Powermatic 66 User Manual

Operating Instructions and Parts Manual

10-inch Table Saw

Model 66

shown with optional extension table and legs,

mobile base, and motor cover

WMH TOOL GROUP

This manual has been prepared for the owner and operat ors of a Powerm atic 66 Table S aw. Its purpose, aside from machine operation, is to promote safety using accepted operating and maintenance procedures. To obtain maximum life and efficiency from your table saw and to aid in using it safely, please read this manual thoroughly and follow the instruct ions carefully.

Warranty and Service

WMH Tool Gr oup warrants ever y product it sell s. If one of our tools needs s ervice or repai r, one of our Authorized Repair St ations located throughout the United St ates can provide quick service or information.

In most cases, a WM H Tool Group Repair Station can assi st in authorizing r epair work, obtaining par ts, or perform routi ne or m ajor maintenance repair on your Powermatic product.

For the nam e of an A uthoriz ed Repair St ation in your area, pl ease call 1-800-274-6848, or v isit our web site at www.wmhtoolgroup.com

More Information

Remember, WMH Tool Group i s consistently adding new products to the li ne. For complete, up-to-dat e product information, check with your local WMH Tool Group distributor, or visit our web site at www.wmhtoolgroup.com

WMH Tool Group Warranty

WMH Tool Group makes every effort to assure that its products meet high qualit y and durability standards and warrants to the original retail consumer/purchaser of our products that each product be free from defects in mat erials and workmanship as foll ows: 1 YEA R LIMITED WARRANTY ON ALL PRODUCTS UNLESS SPECIFIED OTHERWISE. This Warranty does not apply to defects due directly or i ndirectly to misuse, abuse, negl igence or acc idents, norm al wear-and-tear , repair or alterati ons outside our f aciliti es, or to a lack of maintenanc e.

WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD SPECIFIED ABOVE, BEGINNING FROM THE DATE THE PRODUCT WAS PURCHASED AT RETAIL. 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. IN NO EVENT SHALL WMH TOOL GROUP 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.

To take advantage of this warranty, the product or part must be returned for examination, postage prepaid, to an Authorized Repair Station designated by our office. Proof of purchase date and an explanati on of the complaint m ust accompany the merchandi se. If our inspecti on discloses a defec t, we will either repair or replace the product at our discret ion, or r efund t he purchase pri ce if we cannot readi l y and quickly provide a repai r or replac ement. We will return the repai red product or replacem ent at WMH Tool Group’s ex pense, but if it is determ ined there i s no defect, or that the def ect resulted f rom causes not within the scope of WMH Tool Group’s warranty, then the user must bear the cost of storing and returning t he product . This warranty gives you specifi c legal right s; you may also have ot her right s, which vary from state t o state.

WMH Tool Group sells through distribut ors only. Members of the WMH Tool Group reserve the right to effect at any time, wit hout prior notice, alter ations to parts, fittings and accessory equi pment, which they may deem necessary for any reason whatsoever.

Table of Contents

Warranty and Servic e ..............................................................................................................................2

Warning...................................................................................................................................................4

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

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

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

Contents of the Shipping Container......................................................................................................7

Installation and Assembly ........................................................................................................................8

Mounting Extensi on Wings...................................................................................................................8

Installing Blade.....................................................................................................................................9

Mounting Rails and Accu-Fence.........................................................................................................9

Optional Wood Extensi on Table ...........................................................................................................9

Splitter and Guar d Assembly................................................................................................................9

Motor Cover.......................................................................................................................................10

Grounding Instructions...........................................................................................................................10

Extensi on Cords.................................................................................................................................11

Adjustments...........................................................................................................................................11

Blade Raising and Tilting....................................................................................................................11

Miter Slot Alignment...........................................................................................................................11

Tilt Stop Adjustment...........................................................................................................................12

Miter Gauge Adjustm ent..................................................................................................................... 12

Belt Tensioning..................................................................................................................................12

Splitter Alignment...............................................................................................................................13

Insert Adjustment...............................................................................................................................13

Arbor and Arbor Beari ng Rem ov al......................................................................................................13

Blade Raisi ng Mechanism Adjustment................................................................................................13

Tilting Mechanism Adjustment............................................................................................................14

Operating Instructions for Table Saws....................................................................................................14

Rip Sawi ng.........................................................................................................................................16

Resawing...........................................................................................................................................17

Crosscutting .......................................................................................................................................17

Bevel and Miter Operat ions................................................................................................................18

Dado Cutting......................................................................................................................................19

Safety Devices...................................................................................................................................19

Maintenance..........................................................................................................................................20

Optional Accessories .............................................................................................................................23

Replacement Parts ................................................................................................................................23

Parts List: Trunnion Assembly............................................................................................................24

Trunnion Assembly.............................................................................................................................26

Parts List: Miter Gauge.......................................................................................................................27

Parts List: Spli tt er and Guard Assembly..............................................................................................28

Splitter and Guar d Assembly..............................................................................................................29

Parts List: Stand A ssembly.................................................................................................................30

Stand Assembly .................................................................................................................................31

Parts List: Table Extension and Legs (Optional Accessory)................................................................. 32

Electrical Connections ...........................................................................................................................33

Maintenance Checklist...........................................................................................................................37

Warning

1. Read and understand the entire owners manual befor e attempti ng assembly or operation.

2. Read and understand the warnings po sted on the m achine and i n thi s manual. Failur e to comply wit h

all of these warnings m ay cause seriou s i njury.

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

4. This table saw is desi gned and i nt ended f or use by properl y t rai ned and ex perienced per sonnel onl y.

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 tabl e saw for other than its intended use. If used f or other purposes, WMH Tool Group

disclaim s any real or i mplied warrant y and h olds itsel f harml ess from any injury t hat may r esult f rom that use.

6. Always wear approv ed safety glasses/face shiel ds whil e using this table saw. Everyday eyegl asses

only have impact resi stant lenses; they are not safet y glasses.

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

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

8. Wear ear protector s (plugs or muffs) during extended peri ods of oper ation.

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

contain chemi cals known to cause cancer , bir th defects or other r eproductiv e harm . Some examples of these chemic als are:

• Lead from lead based paint.

• Crystalli ne sil ic a from bricks, cement and other masonry pr oduc ts.

• 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 oper ate this machine while tir ed or under t he influence of drugs, alcohol or any m edic ation.

11. Mak e c er tain the switch is in the OFF position before connecting the machine to the power supply.

12. Mak e c er tain the machine is properly grounded.

13. Mak e all machine adj ustments or maintenance with the machine unplugged from t he power source. A

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

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

wrenches are removed from the machine before turning i t on.

15. 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.

16. Chec k the alignment of t he splitter, fence and miter slot to the blade. A caution decal is installed on

each guard and split ter to remind the operator of the dangers of misalignment.

17. 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 part s, binding of moving parts, br eakage of parts, mounting and any other condi ti ons that m ay affect its operati on. A guard or ot her part that i s damaged shoul d be properly repaired or replaced.

18. Pr ov ide for adequate space surroundi ng work area and non-glare, ov er head lighting.

19. Keep the floor around the machine cl ean and fr ee of scrap material, oil and grease.

blahblahblah

20. Keep v isitors a safe distance from the work area. Keep ch il dren away.

21. Mak e y our workshop child proof with padloc k s, m aster switches or by removing starter keys.

22. Giv e your work undivi ded attention. Looking ar ound, carryi ng on a conversation and “ horse-play” ar e

careless acts that can r esul t in serious injury.

23. Maintain a balanced stance at all times so that you do not fall or lean against the bl ade or other

moving part s. Do not over r eac h or use exc essive force to perform any machine operation.

24. Use the right tool at the corr ect speed and f eed rat e. Do not force a t ool or att achment to do a job for

which it was not designed. T he ri ght tool will do the job better and saf er.

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

26. Maintain t ools with care. Keep blade sharp and cl ean for the best and safest perf ormance. Follow

instructions for lubricating and changing accessories.

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

missing teeth or im pr oper set. Mak e sure the blade is securely locked on the arbor.

28. Keep hands cl ear of t he bl ade area. Do not reach pa st the bl ade t o cl ear part s or scrap with t he sa w

blade running. Never saw fr eehand. Avoid awkward oper ations and hand p ositions where a sudden slip coul d cause your hand to c ontact the blade.

29. Do not attempt to saw boards with l oose knots or with nails or other f oreign material, on its surface.

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

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

board to shift position.

31. Always use the splitter, blade guard, push stick and other safety devices for all operations where they

can be used. On op erati ons such as dadoi ng or m ol ding where the bl ade guard cannot be u sed, u se feather boards, f ixtures and other safety devi ces and use extrem e caution. Reinstall the splitter and blade guard immediately after completi ng the operation that required their removal.

32. Be sure t he sa w blade rotates clockwise when viewed from the motor side (left si de) of t he machine.

33. T ur n off the machi ne before cleaning. Use a brush or compressed air t o r emove chips or debris — do

not use your hands.

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

35. Never leave the machine running unattended. Turn t he power off and do not leave the machine until it

comes to a complete stop.

36. Remove loose items and unnecessary work pi ec es from the area before starting the machine.

Familiarize you r self with the following safety notices used in this manual:

This means that if precautions are not heeded, it may result in mi nor i njury and/or

possible machine damage.

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

even death.

- - SAVE THESE INSTRUCTIONS - -

Introduction

This manual is provided by W MH Tool Group cov ering the safe oper ation and mai ntenance procedure s for a Powermatic Model 66 Table Saw. This manual contains instructions on installation, safety precautions, gener al oper ati ng procedur es, mai ntenance i nstructi ons and parts breakdo wn. Thi s mac hine has been designed and con structed t o provide year s of troubl e free operation if used in accordance wi th instructi ons set forth i n this manual . If there are any questions or comm ents, 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........................................................................................................................................66

Maximu m moto r size.........................................................................................................5HP, 3600 RPM

Table size with standard ex tensions (L x W)(in.) ....................................................................... 37-1/2 x 28

Table size without ex tension (L x W)(in.).................................................................................. 21-1/2 x 28

Rip fence (L x W x H)( in.)................................................................................................41-3/4 x 4 x 2-1/2

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

Saw blade diameter (i n.)........................................................................................................................10

Maximum speed of 10” saw blade (SFM ) ........................................................................................ 11,000

Blade tilt maxim um (deg. ) ......................................................................................................................45

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

Maximum cut to right of saw blade with st andar d extension (in.).............................................................25

Maximum width of cutoff in front of saw in 1” stock (i n.)..........................................................................15

Maximum width of cutoff in front of saw in 3-1/8” stock (in.)..............................................................12-1/4

Maximum diam eter of dado (in.)...............................................................................................................8

Maximum width of dado cut (i n.)........................................................................................................ 13/16

Drive belts ....................................................................................................................3VX (t wo required)

Table he igh t to flo o r ( in.)........................................................................................................................34

Dust port diameter (i n.) ............................................................................................................................4

Shipping weight wi th motor, fence and rails (lbs.).................................................................................614

The above specifications were current at the time this manual was publi shed, but because of our policy of continuous im provement, WMH Tool Group reserv es the right to change specif ications at any tim e and without pri or notic e, without incurring obligations.

Unpacking

Open shipping cont ainer and check f or 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 cont ent s of y our cont ainer wit h the following parts list to make sure all parts are intact. Mi ssing parts, if any, should be reported to your distributor. Read the instruction manual thoroughly for assembly, maintenance and safety instructions.

Contents of the Shipping Container

Box 1: 1 Table Saw 2 Extension Wings 1 Miter Gauge 1 Owner’s Manual 1 Warranty Card Box 2: 1 Splitter and Guard Assembly 1 Splitter Support Shaft

Contents of Hardware Bag:

2 Arbor Wrenches 1 Hardware Bag*



Box 3: 1 Accu-Fence 1 Lock Handle 1 Accu-Fence Owner’s Manual Box 4: 1 Front Rail 1 Rear Rail 1 Guide Tube 1 Hardware Bag Box 5: 1 Motor Cover 2 Self-Tapping Screws

Optional:

Box 6: Formica Top Extension Table Box 7: Legs for Extension Table

*The contents of the hardware bag are illustrated below. The contents of the Accu-



Fence Accu-Fence

and Rail hardware can be found in the



manual.

Read and understand the entire contents of this manual before attemp ting set-up

or operation! Failure t o co mpl y may cause seri ous injury.

Installation and Assembly

Tools required for assembly:

7/16, 9/16, 3/8 and 1/ 2” wrenche s 1/8 and 3/32” hex wrenches Flat head screwdriver Hammer and wood block (or r ubber hammer)

1. Remove box and wood crating completely

from around saw.

2. Use a 9/16” wrench t o remove the car riage

bolt, hex nut and washer holding the extension wings together (Figure 1). Set extension wings aside for later installation.

3. With a 7/16” wrench, rem ov e t he lag screws

(Figure 2) holding the saw to the wood pallet. Caref ully sli de the saw from the pallet onto the floor.

4. Tilt the saw, and pop off the metal tabs

(Figure 2) that secured the saw to the pallet, by pushing down on them with y our foot .

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

Figure 1

Figure 2

Exposed metal surfaces, such as the table top and extension wings, have been given a protectiv e coating at the fact ory. 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.

Mounting Extension Wings

1. Mount the cast iron extension wings using

six 3/8-16 x 1 hex head screws and six 3/8 lock washers. See Figure 3. Have an assistant hold t he extension wing up to the table, and insert the screws and washers. Finger tighten only.

NOTE: If an assistant i s not avail able, 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 fi nger tight .

2. It is important that the front edge of the wing

is flush with the front edge of saw table. S ee Figure 4.

Figure 3

Figure 4

3. Level t he extension wing with the sa w table

across its enti re widt h, using a strai ght edge and hammer with block of wood (or rubber hammer). See Fi gure 5. As each area of the wing becomes flush with the table, tighten the screw under t hat area. Cont inue unti l all three screws are fully tightened.

4. Repeat for the other ex tension wing.

Installing Blade

NOTE: The blade m ust be mounted first bef ore rails can be adjusted.

To install or replac e a blade, proceed as follows:

Use care wh en working with

or around sharp saw blade.

1. Disconnect machine from power source.

2. Rem ove tabl e insert, then rem ove arbor nut

and collar.

3. Install blade, making sure the cutting teeth

at the top of t he blade poi nt toward the f r ont of the saw.

Figure 5

4. Sli de the coll ar on to the ar bor and start the

arbor nut on the threads. (NOTE: Righthand threads; turn clockwise to tighten.) Snug the arbor nut against the collar and blade with the pr ovided arbor wrench, while holding blade wit h thumb and finger tips.

5. Wedge a block of wood between the blade

and table to prevent blade rotation, then tighten t he arbor nut securel y with the ar bor wrench. See Figur e 6.

Mounting Rails and Accu-Fence

With the extension wings properly aligned, the rail and f ence assem bl y can no w be m ounted t o the saw. Consult the separate Accu-Fence manual for instructions.



Optional Wood Extension Table

For instructions on mounting the accessory wood extension table, or router table, consult your Accu-F enc e



manual.

Splitter and Guard Assembly

Figure 6

Figure 7

1. Insert the grooved end of the splitter support

shaft through slot in rear of saw and into hole in trunnion. See Figure 7. Make sure the square head setscrew (A, Figure 8) is backed out enough to allow easy insertion of the splitter support shaft.

Figure 8

2. With a 3/8" wrench, reach through the motor

opening in the stand and tight en the square head setscrew (A, F igure 8) into the groov e of the shaft. (NOTE: The groove will be in the proper posi tion if the end of the shaf t is made flush with the opposite side of the trunnion hol e.) Then tighten the hex nut (B, Figure 8) up against the trunnion.

3. The upright member of the rear splitter

support (C, Figure 9) must be oriented toward the right of the shaft, as observed from the rear of the saw.

4. Mount the splitter assembly to the two

adjusting screws. See Figure 9. Place the two flanges of t he spli tter assem bl y onto t he

crews as shown. S nug the scre ws. (NOT E: Make sure the front shield (D, Figure 9) faces in toward the blade)

5. The splitter and guard assembly must be aligned wit h the blade before operati ng the saw. Adjust the splitter according to the directions on page 13, " S plitter Alignment."

Moto r Cover

Figure 9

1. Locate the two 1/4-20 self tapping sheet metal screws and install them in the punched holes on the saw cabinet. Do not screw down all the way, but leave t he heads about 1/4" fr om the surf ac e. See Figure 10.

2. Lift the m otor cover over these scre ws with the cover's bottom lip inside the saw's cabinet.

3. Tighten the two screws.

Grounding Instructions

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 prov ided wit h the Model 66. You may either connect the proper UL/CSA listed pl ug or “hardwire” the mac hine directly t o your electrical panel provided there is a disconnect near the machine for the operator. Consult electrical drawings on pages 33-36 for further clarification of wiring setup.

This machine must be grounded. Grounding provides a path of least resi stance to hel p divert current away from the operator in case of electrical malfunction.

Figure 10

Recommended Gauges (AWG) of Extension Cords

Extension Cord Length *

100

150

Amps

< 5 16 16 16 14 12 12

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 li miting the line voltag e dr op to 5V at 15 0% of t h e rated amp eres. NR: Not Recommended.

feet

200 feet

Figure 11

Make sure the voltage of your power supply matches the specif ications on the m otor plate of the machine.

Extens ion Cords

If an extension cord is necessary, make sure the cord rating i s suitable for the am perage 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 Figure 11 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 cor d.

Adjustments

Blade Raising and Tilting

The front handwheel ( A, Figure 12) controls the raising and lowering of the blade. The side handwheel (B, Figure 12) controls blade tilt, which is indicated by the scale (C, Figure 12). The lock k nobs (D, Figure 12) are use d to lock the setting of the handwheel s.

Figure 12

Figure 13

Miter Slot Alignment

Disconnect machine from

power source before making this adjustment.

1. To check the alignment of the mitre slot to the blade, raise the blade to its maximum height at the 0 degree (vertical) position.

2. Mark one tooth with a grease pencil and position the tooth slightly above the top edge of the table at the front.

3. Raise the m iter gauge sli ghtly out of its slot to serve as a shoul der. Using a com bi nat ion square against the si de of the bar, slide t he scale over until it touches the tip of the blade, and lock the scale in position. See Figure 13.

4. Rotat e the m arked t ooth so that i t is sl ightly above the table top at the rear and, using the square as before, check whether the distance to the blade is the same. See Figure 14. If the distance is not the same, loosen the three m ounting screws that lock the table t o the cabinet ( two in front , one in back) as shown in Fi gure 15, and nudge the table to bring the miter slot in line with the blade.

Figure 14

Figure 15

5. The blade must be kept centered with the

slot in the table insert to ensure clearance at

oth the 90 degree and 45 degree posi tions. After alignment, secure the table to the cabinet by re-tightening the three mounting screws (Figur e 15) .

Tilt Stop Adjustment

Using a combination square, check the 90 degree (0) and 45 degree stops. (Figure 16 shows the 90 degree stop being checked.) Adjust stop positi ons if required, using the stop screws as shown. Check the accuracy of the pointer at 90 degrees (0) and re-adjust if required.

Miter Gauge Adjustment

1. Slide the miter gauge into one of the slots on the table top.

2. The miter gauge is equipped with individually adjustable index stops at 90 degrees and 45 degrees right and l eft. The index stops can be adjusted by loosening the hex nuts and turning t he three adjusting screws (A, Figure 17) as needed. After setting each stop, r etighten the hex nut.

Figure 16

3. To operate the miter gauge, loosen lock handle (B, Fi gure 17) and move t he body of the miter gauge (C, Figure 17) to the desired angle. T he miter gauge body is set to stop at 0 degrees and 45 degrees l eft or right. To move the miter gauge beyond these points, the stop rod (D, Figure 17), must be pulled out.

4. If accurate crosscutting work is to be done using the mit er gauge, check i t s squareness to the slot wit h a square as shown in F igure

17. Re-adjust the st op posi tion as required.

Belt Tensioning

The saw is equipped with a set of two matched belts. If they should need repl acement, replace the complete set.

To tension the belts: Loosen the hex screw (A, Figure 18) and nut (B,

Figure 18) on t he motor brac ket. Piv ot the mot or and bracket to the right. Retighten screw (A, Figure 18) and nut (B, Figure 18).

To remove and replace the belts, loosen the screw (A, Fi gure 18) and nut (B , Fi gure 18) and rotate t he mot or and brack et t o the l eft as f ar as possible. Remove one belt at a time. After installi ng new bel ts, re-tension as indicat ed.

Figure 17

Figure 18

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