Powermatic 201 User Manual

22" PLANER

Model 201

Instruction Manual & Parts List

M-0460224

(800) 274-6848

www.powermatic.com

This manual has been prepared for the owner and operators of a Powermatic M odel 201 Planer. Its purpose, aside from machine operation, is to promote safety t hrough the use of accepted correct oper ating and maintenance procedures. Completely r ead the safety and maintenanc e instructions before operating or servici ng the machi ne. To obtain maximum life and efficiency f r om your pl aner , and to aid i n usi ng the machine safely, read this manual thoroughly and follow all instr uc tions caref ully.

Warranty & Service

WM H Tool Group warrants every product it sell s. If one of our tool s needs service or repair, one of our Authorized Repair Stations located throughout the United States can give you qui c k servi c e.

In most cases, any one of these WMH Tool Gr oup Repair Stations can aut hor ize warranty repair, assist you in obtaining parts, or perform rout ine maintenance and major repair on your J E T, Performax, Powermatic, or Wilton tools.

For the nam e of an Authorized Repair Station in your area, call 1-800-274- 6848.

More Information

WM H Tool Group is consistently adding new products to the li ne. For complete, up- to-date product informati on, check with your local WMH Tool Group distributor or visit wmhtoolgr oup.com.

Limited Warranty

WM H Tool Group makes ev er y effort to assure that its products meet high quality and durability standards and warrants to the original retail consumer/purchaser of our products that eac h pr oduc t be free from defects in materials and workmanship as follows: 1 YEAR LIMITED WARRANTY ON ALL PRODUCTS UNLESS SPECIFIED OTHERWISE. This warranty does not apply to defects due directly or i ndirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, repair or alterations outside our facilities, or to a lack of maintenance.

WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD SPECIFIED ABOVE, FROM THE DATE THE PRODUCT WAS PURCHASED AT RETAIL. EXCEPT AS STATED HEREI N, ANY IMPLIED WARRANTIES OR MERCHANTI B I LI TY 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 CONSEQUENTI AL DAMAGES ARISING FROM THE USE O F 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 Repai r Station designated by our office. P r oof of purchase date and an expl anation of the complaint must accompany the merchandise. If our inspecti on discloses a defect , W MH Tool Group will either repair or replace the pr oduc t, or refund the purchase pric e if we cannot r eadily and qui c k ly provide a repair or replacement, i f you are willing to accept a ref und. W M H Tool Group will return repaired product or replac ement at our expense, but if it is deter mined there is no defect, or that the defect resulted from causes not within the scope of our warrant y, then the user must bear the cost of storing and returning the product. This warranty gives you specific legal rights; you may al so have other r ights which var y from state to state.

WM H Tool Group sells through distributors only. W M H Tool Group reserves the right to effect at any tim e, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem nec essary for any reason whatsoever.

TABLE OF CONTENTS

Safety Rules.................................................................................................................................................... 4-5

Safety: Decals.................................................................................................................................................... 6

Specifications.....................................................................................................................................................7

Receiving...........................................................................................................................................................8

Installation..........................................................................................................................................................8

Installing Dust Chute......................................................................................................................................8

Inspection...........................................................................................................................................................9

Adjustments........................................................................................................................................................9

Depth of Cut..................................................................................................................................................9

Feed Rate Adjustment...................................................................................................................................9

Belt Tension ..................................................................................................................................................9

Opening Hood .............................................................................................................................................10

Knife Install ation & Adjustment ....................................................................................................................10

The Feed System of Your P laner.................................................................................................................11

Anti-Kickback F ingers.............................................................................................................................11

Infeed Roll..............................................................................................................................................11

Chipbreaker............................................................................................................................................12

Pressure Bar...........................................................................................................................................12

Outf eed Roll ...........................................................................................................................................13

Table Roll s .............................................................................................................................................13

Table Adjustments ......................................................................................................................................14

Test Cutti ng & Trouble-S hooting..................................................................................................................14-16

Maintenance.....................................................................................................................................................17

Lubrication.................................................................................................................................................17

Trouble-Shooting......................................................................................................................................... 18-20

Parts Lists & Exploded Views:

Gearbox Assembly............................................................................................................................... 21-22

Cutterhead Assembly............................................................................................................................23-25

Top Cover Assembly............................................................................................................................26-27

Column Assembly.................................................................................................................................28-29

Table Assembly....................................................................................................................................30-31

Base Assembly.....................................................................................................................................32-34

Electrical Sc hematics:

7.5HP 1Ph 230V.......................................................................................................................................35

7.5HP 3Ph 230V............................................................................................................................... ........36

7.5HP 3Ph 460V............................................................................................................................... ........37

SAFETY RULES

As with all m ac hines, t here i s a cert ain am ount of hazar d invol ved with the use of thi s planer. Use the machine with the respect and cauti on demanded where safety precaut ions are concerned. When normal saf ety precautions are overlooked or ignor ed, personal injury to the operator can result.

Read, understand and follow the safety and operat ing instructions found in this m anual. Know the limi tations and hazards associated with this planer.

Electrical grounding. Make certain that the machine fram e is electricall y grounded and that a ground l ead is included in the incoming el ectrical serv ice. In cases where a cord and plug ar e used, make certain that t he grounding plug connects to a suitabl e gr ound. Follow the grounding procedure indicated in the National Elec trical Code.

Eye safety. Wear an approved safety shield, goggles, or glasses to protect ey es. ( NOTE: Common eyeglasses are only impact-r esi stant, they are not safety glasses.)

Personal protection. Before operat ing the mac hine, remove tie, rings, watch and other jewel r y and r oll up sleeves above t he elbows. Remove all loose outer clothing and confine long hair. Prot ective type footwear should be used. Wher e the noise exceeds the lev el of exposure allowed i n S ec tion 1910.95 of the OSHA Regulations, use hearing protecti ve devic es. Do not wear gloves.

Guards. Keep the machine guards in place for every oper ation f or which they can be used. If any guards are removed f or maintenanc e, DO NOT OPERATE t he machine unt il the guar ds are reinstall ed.

Work area. Keep the floor around the machi ne clean and f r ee of scrap m aterial, saw dust, oil and other liqui ds to minimi z e the danger of t ripping or sl ipping. B e sure t he table is free of all scrap, foreign materi al and tools before starting to cut. Make cer tain the work area is well li ghted and that a proper exhaust system i s used to minimize dust. Powermati c r ec ommends the use of anti-skid floor strips on the floor area where the oper ator normally stands and that each m ac hine’s work area be marked off . Provide adequate work space around the machine.

Avoid accidental starting: Make cer tain m otor switch is in off posi tion bef ore connecting power to the planer. Operator position. Maintain a balanced stanc e and k eep your body under control at all times. Stand to the lef t

side out of line with the table and make sure no one else is standing in line with the table. Housekeeping. Before turning on machine, remove all extra equipment such as keys, wrenches, scrap, and

cleaning rags away from the machine Careless acts. Giv e the work you are doing your undiv ided attention. Looki ng ar ound, carryi ng on a c onversation,

and “horseplay” are car eless acts that can result in serious inj ur y . Disconnect machine before perf orming any servi c e or maintenanc e or when changing blades. A m ac hine under

repair should be RED TAGGED t o show it shoul d not be used until the maintenance is com plete. Maintain tools in top condition. Keep tool s sharp and cl ean for saf e and best per form ance. Dull tools increase

noise levels and can cause kic k bac ks and glazed surfaces. B r oken tools or tools that are not securely locked in the cutterhead can be t hrown out of the planer causing severe or fatal injury as well as sev er e damage to the machine. Check the condition and adjustment of the tool s before making any cuts. F ollow the sharpening instructions on knife grinding and jointing, installing and adjustments.

Short sto ck: Do not attem pt to plane boar ds shorter than 12" (305mm ) in l ength without butt ing a board of equal thickness behind it to help it through the pl aner. B e sure the last board of a butted sequence is 12" (305mm) long or longer.

Stacked boards: Do not feed stacked boards through a pl aner ; a kickback can occur causing severe or fatal i njury.

If stock sto ps feedi ng: I f t he board being pl aned stops feedi ng, disengage or turn the feed off and turn the power off . W ait unt il the cutterhead comes t o a compl ete stop before lowering the tabl e to remov e the board. NEVER lower the tabl e with the power on and the stock still in the machine, as a kickback can occur.

Hand safety. Keep hands outside t he machine. NEVER reach under the guards to try to clear stock that stops feeding. Do not clear c hips and sawdust with hands; use a brush. Do not have any part of t he hands under t hat part of the board that is over the table when starting a cut ; the infeed roll will engage the board and force it down against the table causing a pinching ac tion.

Cutterhead rotation: Be sure cutterhead rot ates under power in a countercl ockwise di rection when viewed from the mai n drive motor side.

Material condition: Do not plane boards with l oose knots or wit h nai ls or any foreign m at eri al on i ts surf ace. Knif e impact on t hese obj ect s can cause the kni ves to be pul l ed out and c ause them to shatt er agai nst the c hipbr eaker or pressure bar. Twisted, warped, or wi nd in stock should f i rst be joi nted on one surf ace befor e attem pting t o plane a parallel surface on t he planer. Serious stock flaws cannot be removed by use of a planer alone.

Machine cap acity: Do not make any c uts requiri ng mor e power than is av ail able on the m achi ne. Do not attempt to feed two boards side by side (multiple board surfacing) on any m ac hine not equipped with sectionalized infeed roll and chipbreaker. NOTE: The 22" Pl aner i s rated at 7.5 horsepower with max im um cutt erhead speed of 4800 RPM. DO NOT equi p your pl aner wit h a m ot or of hi gher horsepower or run the c utt erhead i n ex cess of 4800 RP M. Doi ng so voids the warranty and Powermatic holds it sel f harmless from any inj ur y that may r esul t.

Machine adjustment s: M ake all machine adjustments with power off except feed rate. Job completion. I f the operat or leaves the machi ne ar ea for any reason, the planer should be turned "off" and the

cutterhead should c ome to a complete stop before his departur e. In addit ion, if the operat ion is complete, he should clean the planer and the work area. NEVER clean the planer with power "on" and never use the hands to clear sawdust and debris; use a brush. Disconnect mac hine fr om power source before c leaning.

Replacement p art s. Use only Powermat ic or factory author ized replac ement part s and accessories; otherwise the warranty and guarantee i s nul l and v oid.

Misuse. Do not use t his Powermatic planer f or other than its intended use. If used for ot her pur poses, Powerm atic disclai ms any real or impl ied warranty and holds i tself harmless for any injury or damage which may result from t hat use.

If you are not thor oughly familiar with the operation of planers, obtain advice from your supervisor, instructor or other quali fied per son.

Drugs, alcohol, medication. Do not operate this m ac hine while under t he influence of drugs, alcohol, or any medication.

Health hazards. Som e dust c r eated by power sanding, sawing, grinding, drilling and other construction activi ties contains chemicals known to cause cancer , birth defects or other r epr oduc tive harm. Some exampl es of these chemic als are: * Lead from lead-based paint . * Crystalline silica from bricks and cement and other m asonry pr oduc ts. * Arsenic and chromium from chemi c ally-treated lumber. Your risk from t hese exposures varies, depending on how often you do this type of work. To reduc e y our exposure to these chemicals, work in a wel l-ventil ated area, and work with approved saf ety equipm ent, such as those dust masks that are speci fically designed to fi lter out microscopic parti c les.

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

CAUTION: (This m eans that if pr ec autions are not heeded, it may result in minor or moderate i njury

and/or possible machine dam age)

WARNING: (Thi s means that if precautions are not heeded, it could result in serious injury or

possibly even death).

SAFETY

Familiarize yourself with the location and content of this decal on y our machine.

1. Read instruction manual before operating machine.

2. Do not operate wi thout all gu ards properl y installed.

3. Remove or fasten loose articles of clothing such as neckties, etc. Contain l ong hair.

4. Remove jewelry such as finger rings, watches, bracelets, etc.

5. Use approved safety glasses and/or face shield to protect eyes, and use other personal safety equipment as required. Do not wear gloves.

DO NOT REMOVE OR OBSCURE THIS LABEL

6. Disconnect machine from power source before making any adjustments or cleaning chips away from machine.

7. Keep the floor around machine clean and free from scraps, sawdust, oil and grease to minimize the danger of slipp ing.

8. Do not operate this machine w hile under t he influence of alc ohol or drugs.

9. Failure to comply with these warnings may result in serious personal injury.

SPECIFICATIONS: Model 201, 22” Planer

Table with standar d extensions........................................................................................................................ 28” x 38”

Maximum cutting width.............................................................................................................................................22"

Maximum thickness.................................................................................................................................................1/4"

Full wi dth depth of c ut............................................................................................................................................3/16"

Minimum planing lengt h............................................................................................................................................10"

Number of knives ........................................................................................................................................................4

Cutterhead speed ..........................................................................................................................................4800 RPM

Cuts per minute...................................................................................................................................................19,200

Cutterhead diameter.............................................................................................................................................3-1/4"

Blade size ............................................................................................................................22-1/8" L x 7/8" W x 1/8" T

Feed rate...................................................................................................................................................20 & 30 FPM

Overall dimensions................................................................................................................ 32-1/4" W x 50" H x 50" L

Motor......................................................................... 7.5 HP, 3 Ph, 230V or 7.5 HP, 3 Ph, 460V or 7.5 HP, 1 Ph, 230V

Shipping weight..............................................................................................................................................1,197 lbs.

NOTE: T he above speci fications were current at the time this m anual was published, but because of our poli c y of continuous improvement, Powermatic reserves the right t o c hange specifications without notice and wit hout incurring obligat ions.

RECEIVING

Open shipping crate and check for shipping damage. Report any damage immediately to your distributor. Read the instruction manual thoroughly for assembly, maint enanc e and safety i nstr uc tions. Contents of crate: 1 planer 1 dust chute w/ hardware

4 special hex head screws w/ hex nuts 4 foot pads w/ hardware 1 knif e- set ting gauge 1 6mm hex wrench 1 8mm hex wrench 1 10mm hex wrench 1 12mm & 14mm wrench 1 22mm & 24mm wrench

INSTALLATION

Remov e the screws holding the base of the m achine to the skid. Use t he lifti ng eyes on front and back of t he planer for hoisting it off the skid. See Figure 1. Make sure the hex nut s are tight ened before l if ti ng. The ey es should be removed once the planer is situated.

Place the planer on a solid foundation, preferably a concrete floor. The four foot pads should be placed beneath the corners and the screws and hex nuts used for l ev el i ng adj ustm ents. A lt ernat el y, y ou can secure the machine to the floor by using lag screws through the holes in the base.

The machi ne area should be clean, dry, well v enti lated, and well lighted. Since planers can create noise problems, the site selection should be one which minimizes reverberant sound from walls, ceilings and other equi pment. Elect ricals should be install ed so t hat they are protec ted f r om dam age and ex posure. Be sure to properly gr ound the machi ne frame.

Exposed metal parts have been given a protective coating at the factory. This should be removed with a soft rag and kerosene or a good commercial solvent. Do not use an abrasive pad.

Powermatic strongly recommends that an exhaust system be used with this machine. It should be of sufficient volume for this size planer. If an exhaust system is not used, the user is cautioned against the health haz ar d and the lim itations in the OSHA r egulation for employee or student exposure to dust particles.

INSTALLING DUST CHUTE

Mount the dust chute with the eight M6 x 10mm hex screws, eight spring washers, and eight flat washers. See Figure 2.

INSPECTION

Before putting power to the machine, check that all

screws are tight, that all mechanical functions work

freel y and that the cutterhead t urns freely without knif e

contact wit h the chipbreaker or pr essure bar.

ADJUSTMENTS

Tools required

Philips screwdriver

Hex wrenches (provided)

Open-end wrench (provided)

DEPTH OF CUT

Depth of cut is controlled by raising or lowering the

table. T his is done by using the handwheel (A), shown

in Figure 3.

1. Loosen the lock knob (B ) .

2. Raise or lower the table to the desired position

(clockwise to raise). One revolution of the handwheel

equals 1/16". The distance can be read on the scale

(C).

3. Retighten lock knob (B).

4. The pointer ( D) can be adjusted i f the scale should

ever need r ecalibrating.

FEED RATE ADJUSTMENT

The Model 201 is equipped with selectabl e feed speed

rolls t hat feed stoc k at 20 and 30 feet per minute. To

adjust speed, turn lever shown in Figure 4.

IMPORTANT: Always change speeds while the

machine is running.

BELT TENSION

1. Disconnect m achine f r om power source.

2. Remov e lower rear panel of machi ne, and use the

hex nuts to adj ust tension. See Figur e 5. Adjust motor

plate up or down until correct belt tension is achiev ed.

To lower motor plate, loosen lower nuts and tighten

upper nuts. To raise motor pl ate, do the opposit e.

3. Correct tension is obtained when there is

approxim ately 1/4" defl ection in the center span of the

belts using light f inger pressure.

4. Re-tighten the nuts and replace panel. 9

OPENING HOOD

To open t he hood for acc ess to the cutterhead, rem ov e the two hex screws with the 22mm wrench provided. See Figure 6.

KNIFE INSTALLATION & ADJUSTMENT

CAUTION: Use care w hen placing han ds near

knives as they are extremely sharp and can cause severe cuts.

Installi ng knives on a planer is an exac ting process. If the kni ves ar e not to be j ointed and ground, end-t o-end and knif e-to-knif e relat ionship must be hel d within .001" (.03mm) for accurate and smooth planing. To help avoid cutterhead distortion in changing out a set of kniv es, rem ove and repl ace the knif e in one slot before changing the next knife. Any knif e adjustm ent or replacem ent should be done to all four kni v es at the sam e tim e. Fai lur e to do thi s may result in an out -of-bal ance cutterhead which can lead to bearing f ailure.

1. Disconnect m achine f r om power source.

2. To remove k nife, loosen the six hex head screws. See Figure 7.

3. The knife is spring loaded and will rise up in the slot. Carefully rem ove knife f rom cutterhead by lifting straight out. Remove gib and springs, and clean any dust, pit ch or accumul ated foreign mat ter from t he sl ot and the gib.

4. Replace the springs and gib into the slot, then insert new knife and loosely snug the six hex head screws.

5. Carefully place the knife-setting gauge until it contacts t he cut terhead, as shown in Figur e 8. Thi s will hold the high point of the knives to the proper height above the cutterhead (approximately 1/8” or 3.18mm). Use the gauge at both ends of the kni fe, then check t he center section to be sure it is even. If it is low, try backing off slightly on the center gib screw to allow blade to com e up. Gentl y tap blade down with piece of wood until i t conform s to the gauge height. Recheck the full length of the knife.

NOTE: If all knives have been removed, a new set must be installed with the gib screws lightly snugged down but not full y t ight ened. A ll kni ves and gibs should be in place before tightening. Locking one knife in without the others in position can cause cutterhead distortion. The tightening process should proceed working from the center out on each knife and after locking al l gib screws once, repeat the same sequence until all screws are equally tight.

WARNING: After installing kn ives, re-check

all gib screws. Loose gib screws can result in knives being t hrown o ut of th e cutterhead,

causing severe damage to the machine an d possible serious or fatal injury to the operator or bystanders.

THE FEED SYSTEM OF YOUR PLANER

(Figure 9)

1. Anti-kickback fingers

2. Infeed roll

3. Chipbreaker

4. Cutterhead

5. Pressure bar

6. Outfeed roll

ANTI-KICKBACK FINGERS Anti-kickback fingers help prevent stock from being

thrown from the machine. These fingers operate by gravi ty and should be inspected before each day's use for pitch or gum buildup. The fingers must operate freel y and move independently for c or r ec t operation.

INFEED ROLL

The funct i on of t he infeed roll i s to f eed the mat eri al into the machine. It is a corrugated, sectional roll with approximately 5/16" independent movement of each section to acc omodate m ultiple board surfacing. To provide proper drive, it should be set so that the bottom of its arc is 1/16" (1. 6mm) below the arc of the cutterhead knives. The infeed roll is under spring tension and this tension must be sufficient to feed the stock uniformly through the planer without slipping but should not be so tight that it causes damage to the boards. The tension should be equal at both ends of each roll.

To adjust the infeed roll:

1. Place a bed and feed roll gauge (accessory #2230002) under a k nif e in t he cutterhead and r aise the table unti l the gauge c ontact s the kni f e at the apex of i t s curv e. See Figur e 10.

NOTE: If a bed and feed roll gauge is not available, use a finished block of wood with notches cut out for the table rolls, and a feeler gauge. See Figure 11 for an example of a wood bloc k used for a gauge.

2. Move the gauge to the extreme left side of the infeed roll and check the measurement. It should be 1/16" below the kni fe measurem ent. It if is not, correct with the adjustm ent screws (A) on top the side panels, shown in Figure 12.

3. Move the gauge t o the ex t rem e opposite end of the infeed r oll and check . Make necessary adjustments.

It is important that t he setting on bot h si des of the infeed roll be the same height to help avoid skewing of the material as it is fed thr ough the machi ne.

CHIPBREAKER The chipbreak er is a sectionali zed type made of 1" side

spring-loaded secti ons mounted on a bar which swings concentric with the cutterhead. The functions of the chipbreaker are to break chips into small pieces, help avoi d splinteri ng of the wood, hel p avoid board bounc e on thinner boards, t o direct the fl ow of chi ps out of the machine, and to perm it multiple board surfacing.

The chipbreaker in its free position should be 1/32" (.8mm) below the cut ting arc of the kni ves.

CAUTION : A chi pbreaker set too low may

prevent sto ck f rom feeding into t he machine.

Using the same m ethod as indicated f or the infeed roll, adjust the chipbreaker free position using a bed and feed roll gauge and adjust the screws (B) in the piv ot arm at each end if necessary. See Figure 12. It is important that each end be the same height to help avoid skewing of the material as it is fed through the machine. NOTE: If the infeed roll setting is altered, the chipbreaker must be re-adjusted.

PRESSURE BAR Most planing pr oblem s can be traced to im pr oper setting

of the pressure bar. Its function is to hold down the material after it passes under the cutterhead and throughout the rem ainder of the cut. Its basic setting is to be in line with the arc of the cutterhead knives.

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