0 IN 1 METAL & WOODWORKING MACHINE Model 96067 Assembly AND OPERATING Instructions Due to continuing improvements, actual product may differ slightly from the product described herein. ® 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our website at: http://www.harborfreight.com To prevent serious injury, read and understand all warnings and instructions before use. Copyright© 2007 by Harbor Freight Tools®. All rights reserved.
Contents Specifications.............................................................................4 GENERAL SAFETY RULES.............................................................5 Work Area....................................................................................................5 Personal Safety........................................................................................5 Tool Use And Care....................................................................................6 Service.
Contents (continued) TO ADJUST THE SAW TABLE’S 45 DEGREE STOP....................................35 TO ALIGN THE MITER GAUGE......................................................................35 TO ALIGN THE EXTENSION TABLE 90 DEGREES TO THE SAW BLADE..35 TO SET THE CARRIAGE BUMPER BOLT.....................................................36 TO ALIGN THE SAW TABLE 90 DEGREES TO THE POWERHEAD............36 TO ALIGN THE LATHE TAILSTOCK WITH THE POWERHEAD...................37 Parts Lists and Diagrams........
Specifications 120 VAC / 7.5 A / Single Phase/15 Amps at full load 1.5 HP Motor Power Cord Type: 14 AWG x 3 C / 8’ Long Power Switch Type: 2-Position Key Switch Table Saw / Disc Sander / Boring Machine Lathe / Drill Press / Router & Shaper / Mill Machine Sanding Disc Assy. (Qty. 1) / Drill Press Insert (Qty. 1) / Router (Qty. 1) Air Breather Mask (Qty. 1) Earplug Set (Qty. 1) / R8 Collet (Qty. 1) Drawbar Handle (Qty. 1) / Wood Turning Faceplate (Qty. 1) / Dead Center (Qty. 1) Center Cup (Qty.
Save This Manual You will need this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Write the product’s serial number in the back of the manual near the assembly diagram, or write month and year of purchase if product has no number. Keep this manual and invoice in a safe and dry place for future reference.
4. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the power tool in unexpected situations. 5. Use safety equipment. Always wear ANSI-approved safety impact goggles when using this product. Dust mask or respirator, nonskid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.
2. When servicing a tool, use only identical replacement parts. Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of injury. SPECIFIC SAFETY RULES 1. Maintain labels and nameplates on the Metal/Woodworking Machine. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 2.
2. Do not alter or adjust any part of the Metal/Woodworking Machine or its internal mechanisms that are assembled and supplied by the manufacturer or distributor. 3. Always follow and complete scheduled maintenance. NOISE PRECAUTION Prolonged exposure to high noise levels is hazardous to hearing. Always wear ANSI-approved hearing protection when operating or working around the Metal/ Woodworking Machine when it is running. TABLE SAW SAFETY RULES 1. Avoid unintentional starting.
balanced, and is not cracked or bent. 9. Never attempt to cut more than one workpiece at a time. 10. Never attempt to cut freehand. Make sure the workpiece to be cut is pressed firmly against the Table. 11. When cutting a large workpiece, make sure its entire length is properly supported. If necessary, use a roller stand (not included). 12. Always feed the workpiece against the rotation of the Saw Blade. 13. Allow the Saw Blade to spin up to full speed before feeding it into a workpiece.
to a pinched, bound, or misaligned Saw Blade, causing an uncontrolled woodstock to lift up and out from the Table Saw toward the operator. When the Saw Blade is pinched or bound tightly by the kerf closing down, the Saw Blade stalls and the motor reaction drives the woodstock rapidly back toward the op- erator. If the Saw Blade becomes twisted or misaligned in the cut, the teeth at the back edge of the Saw Blade can raise the woodstock (walk up), and eject it toward the operator.
24. Check all guards for proper operation before each use. Never disable guards. Do not operate the Table Saw if the guard assembly does not move freely and close instantly. Before each use, raise the guard assembly and make sure it moves freely and does not touch the Saw Blade or any other part, in all angles and depths of cut. 25. Never perform layout, assembly, or setup work on the Table of the Table Saw when the machine is running. 26.
9. When drilling a large workpiece, make sure its entire length is properly supported. If necessary, use a roller stand (not included). 10. Keep all guards in place, in proper adjustment, and in proper alignment. 11. Do not use rotary planers, wire wheels, or router bits on the Drill Press. 12. Always feed the workpiece into and against the rotational direction of a bit or cutter. 13. When drilling softer materials or small holes, use the higher speed settings.
5. Allow the workpiece to turn up to full speed before feeding a tool bit (not included) into the workpiece. When turning off the Lathe, allow the workpiece to slow down and stop on its own. Do not press against the workpiece to stop it. 6. Feed the tool bit into the workpiece gradually. Do not force a tool bit to re- move material faster than it is designed to cut. 7. Never attempt to remove material stuck in the moving parts of the Lathe while it is plugged in and/or running.
HORIZONTAL BORING SAFETY RULES 1. Avoid unintentional starting. Make sure you are prepared to begin work before turning on the Router/Shaper. 2. Never leave the Router/Shaper unattended when it is running. Turn off the Router/Shaper before leaving the work area. 3. Always place scrap wood behind the workpiece to prevent damage to the drill bit and to avoid splintering. 4. Always firmly support and guide the wood before and during drilling. 5. Use only the speeds listed in the Speed Chart. 6.
8. Feed the workpiece into the Sanding Disc gradually and into the direction of rotation. Do not attempt to force the Disc Sander to remove material faster than it is designed to cut. 9. When replacing the Sanding Disc, make sure the Disc has a minimum 900 RPM rating, and has a 12” diameter. 10. When sanding a large workpiece, make sure its entire length is properly supported. 11. Never attempt to remove material stuck into the moving parts of the Disc Sander when it is plugged in and running.
Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. Extension Cords 1. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage. (See Figure B, next page.) 2. The smaller the gauge number of the wire, the greater the capacity of the cord.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* NAMEPLATE AMPERES EXTENSION CORD LENGTH (at full load) 25 Feet 50 Feet 75 Feet 100 Feet 150 Feet 0 – 2.0 18 18 18 18 16 2.1 – 3.4 18 18 18 16 14 3.5 – 5.0 18 18 16 14 12 5.1 – 7.0 18 16 14 12 12 7.1 – 12.0 18 14 12 10 - 12.1 – 16.0 14 12 10 - - 16.1 – 20.0 12 10 - - - FIGURE B * Based on limiting the line voltage drop to five volts at 150% of the rated amperes.
SKU 96067 CASTER FOOTWHEEL POWERHEAD (LEFT-HAND) SUPPORT BRACKET HANDLE TWIST CLAMP EXTENSION TABLE WAY TUBE LOCK POWER TAKE-OFF COLLET DRAWROD PORT FIGURE D PULLEY BELT LOCK LEVER KEY PULLEY COVER For technical questions, please call 1-800-444-3353.
THE POWER KEY The Power Key is used to turn the Metal/Woodworking Machine on and off. Always keep the Power Key out of reach of children and other unauthorized people. Before turning the Key to its “ON” position, make sure the Variable Speed Control Dial is set at its lowest setting. (See page 16 and 17.) TO MOVE THE POWERHEAD To slide the Powerhead on the way tubes loosen the two Lock Knobs. Then crank the Travel Hand Wheel. The Powerhead and Carriage travel on Way Tubes.
TO MOUNT COLLETS WITH THE DRAWBAR The Drawbar/R-8 Collet combination is used with all of the tools of the Metal/ Woodworking Machine. To attach R-8 Collets, pass the Drawbar through the Spindle from the left. Align the keyway in the exterior of the Collet with the Key in the Spindle and slide the R-8 Collet into the Spindle from the right. Insert the Drawbar into the left end of the Spindle in the place market “Drawbar.
ASSEMBLY INSTRUCTIONS TO ATTACH THE SHELF TO THE STAND NOTE: Always wear ANSI approved safety goggles and work gloves during assembly. NOTE: The assembly procedures will require the help of additional manpower and a proper lifting device. 1. Set the Stand upside-down on a dry, flat, level floor surface. (See Figure E.) 2. Slide the Shelf between the Stand Legs, making sure the holes in the middle of the Shelf face the rear of the Stand. (The slot in each Stand end is located toward the front.
FIGURE F Foot Wheel (109) TO MOUNT THE MACHINE ONTO THE STAND 1. Attach the Support Bracket to the Stand, using four Hex Head Bolts, four Spring Lock Washers, and four Hex Nuts. (See Figure D and Assy. Diagrams, pages 37, 39.) 2. Step on the Footwheels to lower the Casters. Then move the Stand parallel to the Machine. Step on the Footwheels twice more to raise the Casters to keep the Stand from moving. (See Figure G and Assy. Diagrams, pages 37, 39.) 3.
TO ASSEMBLE THE LATHE TOO REST Insert the Tool Rest Post into the Arm. Then tighten the Socket Setscrew using an Allen Wrench (not included). (See Figure H and Assy. Diagrams, pages 44, 55.) FIGURE H TO ATTACH A SAW BLADE TO THE ARBOR 1. Insert the 3/4” Collet into the Spindle. Rotate the Collet until you feel its Keyway slot engages the Spindle Key. (See Figure I, next page and Assy. Diagram, page 42.) 2.
FIGURE I TO INSTALL THE LOWER BLADE GUARD 1. Position the opening of the Lower Blade Guard under the Saw Blade. (See Figure J and Assy. Diagram, page 48.) 2. Secure the Lower Blade Guard in place, using the T-Bolt and Wing Nut. (See Figure J and Assy. Diagram, page 48.) FIGURE J SKU 96067 For technical questions, please call 1-800-444-3353.
TO ASSEMBLE THE MAIN TABLE 1. Set the Table upside down with the Trunnion and its degree scale toward you. (See Figure K and Assy. Diagram, page 46.) 2. Install the second Trunnion Lock and Washers from the provided Accessory Pack. (See Figure K and Assy. Diagram, page 46.) 3. Loosen the Table Setscrews and insert the Legs into the Saw Table with the rack teeth facing left. (See Figure K and Assy. Diagram, page 46.) 4. Finger-tighten the Setscrews.
5. Insert the assembled Table into the Carriage. (See Figure K and Assy. Diagram, page 46.) 6. Hold the Table Lock Lever up and rotate the Table height Adjustment Hand Wheel counterclockwise to position the Table. Then lock the Table at the desired height by pushing the Table Lock Lever down. NOTE: Always use the Table Lock Lever to secure the Table. (See Figure K and Assy. Diagram, page 46.) 7. Firmly tighten the Setscrews. (See Figure K and Assy. Diagram, page 46.
TO INSTALL THE RIP FENCE AND TOP GUARD 1. Slide the Rip Fence onto the front and back Tubular Guides, and align the Rip Fence with the edge of a table slot. Then tighten the front Lock. (See Figure M and Assy. Diagram, page 50.) 2. Align the mounting hole at the rear of the Top Guard with the threaded mounting hole at the rear of the Table. Then tighten the Handle to secure the Top Guard in place. (See Figure M and Assy. Diagram, page 50.
TO INSTALL THE DISC SANDER 1. Insert the Sanding Disc Arbor into the Collet, and insert the Collet into the Quill. Then tighten the Drawrod. Move the saw Table to about 1/16” from the sanding surface. Adjust the height of the Table to about 1” below the centerline of the Disc Sander. (See Figure O and Assy. Diagram, page 53.) 2. NOTE: If your workpiece requires beveled sanding, tilt the Table to the desired angle.
Knobs. Failure to do so could cause the Powerhead and/or Carriage to drop down along the Way Tubes, causing possible personal injury and/or damage to the machine. 5. Mount the Drill Chuck by inserting it into the 3/4” Collet. Then tighten the Drawrod. 6. IMPORTANT: Never allow the Drill Bit to drop, plunge or cut more than 2” below the drill Insert hole. There is a Support Bar just under the Table surface. FIGURE P TO SET UP THE HORIZONTAL BORING TOOL 1.
2. Use the Rip Fence and/or the Miter Gauge to support and guide the workpiece. NOTE: Make sure to lock the Miter Gauge in place by tightening the Setscrew in the Guide Bar. (See Figure Q.) 3. Set the boring depth by adjusting the Depth Gauge on the Quill Feed. (See page 16.) TO SET UP THE SHAPER 1. Install the R8 Collet (653) and draw it in using the Draw bar (SS742). Insert the Shaper Arbor (661) into the R8 Collet.
INSTALLING AND USING THE CUTTER GUARD 1. This machine comes with a Cutter Guard (800) that can be used with the router, shaper or drilling opperations. To attach the guard lower and lock the quill to the desired height. Press the Cutter Guard (800) up onto the quill. Tighten it in place using the nut and bolt pre-installed into the guard. (See Figure 1 below) 2. The guard can be pulled up out of the way when needed.
FIGURE S MACHINE ADJUSTMENT INSTRUCTIONS TO ADJUST THE TORSION SPRING TENSION 1. Move the Carriage and Powerhead all the way to the right end of the Way Tubes and lock them in place. 2. Loosen the Way Tube’s Locking Knobs. Make sure the Way Locks on the Carriage and Powerhead are securely tightened. 3. Lift the Way Tubes, Carriage, and Powerhead to the vertical Drill Press position. Then lock the vertical Locking Knob. 4.
7. Only tension two holes if necessary. Overtensioning the Spring can cause personal injury and/or damage to the Machine. 8. CAUTION! Once the Torsion Spring has been tensioned, DO NOT remove the Torsion Spring Base from the Stand without first relieving tension on the Spring. Failure to do so can result in personal injury and/or damage to the Machine. (See Figure T.
TO ALIGN THE SAW TABLE TO THE SAW BLADE 1. Set up the machine with the Table in place and the Saw Blade/Arbor installed. 2. Set the Table Trunnion to zero. 3. Place the Miter Gauge in the Table Slot closest to the Saw Blade. 4. Hold a pencil against the face of the Miter Gauge while touching the face of the Saw Blade. As you rotate the Saw Blade, the high spot on the Blade will push the pencil away. Mark the high spot with chalk or a felt marker. 5.
TO ADJUST THE SAW TABLE’S 45 DEGREE STOP 1. Loosen the Trunnion Handle and move the Table toward 45 degrees. 2. Push on the Auto Stop Pin. If the Table does not stop at 45 degrees, move the Table back toward 0 to allow room to adjust the 45 Degree Stop Pin. 3. Make a slight adjustment to the Stopscrew and recheck the Stop. Repeat this procedure until it stops at exactly 45 degrees. TO ALIGN THE MITER GAUGE 1. Place the Miter Gauge in the Table Slot closest to the Saw Blade. 2.
4. Place the pencil back in the Miter Gauge and align the pencil point and the high spot together at the infeed end of the Table. Rotate the Saw Blade, and bring the Miter Gauge and the high spot together at the outfeed of the Table. 5. The Extension Table is aligned if the pencil tip touches the Saw Blade just the same touch and place. Make sure all four Hex Head Capscrews attaching the Table are tight. 6.
5. If the Table is not perfectly squared with the Drill Bit, adjust the Table Stops with a wrench. 6. Recheck the Table’s 90 degree setting, and correct as needed. TO ALIGN THE LATHE TAILSTOCK WITH THE POWERHEAD 1. Install the Drill Chuck/Drill Bit in the Horizontal Boring Tool. Make sure the Drill Bit is straight and long. 2. Remove the saw Table and Extension Table from the machine. Then mount the Tailstock with the Tail Center installed. 3.
SPEED CHART Parts Lists and Diagrams PARTS LIST - CABINET & CASTERS Part Description Q’ty Part Description Q’ty 101 Cabinet 1 107 Cam Rod 2 102 Caster Fitting, Left 2 108 Cam 4 103 Caster Fitting, Right 2 109 Foot Wheel 2 104 Caster 4 110 Truss-Head Screw (S11304) 12 105 Caster Spring 4 111 Roll Pin (S22275) 4 106 Roll Pin (S22260) 6 736 Shelf 1 SKU 96067 For technical questions, please call 1-800-444-3353.
ASSEMBLY DIAGRAM - CABINET & CASTERS SKU 96067 For technical questions, please call 1-800-444-3353.
PARTS LIST - MAIN BED Part Description Q’ty Part Description Q’ty 201 Rack 1 213 Lock Knob Assy. 1 202 Tube 1 214 Support Stand 1 203 Tube Spacer 1 215 Handle Clamp 2 204 Socket Setscrew (S12557) 6 216 Screw (Right Hand) 2 205 Tail Pivot 1 217 Screw (Left Hand) 2 206 Pin 1 218 Torsion Spring 1 207 Spacer (Hole) 1 219 Hexhead Capscrew 8 208 Spacer 1 220 Spring Lock Washer 8 209 Hub 1 221 Hex Nut 8 210 Hub (Pivot Hole) 1 222 Lock Knob Assy.
ASSEMBLY DIAGRAM - MAIN BED SKU 96067 For technical questions, please call 1-800-444-3353.
PARTS LIST -Head Assy. Part Description Q’ty Part Description Q’ty 301 Main Head 1 339 Dial Depth Stop 1 302 Pilot Setscrew 1 340 Knob Lock 1 303 Sockethead Capscrew 1 341 Cap Screw 1 304 Hole Plug 1 342 Tapered Knob 7 305 Quill 1 343 Rod Knob Handle 7 306 Bearing 2 344 Qull Feed Knob (Back) 1 307 Snap Ring 1 345 Hex Jam Nut (S18185) 2 308 ------------------------------------------ ------- 346 Hole Plug 3 309 Spindle Assy.
PARTS LIST - head assy. (CONT.) Part Description Q’ty Part Description Q’ty 377 Locking Bar (Long) 1 391 Gear Cluster 1 378 Way Brake Pad (Front) 2 392 Drive Shaft 1 379 Way Brake Pad (Rear) 2 393 Flat Washer 1 380 ------------------------------------------ ------- 394 Gear 1 382 Power Head Knob 1 395 ------------------------------------------- 384 Cap Screw (S11911) 1 396 Gear 1 385 Thrust Washer 3 397 Rear Gear Plate Assy.
ASSEMBLY DIAGRAM - HEAD ASSY. SKU 96067 For technical questions, please call 1-800-444-3353.
PARTS LIST - CARRIAGE ASSY.
ASSEMBLY DIAGRAM - CARRIAGE ASSY. SKU 96067 For technical questions, please call 1-800-444-3353.
PARTS LIST - SAW TABLE ASSY. Part Description Q’ty Part Description Q’ty 204 Socket Setscrew (S12557) 4 514 Flat Washer 6 501 Saw Table 1 515 Pivot Pin 2 502 Rail Mount 6 516 Handle Assy. 2 503 ----------------------------------------- -------- 517 ------------------------------------------- 504 Tube Assy.
ASSEMBLY DIAGRAM - SAW TABLE ASSY. SKU 96067 For technical questions, please call 1-800-444-3353.
PARTS LIST - SAW GUARD ASSY. Part Description Q’ty Part Description Q’ty 530 Top Guard 1 541 Hex Locknut 2 531 Lower Guard 1 542 Arm Weld Assy. 1 532 T-Bolt 1 543 Flat Washer 1 533 Support 1 560 Flanged Elbow 1 534 Clamp 1 561 Screw 4 535 Roll Pin 1 562 Spacer 2 536 Handle 1 563 Spring 1 537 Knob Assy.
ASSEMBLY DIAGRAM - SAW GUARD ASSY. SKU 96067 For technical questions, please call 1-800-444-3353.
PARTS LIST - RIP FENCE ASSEMBLY DIAGRAM Part Description Q’ty Part Description 550-1 Guide Assy. 1 551-12 Rail Assy. 1 550-2 Guide Assy. 1 552-7 Catch Block Assy. 1 550-3 Guide Assy. 1 552-8 Catch Block Assy. 1 550-4 Guide Assy. 1 553-1 Handle Assy. 1 551-5 Rail Assy. 1 553-12 Handle Assy. 1 551-6 Rail Assy. 1 554 Whiz-Lock Hexhead Capscrew 2 551-9 Rail Assy. 1 555 -------------------------------------------- 551-10 Rail Assy.
PARTS LIST & ASSY. DIAGRAM - LATHE TAILSTOCK ASSY. Part Q’ty Part 204 Socket Setscrew (S12557) Description 6 625 Collar 2 622 Tailstock 1 626 Center Cup 1 623 Post 2 628 Sockethead Capscrew 1 624 Tool Retainer 1 629 Flat Washer 1 SKU 96067 Description For technical questions, please call 1-800-444-3353.
PARTS LIST & ASSY. DIAGRAM - EXT. TABLE ASSY. Part Description Q’ty Part Description Q’ty 601 Extension Table 1 606 Post 2 602 Extension Table Mount 1 204 Socket Setscrew (S12557) 2 603 Hexhead Capscrew 4 608 Rail Mount 4 604 Spring Lockwasher 4 609 Tube 2 605 Flat Washer 4 610 Flat Sockethead Capscrew 4 SKU 96067 For technical questions, please call 1-800-444-3353.
PARTS LIST & ASSY. DIAGRAM - SANDING DISC ASSY. Part Description Q’ty Part 642 640-2 Disc 1 641-0 Sanding Disc Hub 1 SKU 96067 Description Sanding Paper (12”) For technical questions, please call 1-800-444-3353.
PARTS LIST & ASSY.
PARTS LIST & ASSY. DIAGRAM - TOOL REST Part Description Q’ty Part Description Q’ty 633 Tool Rest 1 635 Post 1 634 Tool Rest Mount 1 636 Socket Setscrew 2 SKU 96067 For technical questions, please call 1-800-444-3353.
PARTS LIST & ASSY. DIAGRAM - MITER GAUGE ASSY. Part Description Q’ty Part Description Q’ty 612 Miter Gauge Block Assy. 1 672 Disk 2 613 Guide Assy. 1 674 Stud 2 614 Stop Block Assy.
PARTS LIST - ELECTRICAL SYSTEM Part Description Q’ty Part Description Q’ty -------- 715 Roundhead Screw 2 701 --------------------------------------- 702 SCR Module (Head) (Includes SS707 & SS 708) 1 716 Terminal Block 1 703 Flat Sockethead Screw (S11643) 4 717 Coiled Cord Assy.
ASSEMBLY DIAGRAM - ELECTRICAL SYSTEM SKU 96067 For technical questions, please call 1-800-444-3353.
Limited 1 year / 90 Day warranty Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that for a period of ninety days from date of purchase that the engine/motor, the belts (if so equipped), and the blades (if so equipped) are free of defects in materials and workmanship.