed support.

3. Tighten the star knobs shown in Figure 27.

Pattern Work & Jigs

When using a pattern, the rub collar can be positioned either above, below or between cutters.

The pattern is usually used when the entire edge is to be shaped or when many duplicate pieces are needed. Pattern work is particularly useful when rough cutting irregular or oversize pieces and then shaping the edge in a simple two-step operation. A pattern can be incorporated into a jig by way of adding toggle clamps, hand holds or other safety devices.

You have greater flexibility when choosing the correct diameter rub collar for pattern work than

for non-pattern work. If you look at Figure 28, you

will notice that the position of the pattern determines the depth of cut. In other words, your pattern size is dependent upon the interrelationship of the cutting circle, the desired amount of material removed, and the rub collar size. Changing one or more of these will change the amount of material removed. Planning ahead, you can most effectively decide which rub collars are best suited for your application.

Figure 28. Rub collar determines depth of cut.

Pattern

Rub Collar

G9862/G9968 Shaper -25-

Workpieces must be solid, stable, and secured to the jig; or kickback may occur, causing personal injury.

When making a pattern jig here are a few things to consider:

1. Build your jig from a material that will

smoothly follow the rub collar or fence.

2. Make the jig stable, using proven methods

and materials, and fasten the hand holds for operator comfort and safety.

3. Secure your workpiece on the three sides

that will not be cut with toggle clamps, or fasten the workpiece to the jig with wood screws. Ensure that clamps and hidden screws do not come into contact with the cutter.

4. Design your jig so that all cutting occurs

underneath the workpiece as shown in

Figure 29. Notice the operator is not

exposed to the cutting edge of the cutter!

5. Always consider the cutting circle and rub

collar diameter for the correct cutting depth when designing your pattern.

6. Make sure the workpiece rests flat on the

table, not on the fixture.

Figure 29. Pattern jig for making curved pieces

(guard removed for clarity).

Irregular shaping takes a high degree of skill and dexterity. The fence assembly is not used during irregular shaping, so rub collars must be used. Also, unless your jig is designed to touch the rub collar before contacting the blade, a starting fixture must be used to begin your cut.

About starting fixtures:

The purpose of the starting fixture is to support the workpiece during the beginning of the cut. The workpiece is typically placed in the starting position using the starting fixture for support, Then swung into the cutter while holding the workpiece firmly against the starting fixture. After the cut has been started, the work is swung away from the starting fixture and is supported only by

the rub collar. Always feed against the rotation

of the cutter and do not start cuts at corners.

To use your pattern jig:

1. Remove the fence assembly. Choose the

appropriate cutter and rub collar for your application and lock them in place. Secure your workpiece to the pattern jig.

2. Check cutter rotation, and adjust the spindle

height to align the cutter to your workpiece. Clamp a starting fixture to the table surface, using the location that best supports your work.

3. If everything is correct and the cutter is tight.

Turn the shaper on.

4. Place your jig/workpiece against the starting

fixture. Using firm pressure, pivot the workpiece into the cutter and make sure the jig is touching the rub collar. Keep your jig in contact with the rub collar and slowly follow the pattern, moving against the cutter rotation.

Workpiece fits here

-26- G9862/G9968 Shaper

Shaper Accessories

There are many accessories that can be built or purchased to increase the safety of the operator. Many experienced shaper users regularly use proven shop-made fences and safety guards to augment their shaping operations. In addition, many production shops routinely use power feeders with their shapers to streamline their operations.

Here are some basic accessories and their uses:

• Zero Clearance Fence — A shop-made

fence with an opening only as large as the cutter, so that only the part of the cutter being used is exposed.

• Box Fence — A shop-made box that com-

pletely surrounds the cutter. A one-piece fence is attached that allows only the thickness of the board to pass underneath, thereby completely shielding the operator from exposure to the spinning cutter. A clear plexiglass window on top of the box allows the operator to view the workpiece during cutting.

• Power Feeder — A motorized unit that can

be clamped or permanently mounted to the table of a shaper. A power feeder pulls the workpiece through the cut, reducing the risk of operator contact with the spinning cutter and reducing any injuries due to kickback. Because of the steady feed rate, power feeders can also produce cleaner, more consistent cuts. We highly recommend using a power feeder with your shaper! Check the current Grizzly catalog for available power feeders.

Because of the wide range of fences and guards that can be built in the shop, explaining their construction is beyond the scope of this manual. We strongly recommend that you read shaper books magazines, or get formal training to learn more about these.

Freehand Shaping

Freehand methods are one of the most dangerous operations performed on a shaper.

Although this machine is capable of performing freehand operations, we do not recommend that you attempt to do so. If you MUST perform freehand operations, get formal training and read a book that details freehand operations, their inherent dangers, and ways to avoid those dangers!

G9862/G9968 Shaper -27-

Regular periodic maintenance on your Model G9862/G9968 Shaper ensures its optimum performance. Make a habit of inspecting your shaper each time you use it.

Check for the following conditions and repair or replace when necessary.

• Loose mounting bolts.

• Worn switch.

• Worn or damaged cords and plugs.

• Damaged V-belt.

• Any other condition that could hamper the

safe operation of this machine.

SECTION 7: MAINTENANCE

V-Belt

Avoid getting grease or oil on the V-belts or pulleys. Check the V-belts, as part of a monthly inspection for proper tension and belt condition. Cracking and glazing could result in belt failure. Replace the belt if such conditions appear.

General

Lubrication

The only parts on this machine that require periodic lubrication are the ways where the cartridge slide rides on the elevation housing and where the worm gears and bushings are located. Use a light grease or anti-seizing compound on the ways and worm gear, and give the shaft mount a shot of light oil.

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

Table

The table and other non-painted surfaces on the Model G9862/G9968 should be protected against rust and pitting. Wiping the table clean after every use ensures that wood dust isn’t allowed to trap moisture against bare metal surfaces.

Tables can be kept rust-free with regular applications of products like Boeshield

T-9. For long term storage you may want to consider products like Kleen Bore's Rust Guardit™.

Schedule

Regularly blow out cabinet with compressed air

(always wear a dust mask when doing this) and keep dust port clear.

For every 8 hours of use, clean and spray an

application of Boeshield

T-9:

• Table

• Fence faces

For every 24 hours of use, clean and oil:

• Spindle columns and cartridges

• Offset adjustment mechanisms on fence

• All worm drive and other gears

Once a year, replace the V-belt.

-28- G9862/G9968 Shaper

Maintenance Performed

Approximate Hours Of Use

Maintenance Notes

Date

G9862/G9968 Shaper -29-

-30- G9862/G9968 Shaper

G9862/G9968 Shaper -31-

SECTION 8: CLOSURE

The following pages contain general machine data, parts diagrams/lists, troubleshooting guide and Warranty/Return information for your Model G9862/G9968 Shaper.

If you need parts or help in assembling your machine, or if you need operational information, we encourage you to call our Service Department. Our trained service technicians will be glad to help you.

If you have comments dealing specifically with this manual, please write to our Bellingham, Washington location using the address in the

General Information section. The specifications,

drawings, and photographs illustrated in this manual represent the Model G9862/G9968 as supplied when the manual was prepared. However, due 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, add the new information to this manual and keep it for reference.

We have included some important safety measures that are essential to this machine’s operation. While most safety measures are generally universal, Grizzly reminds you that each workshop is different and safety rules should be considered as they apply to your specific situation.

We recommend you keep a copy of our current catalog for complete information regarding Grizzly's warranty and return policy. If you need additional technical information relating to this machine, or if you need general assistance or replacement parts, please contact the Service

Department listed in the Introduction section.

Additional information sources are necessary to realize the full potential of this machine. Trade journals, woodworking magazines and your local library are good places to start.

Like all power tools, there is danger associated with the Model G9862/G9968 Shaper. 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.

The Model G9862/G9968 was specifically designed for wood shaping operations only. DO NOT MODIFY AND/OR USE THIS MACHINE FOR ANY OTHER PURPOSE. Modifications or improper use of this tool will void the warranty. If you are confused about any aspect of this machine, DO NOT use it until all your questions have been answered, or serious personal injury may occur.

Operating this equipment has the potential for flying debris to cause eye injury. Always wear safety glasses or goggles when operating equipment. Everyday glasses or reading glasses only have impact resistant lenses, they are not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American National Standards Institute (ANSI).

-32- G9862/G9968 Shaper

Design Type...................................................................................................... Floor Model

Overall Dimensions:

Working Table Size (Each Side) ..............................................................44

⁄8

" x 33

⁄4

Height (Includes Fence) ..........................................................................................45"

Height From Table To Floor ....................................................................................33"

Overall Width ........................................................................................................44

⁄

Overall Depth ........................................................................................................35

⁄4"

Weight (Shipping)............................................................................................1500 lbs.

Weight (In Place) ............................................................................................1165 lbs.

Crate Size ....................................................................................50"W x 40"D x 43" H

Footprint ................................................................35

⁄8" Max Width x 29" Max Depth

Capacities:

Spindle Sizes ..........................................................................................................1

⁄4"

Spindle Travel ............................................................................................................5"

Exposed Spindle Length ............................................................................................6"

Spindle Openings ................................................................................4

⁄4", 8" and 13"

Spindle Capacity Under Nut ....................................................................................5

⁄

Table Counterbore....................................................................................................13"

Max. Cutter Diameter ..............................................................................................8

⁄2"

Spindle Speeds..............................................................5,500, 7,500 & 10,000 R.P.M.

Spindle Bearings..................................................Shielded & Lubricated Ball Bearings

Dust Port ....................................................................................................................5"

Construction:

Table ..................................................................................Precision Ground Cast Iron

Fence Assembly ..............................................................................Polished Cast Iron

Base................................................................................Heavy-Duty Pre-formed Steel

Motor:

Type ............................................................................TEFC Capacitor-Start Induction

Horsepower..........................................................................................................5 H.P.

Phase ⁄ Voltage ............................................................................Single-Phase ⁄ 220 V

Amps..........................................................................................................................28

Cycle ⁄ R.P.M.............................................................................60 Hertz ⁄ 3450 R.P.M.

Bearings..............................................................Shielded & Lubricated Ball Bearings

Switch ..........................................................Magnetic w/ Thermal Overload Protector

Features:

...................................................................................2 Spring Hold-Down Assemblies

....................................Quick Release Levers and Knob-Equipped Fence Adjustment

...............................................................................................................2 Table Inserts

...............................................................................Spindles Include Spacers and Nuts

.....................................................................................................Vertical Spindle Lock

.................................................................................................................Spindle Brake

...................................................................................................................Miter Gauge

..........................................................................................Includes Service Wrenches

Specifications, while deemed accurate, are not guaranteed.

Customer Service #: (570) 546-9663 • To Order Call: (800) 523-4777 • Fax #: (800) 438-5901

GRIZZLY MODEL G9862 5 H.P. SHAPER

MACHINE DATA

SHEET

G9862/G9968 Shaper -33-

Design Type...................................................................................................... Floor Model

Overall Dimensions:

Working Table Size (Each Side) ..............................................................91

⁄4

" x 33

⁄4

Height (Includes Fence) ..........................................................................................45"

Height From Table To Floor ....................................................................................33"

Overall Width ........................................................................................................91

⁄

Overall Depth............................................................................................................40"

Weight (Shipping)............................................................................................2000 lbs.

Weight (In Place) ............................................................................................1540 lbs.

Crate Size ....................................................................................93"W x 42"D x 44" H

Footprint ................................................................................35

⁄8" Width x 29" Depth

Capacities:

Spindle Sizes ..........................................................................................................1

⁄4"

Spindle Travel ............................................................................................................5"

Exposed Spindle Length ............................................................................................6"

Spindle Openings ................................................................................4

⁄4", 8" and 13"

Spindle Capacity Under Nut ....................................................................................5

⁄

Table Counterbore....................................................................................................13"

Max. Cutter Diameter ..............................................................................................8

⁄2"

Spindle Speeds..............................................................5,500, 7,500 & 10,000 R.P.M.

Spindle Bearings..................................................Shielded & Lubricated Ball Bearings

Dust Port ....................................................................................................................5"

Construction:

Table ..................................................................................Precision Ground Cast Iron

Fence Assembly ..............................................................................Polished Cast Iron

Base................................................................................Heavy-Duty Pre-formed Steel

Motor:

Type ............................................................................TEFC Capacitor-Start Induction

Horsepower......................................................................................................7

⁄2"H.P.

Phase ⁄ Voltage ......................................................................Three-Phase, 220/440 V

Amps ....................................................................................................................20/10