Rojek Woodworking Machinery

Interchangeable Shaper Spindle

Installation and Users Guide
Part #: ROJ-PUB-IS-SPINDLE
Ver #: 0311
Contents
Section 1: Introduction ........................................................................... 5
Safety Instructions ...................................................................................... 5
Delivered Components & Tools Required .......................................................... 6
Section 2: The Interchangeable Spindle .................................................... 7
Description................................................................................................. 7
Spindle Component Identification .................................................................. 7
Specifications ............................................................................................. 8
Section 3: Installation and Setup............................................................. 9
Assembly of the Spindle Components .............................................................. 9
Assembling Outer Components ................................................................ 10
Step Spindle to Solid 5/4 Conversion ..................................................... 12
Router Spindle Assembly........................................................................ 12
Installing Differential Screw ................................................................... 13
Installing Spindle Into Machine .................................................................... 14
Adjust Differential Screw ....................................................................... 14
Section 4: Disassembly and Removal ...................................................... 17
Removing Spindle from Machine.................................................................... 17
Removing Router Collet from Nut .................................................................. 18
Section 5: Service & Support ................................................................. 19
Support Resources ...................................................................................... 19
Limited Warranty and Return Policy ............................................................... 20
3
Introduction
4
This guide is issued as an addition to the machines User Instruction Manual. The standard
configuration for machines with a vertical spindle shaper is with a single, fixed spindle.
This additional guide details more specifically the steps for setup and installation of the
shaper spindles for those machines that have the optional Interchangeable Spindle Assembly
and the optional Chuck For Router Bits.
The text, illustrations and pictures within this guide represent the knowledge and practices
of the Rojek Company, and continue to be the companys intellectual property. No part of
this guide may be copied, nor shall the contents or information it contains be divulged.
The manufacturer reserves the right to particular changes in its continuous technical development
of the machine and these components.
SECTION 1
Introduction
Please pay close attention to all Warning and Caution notices. Warnings refer to personal
injury risks, Cautions refer to risks to the machine.
Safety Precautions
- Proceed entirely according to the following instructional guide. Non-performance of
these instructions can cause death or serious injury to the machine operator.
- The machine should always be turned off and disconnected from the power source
before performing any work on the machine, or changing out cutters. Failure to do so
can result in serious injury.
- Proceed according to this guide during assembly, installation and dismantling of the
interchangeable spindle.
- Tighten the Differential Screw and Locking Nuts by rated torque without use of levers
or beating on the wrench.
- Make sure that fitting surfaces are clean, unbroken and perfectly flat on both sides
before clamping Spacing Rings and a shaper tool onto the spindle.
- Never use deformed or cracked tools.
- Never use tools at a higher speed than recommended by competent manufacturer.
- Make sure that all rotating tools are perfectly balanced, properly sharpened, adapted
and fixed.
Safety Instructions
5
Introduction
6
Delivered Components & Tools Required
The Interchangeable Spindle and the Chuck For Router Bits options for the vertical
spindle shaper are generally ordered together. Each option comes with one spindle, so if
both are installed on the machine there will be two spindles included. The standard shaper
spindle provided is the 3/4 -- 5/4 diameter step spindle, and the spindle provided for the
router chuck is a specially designed, shortened, 5/4 diameter spindle. With various size
spindles available for order, the table below lists the components for all available.
Parts Included With Spindle
Tools Required to Install and Setup
* Tools not determined as of this printing.
Spindle Router
Parts Diameter 30mm 40mm 50mm 3/4 -- 5/4" 1 -- 5/4" 5/4" 5/4"
Locking Nut 1 1 1 1 1 1 1
Spindle 1 1 1 1 1 1 1
Differential Screw 1 1 1 1 1 1 1
Spacing Ring (h=5mm) 2 2 2 5+2+3 5+4+3 2 2
Spacing Ring (h=10mm) -- -- -- 1+1+2 1+2+2 -- --
Spacing Ring (h=15mm) 1 1 1 3+1 3+1 1 1
Spacing Ring (h=20mm) 2 2 2 2 2 2 2
Spacing Ring (h=30mm) 2 2 2 1 1 2 2
Chip Deflector 1 1 1 1 1 1 1
Plastic Cap 1 1 1 1 1 1 1
Router Collet Nut -- -- -- -- -- -- 1
Router Collet ( 8mm) -- -- -- -- -- -- 1
Router Collet ( 1/2" ) -- -- -- -- -- -- 1
Spindle Router
Tools Diameter 30mm 40mm 50mm 3/4 -- 5/4" 1 -- 5/4" 5/4" 5/4"
T-Handle Allen (6mm) -- -- -- 1 -- -- --
T-Handle Allen (10mm) 1 * * 1 1 1
Open-End Wrench (27mm) 1 * * 1 1 1 1
Open-End Wrench (36mm) -- * * -- 1 -- --
Open-End Wrench (41mm) 1 * * -- -- 1 1
Section 2
The Interchangeable Spindle
Description
The standard Rojek machine with a vertical spindle shaper is designed and manufactured
with a single-piece milling/spindle shaft. When ordered with the optional Interchangeable
Spindle Assembly, the milling/spindle shaft is manufactured with two segments. The
upper tool-clamping section is separated and joined to the main milling/spindle shaft with
a differential screw. This two-part construction enables the easy exchange and use of various
size spindle diameters on a single machine.
This removable upper tool-clamping section of the spindle shaft, referred to as the Spindle
to simplify discussions, can be in various lengths and configurations, as well as diameters.
The Spindle can have a single diameter shaft, or two separate diameters - referred to as a
Step-Spindle. Also available is a collet assembly for shank-type cutters (router bits).
Spindle Component Identification
7
Components and tools for the
5/4 diameter router spindle.
This is a special spindle with a
shorter length for router use.
Components and tools for the
3/4 -- 5/4 diameter step
spindle.
Shaper Spindle Router Spindle
1 Plastic Cap 7 Router Collet Nut
2 Locking Nut 8 Router Collet
3 Spacing Rings
4 Chip Deflector
5 Spindle
6 Differential Screw
Specifications
The Interchangeable Spindle
8
Total Spindle Length Spindle Clamping Length
Spindle Diameter L1 (mm) L2 / L3 (mm) Router Collet Diameter
30mm 177.04 100
40mm 177.04 105
50mm 177.04 115
3/4 5/4" 177.04 100 / 30
1 5/4" 177.04 100 / 35
5/4" 177.04 100
Router 5/4" 149.04 70 8mm & 1/2"
8
7
L1 L2
L3
1
2
3
6
5
4
Section 3
Installation and Setup
The following installation and setup steps are not in any critical sequence, unless specifically
stated. In fact, the interchangeable shaper spindle will already be assembled and installed
onto the machine you have purchased. For the most part, the photos were taken so that the
step being illustrated could more easily be seen and understood. For example, in the first
sequence of steps, the assembly of the outer components onto the spindle could just as
easily be accomplished after the spindle has been installed into the machine. Or, the
differential screw could be installed into the spindle prior to assembling the outer components.
Assembly of the Spindle Components
Assembling Outer Components
9
Begin the assembly of the outer
components by first installing the chip
deflector. This should fit onto the very
lower level of the spindle.
The chip deflector, as the name
implies, acts to throw any dust or chips
that fall into the spindle cavity out
toward the outer wall of the cavity so
that the dust collector can pick it up.
Next, slide the spacing rings onto the
spindle shaft. These come in various
heights, so mix them up to achieve the
correct height for the locking nut.
For the actual shaping operation setup,
the spacing rings will be used to
establish the location of the shaper
cutter on the spindle and provide the
locking nut with a surface for
clamping.
Installation and Setup
10
Step Spindle to Solid 5/4 Conversion
Warning: Failure to sufficiently tighten the
locking nut, so that the compression foot engages,
may result in the locking nut coming off during
operation, causing serious injury.
!
Once the spacing rings have been
installed to the appropriate height,
install the locking nut.
Tighten the locking nut against the top
spacing ring or shaper cutting tool, as
the case may be.
The locking nut has a compression
foot on the bottom that exerts torque
on the nut. This prevents the nut from
coming off when operating in reverse.
A plastic cap should be used to plug
the hole in th top of the spindle (see
#1 in Component Identification
diagram on pg. 8) after every mounting
of the interchangeable spindle.
To convert any of the Step Spindles
into a solid 5/4 spindle, simply utilize
the 5/4 diameter spacing rings on the
smaller diameter section of the spindle.
Installation and Setup
11
Router Spindle Assembly
Router Collet and Nut
Just as with the shaper spindle (on page
9), begin the assembly of the outer
components by first installing the chip
deflector. This should fit onto the very
lower level of the spindle.
Next, slide the spacing rings onto the
spindle shaft. When used with the
router spindle, these spacers serve only
to weigh down the chip deflector so
that it will remain at the bottom of the
spindle during operation.
As shown in the photo, limit the
number of spacing rings installed so
that the open-end wrench can still be
used on the spindle.
To put together the router collet
assembly, place the head of the router
collet into the router collet nut, as
shown.
12
Installation and Setup
Place both thumbs on the end of the
router collet, as shown, and press
firmly.
The router collet should snap into the
router collet nut so that the end of the
collet is flush with the top of the nut.
Insert a 1/2 router bit into the collet
and tighten, as shown.
The correct operating rotation for the
router spindle, looking from the top
down, is counter-clockwise.
The router collet nut does not have a
compression foot, so it cannot be
operated in reverse. Do not operate
the machine in a clockwise rotation
with the router spindle installed.
!
Warning: Use extreme caution when operating the router to ensure
that the spindle is set to rotate in a counter-clockwise direction.
Operating the router spindle in a clockwise rotation may result in
the router collet nut coming off, causing serious injury.
!
Installation and Setup
13
Insert the appropriate T-Handle allen
wrench through the end of the spindle
shaft, as shown.
With the T-Handle wrench inside the
spindle, insert the differential screw
onto the allen wrench.
The differential screw is threaded on
both the shaft and the head. The head
and the shaft are counter-threaded so
that they thread in opposite directions.
Looking from the top-end of the
spindle (the end with the T-Handle
inserted into it), rotate the wrench
counter-clockwise and thread the
differential screw into the spindle.
Thread the differential screw all the
way into the spindle until it bottoms
out.
Installing Differential Screw
14
Installation and Setup
Installing Spindle Into Machine
Adjust Differential Screw
In order to install the spindle, you must
first remove at least the first table ring.
This is necessary to accomodate the size
of the chip deflector.
There are multiple removable rings
that allow the use of various sized
shaper cutter tools.
Prior to installing the spindle, re-insert
the T-Handle Allen wrench and engage
the differential screw. Rotate the
wrench counter-clockwise to ensure
that the differential screw is threaded
into the spindle as far as it will go.
Then back it out, rotating the wrench
clockwise, 2 to 3 turns (use the T-
Handle on the wrench to judge the
rotation).
Leave the T-Handle wrench inside the
spindle and engaged with the screw.
The purpose of backing out the
differential screw is to provide
approximately 0.18 (4.5mm) of space
above the screw that will be needed to
back out the screw later, when
removing the spindle (see Section 4
Disassembly and Removal for this
discussion).
4.5mm
(approx. 2 to 3 revolutions)
Installation and Setup
15
Next, place the spindle and T-Handle
Allen wrench, as a unit, onto the main
milling/spindle shaft as shown. The
thread of the differential screw will be
inserted into the thread of the main
shaft.
To properly install the spindle, it is
important that the differential screw
and spindle rotate together,
synchronously, so that the 4.5mm
space that was created earlier does not
change.
To accomplish this, rotate the spindle
and the T-Handle Allen wrench
clockwise together as a single unit. Pay
particular attention to the position of
the T-Handle to ensure that the
relationship of the differential screw
to the spindle remains the same.
Once the spindle bottoms-out on the
main milling/spindle shaft, place the
open-end wrench on the spindle (or
the locking nut, as the case may be)
and hand-tighten the spindle only.
Then, after removing the open-end
wrench, firmly turn the T-Handle
Allen wrench clockwise, tightening the
differential screw with approximately
7.38 ft-lbs (10 ntn-m) of torque.
Now, the spindle is ready for the outer
components and shaper cutter (if not
previously installed).
Do not forget to plug the hole with a
plastic cap after every mounting of the
interchangeable spindle to prevent
chips and debris from getting inside
the spindle.
16
Installation and Setup
Section 4
Disassembly and Removal
The following disassembly and removal instructions are abbreviated. Most of the steps
have been discussed earlier during the installation and setup steps. Removal of the outer
components and the differential screw can be accomplished by simply using the installation
steps in reverse sequence.
As with the installation steps, disassembly and removal can also be performed in different
sequences. The illustration below shows a bare spindle being removed from the machine.
This can also be accomplished not only with the outer components still installed, but also
with the particular shaper cutter tool that is being used still mounted on the spindle. This
allows the use of multiple spindles with pre-installed shaper cutters to perform multiple
operations, cutting down on changeover and setup time.
Removing Spindle from Machine
17
To remove the spindle from the shaper,
hold the spindle stationary with the
open-end wrench while turning the T-
Handle Allen wrench counter-
clockwise.
This is where the importance of the
0.18 (4.5mm) space referred to in the
Installing Spindle Into Machine section
on page 14 becomes apparent. The
additional space provides the needed
room for the differential screw to back
out from the main shaft/spindle.
Once the spindle has broken free of
the main shaft/spindle, the open-end
wrench can be removed and the T-
Handle wrench rotated counter-
clockwise until the differential screw
and spindle are free.
4.5mm
(approx. 2 to 3 revolutions)
TROUBLESHOOTING:
If the differential screw will not turn counter-
clockwise in the previous step, it is probably due to a
lack of space above the screw (0.18, 4.5mm). In
this case, the only way to break the spindle free will
be to hold down the main shaft/spindle at the bottom
end where the pully assembly is mounted, rather than
with the open-end wrench on the interchangeable
spindle.
18
Disassembly and Removal
Removing Router Collet from Nut
Illustrated is a simple method for
removing the router collet from the
nut.
Place the router collet nut on a surface
that will allow space below the router
collet for it to fall.
If using a spacing ring, as shown, take
care not to damage it during the
remaining steps.
Place a round pin, slightly smaller than
the outside diameter of the router
collet, on top of the router collet.
Ideally, a wooden dowel should be
used. Here, the illustration shows a
7/16 socket being used for this
purpose.
Take care not to damage the collet.
With the pin placed carefully on just
the router collet and not in contact
with the nut, strike the pin slightly
with a mallet to dislodge the collet from
the nut.
Tech Mark, Inc
7901 Industry Drive
North Little Rock, AR 72117
tel (501) 945-9393 fax (501) 945-0312
www.rojekusa.com
Section 5
Service & Support
19
Tech Mark provides a variety of resources to assist in troubleshooting and correcting any
problems you may encounter.
Support Resources
Email support
[email protected]
Cant resolve the problem using the Technical Guide? Send an email to our support
staff and expect a response within 24 business hours (weekends and holidays excluded).
Phone Support
(800) 787-6747
If your problem requires phone assistance, please call us to speak directly with a Tech
Mark technician. Technicians are available Monday through Friday, 8 a.m. to 5 p.m.
CST.
Rojek Woodworking Machinery Limited Warranty and Return Policy
One-Year Limited Warranty (U.S. Only)
Tech Mark, Inc. (TMI), as the exclusive importer and agent, warrants that Rojek Woodworking
Machinery Company (Rojek) manufactures its products to meet high quality and durability standards
in accordance with industry-standard practices. TMI fully supports Rojeks warranty that the products it
manufactures will be free from defects in materials and workmanship. The limited warranty term is one
year beginning on the date of invoice, as described in the following text.
Damage due to shipping the products to you is not covered under this limited warranty. Shipping
damage is covered by shipping insurance and is therefore dependent on you thoroughly examining
shipping containers for any sign of abuse or damage, and noting exceptions on shipping documents,
before signing for, and releasing shipper.
Otherwise, this limited warranty does not cover any asserted defect which has resulted from normal
wear or due to external causes, including accident, abuse, misuse, problems with electrical power,
servicing or alteration not authorized by TMI, usage not in accordance with product instructions, failure
to perform required preventive maintenance, and problems caused by use of parts and components
not supplied by Rojek, or its agent TMI.
Examination and Repair
You must make a decision to accept the product or identify defects at once, check the product now.
Our 30-day satisfaction guarantee on machinery is for examination only. We are not able to accept
machines placed into service unless we have confirmed that it is defective. Returns during this
period will be subject to a 25% restocking fee. Any refund, or credit, is subject to satisfactory return
and inspection of machinery. To return machinery you must first obtain a Return Material Authorization
Number. TMI will issue a call ticket for shipper to pick up machine, at TMIs expense, at a designated
location. Prior to pickup, the machine must be returned to its original or equivalent crating, or
packaging, for safeguarding or you accept risk of loss or damage during shipment.
During the one-year period beginning on the invoice date, TMI will repair or replace defective parts
covered under this limited warranty that are returned to TMIs facility. To request warranty repairs, you
must contact TMI within the warranty period. If a warranty repair is required, TMI will issue a Return
Material Authorization Number. You must ship the products back to TMI in their original or equivalent
packaging, prepay shipping charges, and insure the shipment or accept the risk of loss or damage
during shipment. TMI will ship the repaired or replacement products to you freight prepaid if you use
an address in the continental U.S., where applicable. Shipments to other locations will be made freight
collect.
TMI owns all parts removed from repaired products. TMI uses new and reconditioned parts made by
various manufacturers in performing warranty repairs and building replacement products. If TMI
repairs or replaces a part, the warranty term is not extended.
General Provisions
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS, WHICH VARY FROM STATE TO STATE (OR JURISDICTION TO JURISDICTION).
ROJEKS OR TMIS RESPONSIBILITY FOR MALFUNCTIONS AND DEFECTS IN MACHINERY IS
LIMITED TO REPAIR AND REPLACEMENT OF PARTS AS SET FORTH IN THIS LIMITED
WARRANTY STATEMENT. THIS WARRANTY IS ROJEKS, AND TMIS, SOLE WARRANTY AND
SETS FORTH THE CUSTOMERS EXCLUSIVE REMEDY, WITH RESPECT TO DEFECTIVE
PRODUCTS; ALL OTHER WARRANTIES, EXPRESS AND/OR IMPLIED, WHETHER OF
MERCHANTABILITY, FITNESS FOR PURPOSE OR OTHERWISE, ARE EXPRESSLY DISCLAIMED
BY ROJEK AND TMI. UNDER NO CIRCUMSTANCES WILL ROJEK, OR TMI, BE LIABLE FOR
DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECIAL,
OR CONSEQUENTIAL DAMAGES RESULTING FROM THE USE OF OUR PRODUCTS. SOME
STATES (OR JURISDICTIONS) DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED
WARRANTY LASTS, SO THE PRECEDING LIMITATION MAY NOT APPLY TO YOU.
ROJEK, OR TMI, DO NOT ACCEPT LIABILITY BEYOND THE REMEDIES SET FORTH IN THIS
LIMITED WARRANTY STATEMENT OR LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES, INCLUDING WITHOUT LIMITATION ANY LIABILITY FOR PRODUCTS NOT BEING
AVAILABLE FOR USE OR FOR LOST TIME OR MATERIAL. SOME STATES (OR JURISDICTIONS)
DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL
DAMAGES, SO THE PRECEDING EXCLUSION OR LIMITATION MAY NOT APPLY TO YOU.
20
Service & Support
Rojek Woodworking Machinery
Interchangeable Shaper Spindle
Installation and Users Guide
Part #: ROJ-PUB-IS-SPINDLE
Ver #: 0311