EQUIPMENT & TOOLS OPERATOR'S MANUAL Installation ¦ Operation ¦ Maintenance - Parts SINGLE SPINDLE SHAPER JWS-34L JET EQUIPMENT & TOOLS, INC. A WMH - Walter Meier Holding Company P.O. BOX 1349 Auburn, WA 98071-1349 253-351-6000 Fax 253-939-8001 No. M-708502 11/93 Important Information 1 YEAR LIMITED WARRANTY JET offers a one year limited warranty on this product REPLACEMENT PARTS Replacement parts for this tool are available directly form JET Equipment & Tools. To place an order, call 1-800-274-6848. Please have the following information ready: 1. Visa, MasterCard, or Discover Card number 2. Expiration date 3. Part number listed within this manual 4. Shipping address other than a Post Office box. REPLACEMENT PART WARRANTY JET Equipment & Tools makes every effort to assure that parts meet high quality and durability standards and warrants to the original retail consumer/purchaser of our parts that each such part(s) to be free from defects in materials and workmanship for a period of thirty (30) days from the date of purchase. PROOF OF PURCHASE Please retain your dated sales receipt as proof of purchase to validate the warranty period. LIMITED TOOL AND EQUIPMENT WARRANTY JET makes every effort to assure that its products meet high quality and durability standards and warrants to the original retail consumer/purchaser of our products that each product be free from defects in materials and workmanship as follows: 1 YEAR LIMITED WARRANTY ON THIS JET PRODUCT. Warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities or to a lack of maintenance. JET LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD SPECIFIED ABOVE FROM THE DATE THE PRODUCT WAS PURCHASED AT RETAIL. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR MECHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. JET SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERY OR FOR INCIDENTAL, CONTINGENT, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. To take advantage of this warranty, the product or part must be returned for examination, postage prepaid, to an authorized service station designated by our Auburn office. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection discloses a defect, JET will either repair or replace the product or refund the purchase price, if we cannot readily and quickly provide a repair or replacement, if you are willing to accept such refund. JET will return repaired product or replacement at JET's expense, but if it is determined there is no defect, or that the defect resulted from causes not within the scope of JET's warranty, then the user must bear the cost of storing and returning the product. This warranty gives you specific legal rights, and you have other rights which vary from state to state. JET Equipment & Tools P.O. Box 1349, Auburn, WA 98071-1349 (253)351-6000 TABLE OF CONTENTS Warranty 2 Table of Contents 3 Specifications 4 General Dimensions 4 Shaper Features 5 Warnings 6 Additional Warnings for Wood Shapers 7 Preinstallation Cleaning and Checking 8 Installation and Leveling 8 Electrical Installation 9 Electrical Controls 9 Adjusting and Operating Shaper 10 Lubrication Guide 16 Troubleshooting 17-18 Electrical Schematic 19 Spindle Assembly Parts List 20 Fence Assembly Parts List 22 Base Assembly Parts List 24 AWARNING: Failure to properly install, operate, and maintain this equipment may subject you, the operator, and those around you to serious personal injury and/or property damage. All personnel who will install, use, or maintain this equipment should read this manual. Follow all instructions and recommendations contained herein. RECORD YOUR PURCHASE AND INSTALLATION INFORMATION HERE: Purchased From: Date: Serial Number: Model No: Stock Number: Installed at: Installer: Date Installed: Date in Service: SPECIFICATIONS Model number JWS-34L Stock Number 708502 Arbor Capacity (Under Nut) 3-3/16" Spindle Speeds 8,000 RPM & 10,000 RPM Spindle Travel 2-7/8" Spindle Size 3/4" & 1" Router Bit Size 1/4" & 1/2" Table Size 21-5/8" x 25" Table Height 32-3/4" Table T-Slot 3/4" Table Opening 6-3/16" Inserts Opening 3-1/4", 1-13/16" Fence Size (each side) 11-1/4" x 2-7/8" Dust Chute 4" Motor 2HP (1.5KW) single phase 230V only Shipping Weight (Approx.) 351 lbs. Net Weight (Approx.) 317 lbs. GENERAL DIMENSIONS 21-5/8" 32-3/4" 1/2" Shaper Features Pressure Guides Holddown Guides Safety Guard Dust Chute Fence Worktable Miter Gauge Control Switch Spindle Height Handwheel Reverse Switch Base Spindle Lock Spindle Clamp AWARNING! Installation, operation, and maintenance of your wood shaper must be done in accordance with all Codes and Acts for your personal safety. The machine should be installed by trained and experienced equipment installers. Keep the floor area around the machine clean and free of chips, liquids, stock material or anything else that may prevent the operator from using the machine safely. Disconnect machine from electrical power before performing any maintenance. Check that the power switch is in the OFF position before connecting machine to power. Give your work your full attention. Horseplay, looking around, and carrying on a conversation while using the machine are careless acts that can result in serious injury. Keep this manual and all maintenance records handy for operators and maintenance technicians. Know your power tool. Read this manual carefully. Learn the tool's applications and limitations as well as the potential hazards to using it. Remove adjusting keys and wrenches after making adjustments. Avoid working in a dangerous environment. Don't use power tools in damp or wet locations or expose them to rain. Work only in a well lighted area. Keep children and visitors a safe distance from the machine while it is running or when adjustments are being made. All children and visitors should be kept under close observation while in the work area. Don't force tool. It will do the job better and safer at the rate for which it was designed. Wear proper apparel. Do not wear loose clothing, gloves, neckties, or jewelry as they may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair. Use safety glasses. Also use face or dust masks if cutting operation is dusty. Eyeglasses only have impact resistant lenses, they are not safety glasses. Secure work. Use clamps to hold work when practical. It's safer than using your hands and frees both hands to operate tool or hold the work piece. Use a pushstick to feed work piece whenever possible or when feeding smaller work pieces that do not allow a reasonable clearance between cutterhead and hands. Don't overreach. Always keep proper footing and balance. Feed work into a cutter or bit against the direction of rotation of the cutter or bit only. Replace all obscured or missing warning labels. Keep guards in place and in working order. Stop machine to remove chips and scrap. Disconnect tools before servicing and when changing accessories such as cutters, arbors, and adapters. Maintain tools in top condition. Keep bits sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. Don't operate tool while under the influence of drugs, alcohol, medication or fatigued. Never leave a tool running unattended. Turn power off and don't leave tool until it comes to a complete stop. Check for alignment and binding of moving parts, broken or missing parts, and any other conditions that may affect operation. Check for damaged parts. A guard or other part that is damaged should be carefully checked to ensure that it will operate properly and perform its intended function. Never stand on the tool. Serious injuries could occur if the tool is tipped or the cutting bit is accidentally contacted. Use recommended accessories. Consult the manual for recommended accessories. The improper accessories may expose operator to risk of injury. Additional Warnings for Wood Shapers Workpiece Never run stock between the fence and cutter head. The fence should be adjusted so the opening is never more than is required to clear the cutter. Always use a miter gage and clamp attachment when edge shaping work less than 6" wide. Be sure the special arbor nut and the draw bar are tightened. Check that the keyed collar and washer are directly under the arbor hex socket head screw and arbor screw is tight. Release the main spindle from the locking mandrel lever before starting machine. Always feed stock against cutter rotation as shown in figure 1. Figure 3 illustrates the wrong way for this operation as the collar does not have sufficient bearing surface. Collar Cutter Figure Wrong! Short, light work with poor bearing surface as shown in figure 4 is extremely dangerous and should never be attempted. Workpiece Cutter Rotation Workpiece Wrong! Figure Feed Figure 1. When shaping with collars and starting pin, the workpiece must have sufficient bearing surface and be fairly heavy in proportion to the cut being made as shown in figure 2. When shaping with collars and starting pin, the cutter should be positioned below the collar whenever possible, as shown in figure 5. Workpiece Bearing Surface Collar Cutter Workpiece Right! Figure Right! Figure 2. Preinstallation Cleaning and Checking For maximum performance and safety from your spindle shaper, clean and check it carefully before installation. Inspect the packing crate for physical or water damage. Immediately contact the shipper if any damage is noted. After opening the packaging, check that all parts are present and undamaged. Check the specification plate on the shaper to confirm the correct model shaper has been shipped to you. Check that all shipping packaging is removed from the shaper, particularly in and around all moving parts. Remove all tape, wire, tags, and any other foreign materials. Clean shaper using products suitable for removing protective coatings. Do not use solvents on plastic parts or electrical cord or damage may result. Before lifting machine, remove all foot bolts locking it to the shipping base. Transport the machine to the installation site using a hand truck or dolly suitable for the weight. Contents of Shipping Container Qty. Description 1 Shaper 1 Fence Assy including Cutter Guard (mounted) 1 Miter Gauge (mounted) 1 3/4" Spindle Assembly (mounted) 1 Work Hold Down Assy (mounted) 1 Dust chute (shipped inside base) Contents of Accessory Package Qty. Description 1 8mm-1 Omm Combination Wrench 2 12mm-14mm Combination Wrench 1 17mm-19mm Combination Wrench 1 Wheel Handle 2 3/16" x 1/2" Pan Head Machine Screws 2 3/16" Washers 1 Spindle Wrench 1 1" Spindle Assembly 1 1/4" Collet 1 1/2" Collet 1 Collet Nut 1 Starting Pin 1 3mm Hex Wrench 1 5mm Hex Wrench 1 6mm Hex Wrench 1 8mm Hex Wrench 1 Can Touch-up Paint 1 Operator's Manual Installation and Leveling The spindle shaper comes assembled except for an interchangeable arbor, work hold-down guides, handle and fixing rod on the fence assembly. Select a well illuminated installation site with a solid, level surface with plenty of room to maneuver the workpiece. Level machine in both directions using metal shims, if needed. Check that all four corners are properly supported. If machine is not to be bolted to the floor, make sure it rests solidly after leveling. Electrical Installation All wiring must conform to state and local codes. Check the voltage specification located on the motor, specification plate or tagged to the power cord. Connecting the shaper to the improper voltage may expose installation personnel and operators to a serious electrical hazard and damage the electrical components. Low voltage will damage the motor. The machine is shipped with a 3-wire power cord that must be terminated by the installer. The green wire is the ground wire. Connect the shaper to a grounded, metal-enclosed wiring system or an equipment-grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the spindle shaper. The final electrical connections must be checked by a trained, experienced electrician. Double-check that the machine is properly grounded. Electrical Controls The spindle shaper is equipped with a pushbutton control system and reversing switch. The green start and red stop pushbuttons mounted in a control enclosure on the front of the machine (A in fig. 6). ACaution Release the main spindle from the locking mandrel lever before starting machine. To reverse the rotation of the spindle, simply shut off the motor, wait until it comes to a complete stop, and rotate the reversing switch (B in fig 6). ACaution Do not operate the reverse switch while the motor is running. Wait until the spindle comes to a complete stop before rotating the reversing switch. Note: The red stop button on the pushbutton control system (A in figure 6) also acts as an overload reset button. If overload should trip, reset by depressing red stop button. Figure 6 Electrical Controls Adjusting and Operating Shaper Changing Cutter Speed Your shaper is equipped with pulleys (A in fig. 7) that allow you to change the spindle speed. The upper pulley provides a 8,000 RPM spindle speed and the lower pulley provides a 10,000 spindle speed. 1. Disconnect and lock out the machine from the power source. 2. Open the door on the cabinet and identify the major components. 3. Loosen the two motor bracket bolts and nuts (D in fig. 7). 4. Turn the tensioning knob (C in fig. 7) counterclockwise to release the belt tension (B in fig. 7). Move the belt to the other groove. 5. Turn the tensioning knob clockwise to adjust tension. Adjust tension until light finger pressure deflects belt 1/4" midway between the pulleys. 6. Tighten the two motor bracket bolts and nuts. Figure Arbor Installation and Removal The arbor is mounted to the main spindle with a draw bar and nut. Use the following procedure to install the arbor. Reverse the order to remove the arbor. 1. Disconnect and lock out the machine from the power source. 2. Use the spindle locking mandrel (A in figure 8) to lock spindle in place by following instructions on label next to mandrel. 3. Select the proper size arbor (3/4" or 1" - B in figure 9) and install the special nut (C in figure 9) by slipping nut over tapered end of arbor and threading the arbor until hand tight. Figure 10 Figure 4. Clean the arbor shank and bore of the main spindle (A in figure 10). 5. Place arbor onto the main spindle and thread the arbor nut on the shaft. Tighten the nut using the supplied spanner wrench (A in figure 11). 6. Place the draw bar (A in figure 12) into the bottom of the main spindle and tighten the nut with spanner wrench. 7. Pull the spindle lock knob out and turn to release the main spindle. 8. Check all around in the cabinet for tools, rags, and parts. Close and latch cabinet door. 9. Reconnect machine to power source. 10. Start shaper cautiously. Listen for unusual noises and look for abnormal operation. Figure 10 Collet Installation 1. Disconnect the machine from the power source. 2. To set the shaper up for use with collets (1/4" or 1/2", remove arbor, and clean spindle taper. 3. Install adapter in spindle opening by pushing tapered end into spindle followed by the collet and special nut. Note: special nut upper internal opening is tapered to mate with upper tapered surface of collet. 4. Refer to page 20, figure 34 for assembly sequence. Figure 11 Figure 12 11 Shaper Cutter Installation Use the following procedure to install the shaper cutter. Reverse the order to remove the cutter. 1. Disconnect the machine from the power source. 2. Use the locking mandrel lever (A in figure 8) to tightly lock the main spindle (A in figure 9). 3. Place the cutter (A in figure 13) onto the arbor oriented for the proper rotation. 4. Place the spacer (B in figure 13) and keyed collar (C in figure 13) onto the arbor. 5. Place the washer (D in figure 13) and Arbor screw (E in figure 13) onto the arbor. 6. Tighten the arbor screw (E in figure 13) securely. 7. Pull the spindle lock knob (A in figure 8) and turn to release the main spindle. 8. Check all around for tools, rags, and parts. 9. Reconnect machine to power source. Figure 13 Spindle Vertical Travel Adjustment Spindle height is adjustable to set proper cutter height. To change the spindle height, loosen the clamping lever (A in figure 14) and turn the handwheel (B in figure 14) to raise or lower the spindle. Tighten the clamping lever after the spindle is at the desired height. Table Inserts Two table inserts (A in figure 15) are included for use with your shaper. The two inserts have openings 3-1/4" and 1-13/16". The smaller insert also has a guide shoulder 2-15/16" diameter for shaping without using a collar. 12 Figure 14 Figure 15 Assembling and Installing Shaper Fence Assemble the shaper fence as shown in figure 16. Place the assembled fence in position on the table and attach using the two rods and washers. Adjusting the Fence Have a scrap workpiece available to allow proper positioning of the fence and holddown guides. Adjust both fence ends to support your work piece before and after passing the cutter. To move a fence end, loosen the locking lever (A in fig. 17) and turn the adjuster knob (B in fig. 17) to move the fence to the desired position. Tighten the locking lever to lock the fence in position. Adjust both fence ends as close to the cutter as possible. To move a fence end, loosen the hex head cap screw (A in fig. 18), slide the fence into position and retighten the cap screw. Additional adjustment can be obtained by moving the cap screw to the other bolt hole in the fence plate. Adjusting the Work Hold-Down Guides Loosen the hex head cap screws (C in fig. 17), turn the spring plate (D in fig. 17) to the desired angle and retighten the cap screws. Loosen the locking lever (E in fig. 17) and adjust the jack stay to put moderate pressure on the workpiece and retighten the locking lever. Loosen the locking knob (F in fig. 17), slide the spring guide plates (G in fig. 17) in to increase pressure on the workpiece and retighten the locking knob. Figure 16 Figure 17 Figure 18 13 Operation Use the following as a guide to using the shaper fence, collars and starting pin. Using the Fence Using the fence when shaping is the safest and most satisfactory method of working. Almost all straight work can be used with the fence. 1. For average work, where a portion of the original edge of the work is not touched by the cutter, both the front and rear fences are in a straight line as shown in figure 19. 2. When the shaping operation removes the entire edge of the work, the shaped edge will not be supported by the rear fence if both fences are in line. This is common when joining or making a full bead. See figure 20. Using scrap, advance the work past the cutter. Turn power off and adjust the rear fence until the shaped portion of the work is supported as shown in figure 21. Remove the work piece, start motor, and feed work piece through cutter head. Awarning Always remove work piece before starting machine. Failure to comply may cause work piece to be kicked back which may cause serious injury. Shaping with Collars and Starting Pin When shaping with collars and starting pin, the following rules must always be followed for good work and safety in operation: 1. The stock must be fairly heavy in proportion to the cut being made as shown in figure 22. Short, light stock, as shown in figure 23, should not be shaped using collars. 2. A portion of the edge must remain untouched by the cutter head in order that the collar will have sufficient bearing surface. 3. The bearing surface on the collar must be adequate to support the workpiece. Figure 24 shows an edge too thin to properly support the workpiece. 4. The edge of the work to be shaped must be smooth as any irregularity on the surface which rides against the collar will be duplicated on the molded surface. 5. Collars must be smooth and free from pitch or other substances. Collar Cutter Right! Collar Cutter Wrong! Collar Wrong! Cutter Workpiece Figure 19 Cutter . Workpiece Figure 20 Cutter Workpiece Figure 21 lece JWorkpi Figure 22 Workpiece Figure 23 Workpiece Figure 24 14