Powermatic DT45 User Manual

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Operating Instructions and Parts Manual

Single End Dovetailer

Model DT45

WMH TOOL GROUP, Inc.

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 Centers 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

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 Center in your area call 1-800-274-6848.

Warranty and Service .............................................................................................................................. 2

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

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

Description .............................................................................................................................................. 6

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

Features of the DT45 Dovetailer.............................................................................................................. 7

Terminology ............................................................................................................................................ 7

Unpacking ............................................................................................................................................... 8

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

Installation & Assembly............................................................................................................................9

Installing Handle ..................................................................................................................................9

Installing Switch ................................................................................................................................. 10

Installing Dust Hood........................................................................................................................... 10

Installing Clamping Handles............................................................................................................... 10

Dust Collection................................................................................................................................... 10

Grounding Instructions ....................................................................................................................... 11

115 Volt Operation ............................................................................................................................. 11

230 Volt Operation ............................................................................................................................. 12

Extension cords ................................................................................................................................. 12

Adjustments .......................................................................................................................................... 13

Lower Work Support .......................................................................................................................... 13

Locking Handles ................................................................................................................................13

Clamping Bars ................................................................................................................................... 13

Template Bar ..................................................................................................................................... 14

Horizontal and Vertical Fences........................................................................................................... 14

Buffer Pads........................................................................................................................................ 16

Cutter Height...................................................................................................................................... 16

Mortise Depth .................................................................................................................................... 16

Thickness of Tenon Cut ..................................................................................................................... 17

Tightness of Mortise/Tenon Fit ........................................................................................................... 17

Drive Belt Tension..............................................................................................................................18

Replacing Cutter ................................................................................................................................ 18

Operation.............................................................................................................................................. 18

Preventing Chip Out........................................................................................................................... 20

Dovetails in Plywood.......................................................................................................................... 20

Maintenance.......................................................................................................................................... 21

Lubrication ......................................................................................................................................... 21

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

Parts List: Base Assembly..................................................................................................................24

Base Assembly.................................................................................................................................. 25

Parts List: Headstock Assembly ......................................................................................................... 26

Headstock Assembly.......................................................................................................................... 27

Parts List: Cabinet Assembly.............................................................................................................. 28

Electrical Connections – 115 volt ........................................................................................................... 29

Electrical Connections – 230 volt ........................................................................................................... 30

Warning

1. Read and understand the entire owner’s 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 dovetailer 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 dovetailer, do not use until proper training and knowledge have been obtained.

5. Do not use this dovetailer 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 dovetailer. Everyday eyeglasses

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

7. Before operating this dovetailer, 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 switch is in the OFF position before connecting the machine to the power supply.

12. Make certain the machine is properly grounded.

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

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 it 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. 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 starter 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 cutter 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 cutters sharp and clean for the best and safest performance. Follow

instructions for lubricating and changing accessories.

26. Make sure the work piece is securely attached or clamped to the table. Never use your hand to hold

the work piece.

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

not use your hands.

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

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

cutter comes to a complete stop.

30. 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.

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 WMH Tool Group, Inc., covering the safe operation and maintenance procedures for a Model DT45 Single End Dovetailer. 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 to 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.

Description

The Model DT45 Dovetailer will make cleanly cut half-blind dovetails for drawer or box construction. A four-sided template allows any of four pitches, from 1” up to 2-1/2”. The use of different dovetail pitches will give a unique custom appearance to your work. The cutter is carbide-tipped. The machine is built to last with cast iron and steel construction. The manual clamping system is quick and easy to use.

Specifications

Model Number...................................................................................................................................DT45

Stock Number...............................................................................................................................1791304

Minimum work piece size (in.)................................................................................................ 7-7/8 x 2-3/8

Maximum work piece size (in.)........................................................................................................31 x 11

Minimum dovetail height (in.) .............................................................................................................. 3/16

Maximum dovetail height (in.) ............................................................................................................... 3/4

Minimum front thickness (in.) .............................................................................................................. 9/32

Maximum front thickness (in.) ............................................................................................................ 1-3/4

Minimum side thickness (in.)............................................................................................................... 9/32

Maximum side thickness (in.)........................................................................................................... 1-3/16

Number of spindles..................................................................................................................................1

Spindle speed (RPM)...................................................................................................................... 18,500

Center-to-center dovetail spacing (in.) .......................................................................1, 1-1/2, 2, and 2-1/2

Table height from floor (in.).................................................................................................................... 35

Overall dimensions (L x W x H) (in.)........................................................................................ 33 x 33 x 61

Motor....................................................................................... TEFC, 1HP, 1Ph, 115/230V (prewired 115)

Dust collection ports diameter (in.).................................................................................. front 2-1/2, rear 4

Dust collection minimum CFM required................................................................................................ 500

Approximate Weight, Shipping/Net (lbs.)........................................................................................447/345

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

Features of the DT45 Dovetailer

Terminology

Below are the terms used in this manual to identify types of cuts and measurements.

Unpacking

Open shipping container and check for shipping damage. Report any damage immediately to your distributor and shipping agent. Do not discard any shipping material until the dovetailer is assembled and running properly.

Remove the box from inside the cabinet. Compare the contents of your container with the following parts list 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.

Contents of the Shipping Container

1 Dovetail Machine 2 Clamping Handles (with hex nuts) 1 Set of Open-Ended Wrenches (8-10, 11-13,

12-14 and 17-19mm) 1 Set of Hex Wrenches (1.5 to 6mm) 2 Sample Dovetailed Boards 1 Owner's Manual 1 Warranty Card

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

or operation! Failure to comply may cause serious injury.

Installation & Assembly

Tools required for assembly

forklift or hoist with straps/slings 11mm wrench (provided)

[NOTE: A socket set with ratchet wrench may

speed assembly] 4 and 5mm hex wrenches (provided) knife or wire cutter

1. Remove the four screws and flat washers

holding the machine to the pallet with an 11mm wrench, as shown in Figure 1.

2. Place lifting straps through the two eyebolts

at the top of the machine (Figure 2). Using a forklift or hoist, lift the machine off the pallet and into its desired location. The Dovetailer should be located in a dry area with sufficient lighting. Leave plenty of space around the machine for operations and routine maintenance work.

3. When the machine is situated, the eyebolts

(Figure 2) can be left on the machine, or unscrewed and removed, if so desired. Be sure to retain the eye bolts for future use.

4. If desired, the Dovetailer can be further

stabilized by securing it to the floor, using lag screws through the four holes at the bottom of the cabinet.

Figure 1

Figure 2

The dovetailer should be

unplugged from the power source during assembly procedures.

5. A cord holds the headstock secure to an

eyebolt to prevent the headstock from moving during shipping. This cord should now be cut and removed.

6. Exposed metal areas of the dovetailer

(such as the table, template bar, clamp bars, rods, etc.) have been factory coated with a protectant. This should be removed with a soft cloth dampened with kerosene or mineral spirits. Do not use an abrasive pad. Do not let solvent contact plastic or rubber parts as it may damage them.

Installing Handle

The rubber-covered handle (Figure 3) has been placed backwards for shipping purposes, and must be reversed before operating the machine.

1. Remove the four socket head cap screws

from the headstock (two of them are holding the handle), and turn the handle around as shown in Figure 3.

2. Secure the handle to the headstock with all

four socket head cap screws.

Figure 3

3. Tighten the four socket head cap screws.

Installing Switch

1. Remove any protective wrapping from the

switch.

2. Remove the two socket head cap screws

from their holes on the left side of the frame with a 5mm hex wrench. See Figure 4.

3. Place the flange of the switch box over the

holes, and re-insert the two socket head cap screws, as shown in Figure 4.

4. Tighten both socket head cap screws.

Installing Dust Hood

1. Open the cabinet door and pull out the dust

hood, which is connected to a hose.

2. Loosen the two socket head cap screws on

the front of the headstock (Figure 5) with a 4mm hex wrench.

3. Slide the flanges of the dust hood behind

the screws and flat washers as shown.

4. Tighten both socket head cap screws.

Installing Clamping Handles

There are two hubs at the right side of the machine which are used for clamping (Figure 6). Screw one clamp handle into a threaded hole on each hub. (Each hub has three such holes – choose one that will prevent the clamping handles from conflicting with each other.)

Figure 4

Figure 5

When the clamping handles are screwed in completely, tighten the hex nuts against the hubs with a 19mm wrench.

Dust Collection

The use of a dust collection system is recommended for this machine. It will help keep your shop clean as well as minimize any health risks caused by wood dust. Make sure your dust collector has a capacity of at least 500 CFM. Connect the intake hose of your dust collector to the 4” diameter port at the back of the cabinet. See Figure 7.

NOTE: A wide variety of dust collection systems are available from WMH Tool Group. Call customer service at 1-800-274-6848 for more information.

Figure 6

Figure 7

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