Powermatic 2000 User Manual

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Operating Instructions and Parts Manual

10-inch Cabinet Saw

Model: 2000

Model 2000 Table Saw shown with optional extension table and legs

WMH TOOL GROUP

WARRANTY AND SERVICE

WMH Tool Group, Inc., warrants every product it sells. If one of our tools needs service or repair, one of our Authorized Service Center located throughout the United States can give you quick service. In most cases, any of these WMH Tool Group Authorized Service Centers can authorize warranty repair, assist you in obtaining parts, or perform routine maintenance and major repair on your POWERMATIC Center in your area call 1-800-274-6848.

MORE INFORMATION

WMH Tool Group is consistently adding new products to the line. For complete, up-to-date product information, check with your local WMH Tool Group distributor, or visit powermatic.com.

WARRANTY

POWERMATIC products carry a limited warranty which varies in duration based upon the product.

WHAT IS COVERED?

This warranty covers any defects in workmanship or materials subject to the exceptions stated below. Cutting tools, abrasives and other consumables are excluded from warranty coverage.

WHO IS COVERED?

This warranty covers only the initial purchaser of the product.

WHAT IS THE PERIOD OF COVERAGE?

The general POWERMATIC warranty lasts for the time period specified in the product literature of each product.

WHAT IS NOT COVERED?

The Five Year Warranty does not cover products used for commercial, industrial or educational purposes. Products with a Five Year Warranty that are used for commercial, industrial or education purposes revert to a One Year Warranty. This warranty does not cover defects due directly or indirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, improper repair or alterations, or lack of maintenance.

HOW TO GET SERVICE

The product or part must be returned for examination, postage prepaid, to a location designated by us. For the name of the location nearest you, please call 1-800-274-6848.

You must provide proof of initial purchase date and an explanation of the complaint must accompany the merchandise. If our inspection discloses a defect, we will repair or replace the product, or refund the purchase price, at our option.

We will return the repaired product or replacement at our expense unless it is determined by us that there is no defect, or that the defect resulted from causes not within the scope of our warranty in which case we will, at your direction, dispose of or return the product. In the event you choose to have the product returned, you will be responsible for the handling and shipping costs of the return.

HOW STATE LAW APPLIES

This warranty gives you specific legal rights; you may also have other rights which vary from state to state.

LIMITATIONS ON THIS WARRANTY

WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR MERCHANTABILITY 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.

WMH TOOL GROUP SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, 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.

WMH Tool Group sells through distributors only. The specifications in WMH catalogs are given as general information and are not binding. Members of WMH Tool Group reserve the right to effect at any time, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem necessary for any reason whatsoever.

tools. For the name of an Authorized Service

WARRANTY AND SERVICE ........................................................................................................................2

Table of Contents.......................................................................................................................................... 3

Warnings .......................................................................................................................................................4

Introduction ...................................................................................................................................................6

Specifications ................................................................................................................................................6

Shipping Contents......................................................................................................................................... 7

Unpacking.................................................................................................................................................. 7

Cleaning ....................................................................................................................................................7

Contents of the Shipping Container ..........................................................................................................8

Assembly..................................................................................................................................................... 10

Mounting Extension Wings...................................................................................................................... 10

Lock Knobs and Swivel Handles .............................................................................................................11

Dust Chute............................................................................................................................................... 11

Blade Installation/Replacement...............................................................................................................12

Mounting Rails and Accu-Fence............................................................................................................ 12

Optional Wood Extension Table.............................................................................................................. 12

Switch Installation....................................................................................................................................12

Riving Knife and Guard Installation ......................................................................................................... 13

Grounding Instructions ................................................................................................................................14

Extension Cords ...................................................................................................................................... 14

Zero-Clearance Insert Setup ...................................................................................................................15

Miter Slot Alignment ................................................................................................................................ 16

Tilt Stop Adjustment ................................................................................................................................16

Precision Miter Gauge ............................................................................................................................. 17

Riving Knife Adjustment .......................................................................................................................... 18

Insert Adjustment..................................................................................................................................... 19

Arbor and Arbor Bearing Removal .......................................................................................................... 19

Operating Controls ......................................................................................................................................20

Start/Stop................................................................................................................................................. 20

Safety Key ............................................................................................................................................... 20

Motor Cover............................................................................................................................................. 12

Adjustments ................................................................................................................................................14

Handwheel Adjustments.......................................................................................................................... 14

Drive Belt .................................................................................................................................................17

Operations................................................................................................................................................... 21

Overview.................................................................................................................................................. 21

Kickback .................................................................................................................................................. 21

Bevel and Miter Operations..................................................................................................................... 24

Safety Devices ............................................................................................................................................25

Feather Board and Push Blocks.............................................................................................................. 25

Push Stick................................................................................................................................................ 25

Filler Piece............................................................................................................................................... 25

Maintenance................................................................................................................................................ 26

Cleaning ..................................................................................................................................................26

Lubrication ...............................................................................................................................................26

Miscellaneous.......................................................................................................................................... 26

Troubleshooting ..........................................................................................................................................27

Optional Accessories ..................................................................................................................................28

Ordering Replacement Parts................................................................................................................... 28

Model 2000 Table Saw Parts List ............................................................................................................... 29

Wiring Diagrams.......................................................................................................................................... 38

The specifications in this manual are given as general information and are not binding. WMH Tool Group reserves the right to effect, at any time and without prior notice, changes or alterations to parts, fittings, and accessory equipment deemed necessary for any reason whatsoever.

Warnings

1. Read and understand the entire owners manual before attempting assembly or operation.

2. Read and understand the warnings posted on the machine and in this manual. Failure to comply with

all of these warnings may cause serious injury.

3. Replace the warning labels if they become obscured or removed.

4. This table saw is designed and intended for use by properly trained and experienced personnel only.

If you are not familiar with the proper and safe operation of a table saw, do not use until proper training and knowledge have been obtained.

5. Do not use this table saw for other than its intended use. If used for other purposes, WMH Tool Group

disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use.

6. Always wear approved safety glasses/face shields while using this table saw. Everyday eyeglasses

only have impact resistant lenses; they are not safety glasses.

7. Before operating this table saw, remove tie, rings, watches and other jewelry, and roll sleeves up past

the elbows. Remove all loose clothing and confine long hair. Non-slip footwear or anti-skid floor strips are recommended. Do not wear gloves.

8. Wear ear protectors (plugs or muffs) during extended periods of operation.

9. Some dust created by power sanding, sawing, grinding, drilling and other construction activities

contain chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead based paint.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically treated lumber.

Your risk of exposure 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 face or dust masks that are specifically designed to filter out microscopic particles.

10. Do not operate this machine while tired or under the influence of drugs, alcohol or any medication.

11. Make certain the machine is properly grounded.

12. Make all machine adjustments or maintenance with the machine unplugged from the power source. A

machine under repair should be RED TAGGED to show it must not be used until maintenance is complete.

13. Remove adjusting keys and wrenches. Form a habit of checking to see that keys and adjusting

wrenches are removed from the machine before turning it on.

14. Keep safety guards in place at all times when the machine is in use. If removed for maintenance

purposes, use extreme caution and replace the guards immediately.

15. Check the alignment of the riving knife, fence and miter slot to the blade. A caution decal is installed

on each guard to remind the operator of the dangers of improper machine operation.

16. Check damaged parts. Before further use of the machine, 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.

17. Provide for adequate space surrounding work area and non-glare, overhead lighting.

18. Keep the floor around the machine clean and free of scrap material, oil and grease.

19. Keep visitors a safe distance from the work area. Keep children away.

20. Make your workshop child proof with padlocks, master switches or by removing safety keys.

21. Give your work undivided attention. Looking around, carrying on a conversation and “horse-play” are

careless acts that can result in serious injury.

22. Maintain a balanced stance at all times so that you do not fall or lean against the blade or other

moving parts. Do not overreach or use excessive force to perform any machine operation.

23. Use the right tool at the correct speed and feed rate. Do not force a tool or attachment to do a job for

which it was not designed. The right tool will do the job better and safer.

24. Use recommended accessories; improper accessories may be hazardous.

25. Maintain tools with care. Keep blade sharp and clean for the best and safest performance. Follow

instructions for lubricating and changing accessories.

26. Check the saw blade for cracks or missing teeth. Do not use a cracked or dull blade or one with

missing teeth or improper set. Make sure the blade is securely locked on the arbor.

27. Keep hands clear of the blade area. Do not reach past the blade to clear parts or scrap with the saw

blade running. Never saw freehand. Avoid awkward operations and hand positions where a sudden slip could cause your hand to contact the blade.

28. Do not attempt to saw boards with loose knots or with nails or other foreign material, on its surface.

Do not attempt to saw twisted, warped, bowed or “in wind” stock unless one edge has been jointed for guiding purposes prior to sawing.

29. Do not attempt to saw long or wide boards unsupported where spring or weight could cause the

board to shift position.

30. Always use the riving knife, blade guard, push stick and other safety devices for all operations where

they can be used. On operations such as dadoing or molding where the blade guard cannot be used, use feather boards, fixtures and other safety devices and use extreme caution. Reinstall the riving knife and blade guard immediately after completing the operation that required their removal.

31. Be sure the saw blade rotates clockwise when viewed from the motor side (left side) of the machine.

32. Turn off the machine before cleaning. Use a brush or compressed air to remove chips or debris — do

not use your hands.

33. Do not stand on the machine. Serious injury could occur if the machine tips over.

34. Never leave the machine running unattended. Turn the power off and do not leave the machine until it

comes to a complete stop.

35. Remove loose items and unnecessary work pieces from the area before starting the machine.

Familiarize yourself with the following safety notices used in this manual:

This means that if precautions are not heeded, it may result in minor injury and/or

possible machine damage.

even death.

This means that if precautions are not heeded, it may result in serious injury or possibly

Introduction

This manual is provided by WMH Tool Group covering the safe operation and maintenance procedures for a Powermatic Model 2000 Table Saw. This manual contains instructions on installation, safety precautions, general operating procedures, maintenance instructions and parts breakdown. This machine has been designed and constructed to provide years of trouble free operation if used in accordance with instructions set forth in this manual. If there are any questions or comments, please contact either your local supplier or WMH Tool Group. WMH Tool Group can also be reached at our web site: www.wmhtoolgroup.com.

Specifications

Model number ......................................................................................................................................... 2000

Stock Number

3HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ........................................................................... 1791999

5HP, 230V, 60Hz, 1 Phase, 3600 RPM, TEFC ........................................................................... 1791998

5HP, Prewired 230V (for 460V see Note below), 60Hz, 3 Phase, 3600 RPM, TEFC................. 1791997

Table size with standard extensions (L x W/in.)............................................................................ 42 x 30 1/2

Table size without extensions (L x W/in.)...................................................................................... 22 x 30 1/2

Arbor diameter (in.) .................................................................................................................................... 5/8

Saw blade diameter (in.) ............................................................................................................................. 10

Arbor speed (RPM) ................................................................................................................................. 4300

Left tilt range ........................................................................................................................................... 0–45

Maximum depth of cut (in.).............................................................3-1/8 at 90-degrees; 2-1/8 at 45-degrees

Maximum diameter of dado (in.) ................................................................................................................... 8

Maximum width of dado cut (in.) ............................................................................................................13/16

Drive system ................................................................................................................................. Poly-V Belt

Table height to floor (in.) .......................................................................................................................34-1/2

Dust port diameter (in.) ................................................................................................................................. 4

Shipping weight (saw only) ..............................................................All Models: Net: 540 lbs, Gross: 604 lbs

Note: For 460V operation, magnetic switch (Part No. PM2000-293C) must be purchased separately and installed. A qualified electrician is recommended.

The above specifications were current at the time this manual was published, but because of our policy of continuous improvement, WMH Tool Group reserves the right to change specifications at any time and without prior notice, without incurring obligations.

Read and understand the entire contents of this manual before attempting

assembly or operation! Failure to comply may cause serious injury

Shipping Contents

Unpacking

Remove box and wood crating completely from around saw. Check for shipping damage. Report any damage immediately to your distributor and shipping agent. Do not discard any shipping material until the Table Saw is assembled and running properly.

Compare the contents of your container with the parts lists in the next two pages to make sure all parts are intact. Missing parts, if any, should be reported to your distributor. Read the instruction manual thoroughly for assembly, maintenance and safety instructions.

1. Unbolt the saw from the skid.

2. Carefully slide the saw from the pallet onto

the floor.

Make sure that the castors do not get damaged when removing from the skid.

The Table Saw should be placed in an area with a sturdy level floor, good ventilation and sufficient lighting. Leave enough space around the machine for mounting extension wings and rail assemblies, and loading and off-loading stock and general maintenance work.

Cleaning

Exposed metal surfaces, such as the table top and extension wings, have been given a protective coating at the factory. This should be removed with a soft cloth moistened with kerosene. Do not use acetone, gasoline, or lacquer thinner for this purpose. Do not use solvents on plastic parts, and do not use an abrasive pad because it may scratch the surfaces.

Contents of the Shipping Container

Main Saw Container

1 Table Saw (A) 1 Table Insert (B)

The following items are inside the saw:

1 Miter Gauge Assembly (C) 1 Blade Guard Assembly (D) 1 Switch in box (E) 1 Owner's Manual (F) 1 Warranty Card (not shown)

Small Box

The small box consists of the following items:

1 Push Stick (G) 1 27mm Arbor Wrench (H) 2 Lock Knobs (J) 2 Swivel Handles (K) 1 Riving Knife and Pawl Assembly (L) 1 Hardware Bag (M) consisting of: 6 3/8-16 x 1 Hex Cap Screw (AA) 6 3/8 Lock Washer (BB) 6 3/8 Flat Washer (CC)

Main Saw Container

Contents of the Small Box

Extension Tables

Two extension tables are packaged in individual boxes.

Extension Tables

Side Cover Box

2 Hinge Pin (N) 1 Side Cover (O)

Contents of Side Cover Box

Fence and Rail

Carton contents and installation instructions for the fence, rail system, and optional wooden extension table are described in the Accu-Fence Owner's Manual (No. M-0460284).

Assembly

Mounting Extension Wings

Referring to Figure 1:

1. Mount a cast iron extension wing (A) to the

right or left side of the table (B) using three each 3/8-16x1 hex head screws (C), 3/8 lock washers (D) and 3/8 flat washers (E). Have an assistant hold the extension wing up to the table while inserting the screws and washers. Finger-tighten only.

Note: If an assistant is not available, hold the wing in vertical position up to the saw table, insert the middle screw and lock washer finger tight, then pivot the wing to level position. Insert the other two screws and washers finger tight.

Figure 1

2. Mount the remaining extension wing to the

other side of the table in the same manner.

3. Make sure that the front edge of the extension

wings are flush with the front edge of saw table (Figure 2).

4. Level the extension wing with the saw table

across its entire width (Figure 3) using a straight edge and hammer with block of wood (or rubber hammer).

Figure 2

As each area of the wing becomes flush with the table, tighten the screw under that area. Continue until all three screws are fully tightened.

5. Repeat for the other extension wing.

Figure 3

Lock Knobs and Swivel Handles

Referring to Figure 4:

1. Thread the swivel handles (A) into the front and

side handwheels (C) and tighten with a 14mm wrench.

2. Screw lock knobs (B) into the threaded

openings on the end of the shafts located in the middle of the handwheels (C).

Note: Do not tighten the lock knobs all the way at this time.

Dust Chute

Referring to Figure 5:

The Model 2000 comes equipped with a dust chute

and hose assembly (Inset 2) for use with a dust collection system. If you do not intend to use a dust

collection system, the dust chute may be disconnected and removed as described below.

To provide sufficient clearance for removal of the dust chute:

Figure 4

1. Raise the blade height all the way up and set

the blade tilt to 0º (refer to Handwheel Adjustments on page 14).

2. Remove the arbor nut and collar as described

in the Blade Installation/Replacement on page 12, steps 3-4.

Removing the dust chute:

3. Remove two socket head button screws (D, E)

with 4mm and 5mm hex wrenches respectively.

4. Through the opening on the left side of the

cabinet, remove the hose (Inset 1, 2) by twisting and pulling back on the dust port (F).

Take the entire assembly (Inset 2) out through the side opening.

Do not replace the arbor nut and collar at this time, but proceed to the Blade Installation/Replacement section (following page).

Figure 5

Blade Installation/Replacement

Use care when working with or around sharp saw blade to prevent injury!

To install or replace a blade (refer to Figure 6):

1. Disconnect machine from power source.

2. Raise the blade height all the way up and set

the blade tilt to 0º (refer to Handwheel Adjustments on page 14).

3. Press the arbor lock (D) in the direction shown

by the arrow to engage it into the slot in the arbor (C). At the same time remove the arbor nut (loosen with a 27mm wrench if necessary).

4. Remove the collar (B).

5. Install the blade, making sure the cutting teeth

at the top of the blade point toward the front of the saw. If unsure, refer to Figure 10 for the proper blade orientation.

6. Replace the collar (B) and arbor nut (A).

7. Engage the arbor lock (D) and tighten the nut

(A) with a 27mm wrench.

Figure 6

8. Lower the blade below the table.

Mounting Rails and Accu-Fence

With the extension wings properly aligned, the rail, guide tube and fence assembly can now be mounted to the saw. Consult the Accu-Fence Owner's Manual (Part No. M-0460284) for instructions.



Optional Wood Extension Table

For instructions on mounting the accessory wood extension table, or router table, consult the

Accu-Fence

M-0460284) for instructions.



Owner's Manual (Part No.

Switch Installation

Referring to Figure 7:

1. Place the switch assembly (A) under the rail

(B) and guide tube (C) so that the two holes in the switch bracket (D) line up with the left two holes in the rail and guide tube.

Note: The screws and lock washers may already have been installed when the rail and guide tube were installed and need to be removed for this operation.

2. Secure with two 1/4 lock washers (E) and

1/4 x 3/4 hex cap screws (F).

Figure 7

Figure 8

Motor Cover

Line up the door hinges (A. Fig. 8) with the cabinet hinges (B, Fig. 8) and insert hinge pins (C, Fig. 8).

Note: The locking mechanism may require adjustment to insure proper alignment.

Riving Knife and Guard Installation

Description

Referring to Figure 9:

The complete riving knife and guard assembly is shown in A. Before installing onto the saw, the anti-

kickback pawl (E) must be separated from the riving knife (H) as described below.

1. Press and hold the quick-release button (D) on

the base of the anti-kickback pawl (E) and lift the pawl to remove from the riving knife (H).

Installation

Referring to Figure 10:

1. Set the saw blade to the 90 degree position

and raise it all the way (refer to Handwheel Adjustments on page 14).

2. Remove the table insert (J).

3. Located inside the table and accessible

through the insert opening (Figure 10 inset), place the quick-release clamp lock handle (K) in the unlock position.

4. The floating clamp block (L) is spring loaded

and will move away (O) from the fixed block (M), leaving a gap.

5. Insert the bottom of the riving knife (N

, N2) all

the way into the gap between the clamp blocks (L, M), then lock the handle (K).

6. Replace the insert (J) back on the table. The

saw blade and riving knife should protrude through the slot in the insert.

Referring back to Figure 9:

7. Attach the anti-kickback pawl (E) by pressing

and holding the quick-release button (D) and inserting the lock pin of the pawl into the appropriate slot (F) on the riving knife.

8. In similar manner attach the guard (C) by

pressing and holding the quick-release button (B) and inserting the lock pin of the guard into the appropriate slot (G) on the riving knife.

You should feel a snap as each piece locks in position. Attempt to lift as a test to make sure that they are securely locked in place.

Adjustment

Figure 9

The clamping blocks (L, M, Fig. 10) are adjusted at the factory and no further adjustment of the blade guard and riving knife assembly should be necessary. However, proper alignment is very important. Before operating the table saw, read the Riving Knife Adjustment section (page 18) to verify and follow the adjustment procedure if necessary.

Figure 10

Grounding Instructions

Adjustments

Electrical connections must be made by a qualified electrician in compliance with all relevant codes. This machine must be properly grounded to help prevent electrical shock and possible fatal injury.

A power plug is not provided with the Model 2000. You may either connect the proper UL/CSA listed plug or “hardwire” the machine directly to your electrical panel provided there is a disconnect near the machine for the operator. Consult electrical drawings on pages 37-39 for further clarification of wiring setup.

This machine must be grounded. Grounding provides a path of least resistance to help divert current away from the operator in case of electrical malfunction.

Make sure the voltage of your power supply matches the specifications on the motor plate of the machine.

Extension Cords

If an extension cord is necessary, make sure the cord rating is suitable for the amperage listed on the machine's motor plate. An undersize cord will cause a drop in line voltage resulting in loss of power and overheating.

The chart in Table 1 shows the correct size cord to use based on cord length and motor plate amp rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Extension Cord Length *

100

150

Amps

< 5 16 16 16 14 12 12

feet

200 feet

Handwheel Adjustments

Referring to Figure 11:

The front handwheel (B) controls the raising and lowering of the blade (blade height).

The side handwheel (C) controls the blade tilt and castors. The blade can be adjusted for a tilt between 90º (vertical or a setting of 0º on the scale) and 45º left tilt (D). The Model 2000 also has a retractable castor system that can be extended to permit the table saw to be rolled from one location to another.

Blade height

1. Loosen the lock knob (A) on the blade height adjust handwheel.

2. Turn the handwheel (B) clockwise to raise and counterclockwise to lower the blade.

3. Tighten the lock knob (A).

Blade tilt adjustment

1. Loosen the lock knob (A) on the side handwheel (C).

2. Push the handwheel in (F).

3. Turn the handwheel (C) counterclockwise to adjust the saw blade down to 45º left tilt (D). Turn clockwise to adjust the saw blade to maximum of 90º (D).

4. After selecting the position, tighten the lock knob (A).

5 to 8 16 16 14 12 10 NR

8 to 12 14 14 12 10 NR NR

12 to 15 12 12 10 10 NR NR

15 to 20 10 10 10 NR NR NR

21 to 30 10 NR NR NR NR NR

*based on limiting the line voltage drop to 5V at 150% of the rated amperes. NR: Not Recommended.

Table 1

Figure 11

+ 30 hidden pages