Powermatic DT65 User Manual

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Operating Instructions and Parts Manual

Single End Dovetailer

Model DT65

Powermatic

Warranty and Service

Powermatic warrants every product it sells against manufacturers’ defects. If one of our tools needs service or repair, please contact Technical Service by calling 1-800-274-6846, 8AM to 5PM CST, Monday through Friday.

Warranty Period The general warranty lasts for the time period specified in the literature included with your product or on the official Powermatic branded website.

• Powermatic products carry a limited warranty which varies in duration based upon the product. (See chart below)

• Accessories carry a limited warranty of one year from the date of receipt.

• Consumable items are defined as expendable parts or accessories expected to become inoperable within a

reasonable amount of use and are covered by a 90 day limited warranty against manufacturer’s defects.

Who is Covered

This warranty covers only the initial purchaser of the product from the date of delivery.

What is Co vered

This warranty covers any defects in workmanship or materials subject to the limitations stated below. This warranty does not cover failures due directly or indirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, improper repair, alterations or lack of maintenance.

Warranty Limitations

Woodworking products with a Five Year Warranty that are used for commercial or industrial purposes default to a Two Year Warranty. Please contact Technical Service at 1-800-274-6846 for further clarification.

How to Get Technical Support Please contact Technical Service by calling 1-800-274-6846. Please note that you will be asked to provide pro of of initia l p u rch a s e whe n calling. If a product requires further inspection, the Technical Service representative will

explain and assist with any additional action needed. Powermatic has Authorized Service Centers located throughout the United States. For the name of an Authorized Service Center in your area call 1-800-274-6846 or use the Service Center Locator on the Powermatic website.

More Informa t io n

Powermatic is constantly adding new products. For complete, up-to-date product information, check with your local distributor or visit the Powermatic website.

How S tate Law Applies

This warranty gives you specific legal rights, subject to applicable state law.

Limitations on This Warranty

POWERMATIC LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

POWERMATIC 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.

Powermatic sells through distributors only. The specifications listed in Powermatic printed materials and on the official Powermatic website are given as general information and are not binding. Powermatic reserves 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.

Product Listing with Warranty Period

90 Days – Parts; Consumable items 1 Year – Motors, Machine Accessories 2 Year – Woodworking Machinery used for industrial or commercial purposes 5 Year – Woodworking Machinery

NOTE: Powermatic is a division of JPW Industries, Inc. References in this document to Powermatic also apply to JPW Industries, Inc., or any of its successors in interest to the Powermatic brand.

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

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

Warning ................................................................................................................................................... 4

Introduction ............................................................................................................................................. 6

Desc ription ................................................................................................................... ........................... 6

Specifica tions ................................................................................................................ .......................... 6

Features of the DT65 Dovetai ler .............................................................................................................. 7

Termino lo g y ............................................................................................................................................ 7

Unpac king ............................................................................................................................................... 8

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

Installati on & Assembly ............................................................................................................................ 9

Attaching Dust Hose ............................................................................................................................ 9

Installing Dust Chute .......................................................................................................................... 10

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

Grounding Inst r uc tions ....................................................................................................................... 10

230 Volt Operati on ............................................................................................................................. 11

Extension cords ................................................................................................................................. 11

Air Connecti on ................................................................................................................................... 1 1

Adjustments .......................................................................................................................................... 12

Clamping Cylinders ............................................................................................................................ 12

Clamping Pr e ssur e............................................................................................................................. 1 3

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

Template Bar ..................................................................................................................................... 13 

Indicat ion Template ............................................................................................................................ 14 

Fixed Chaser ..................................................................................................................................... 1 4

Horizontal and Vertical Fences ........................................................................................................... 15

Buffer Pads ........................................................................................................................................ 17

Cutter Height ...................................................................................................................................... 17

Mortise Depth .................................................................................................................................... 1 7

Thickness of Tenon Cut ..................................................................................................................... 18

Tightness of Morti se/Tenon Fit ........................................................................................................... 18

Drive Belt Tension .............................................................................................................................. 19

Replacing cutter ................................................................................................................................. 19

Oil Output .......................................................................................................................................... 19

Operation .............................................................................................................................................. 2 0

Preventing Chip Out ........................................................................................................................... 22

Dovetails in Plywood .......................................................................................................................... 22

Maintenance .......................................................................................................................................... 23

Lubrication ......................................................................................................................................... 23

Replacement Parts ................................................................................................................................ 26

Parts List: Base Assembly .................................................................................................................. 26

Base Assembly .................................................................................................................................. 27

Parts List: Hold-Down Assembly ........................................................................................................ 28

Hold-Down Assembly ......................................................................................................................... 29

Parts List: Headstoc k A ssembly ......................................................................................................... 30

Headstock Assembly .......................................................................................................................... 32 

Parts List: Cabinet Assembly .............................................................................................................. 33

Electri c al Connec tions ........................................................................................................................... 34



Warning

1. Read and understand the ent ire owner’s manual before att em pting assembly or operation.

2. Read and understand the warnings po sted on the m achine and i n thi s manual. Fail ure 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 dovetailer i s designed and i ntended f or use by pr operl y tr ained and ex peri enced 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, Powermatic 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. Al ways wear approved safety glasses/f ace shields while using thi s dovetailer. Everyday eyeglasses only have impact resi stant lenses; they are not safet y glasses.

7. Before operating this dovetailer, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all l oose clothing and confine long hair. Non-slip f ootwear or anti-skid 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 exampl es 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 tired or under t he influenc e of drugs, alcohol or any medic 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 adjustment s 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 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. 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. Chec k for alignment of moving par ts, binding of moving parts, breakage 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 should be properly repaired or replaced.

17. Pr ov ide for adequate space surrounding work area and non-glare, ov er head lighting.

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

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

20. Mak e y our workshop chi ld proof with padlocks, m aster switc hes or by r em ov ing starter keys.

21. Giv e your work undivi ded attention. Looki ng around, carryi ng on a conversati on and “horse-play” ar e careless acts that can r esul t in serious injury.

22. Maintain a balanced stance at all tim es so that you do not fall or lean against the cutter or other moving part s. Do not over r eac h or use excessive force to perform any machine oper ation.

23. Use the right tool at the correc t 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.

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

25. Mai ntain tools with care. Keep cutter s sharp and clean for the best and safest perf ormance. Follow instructions for lubricating and changing accessories.

26. Make sure the work piec e is securely clamped t o the table. Never use your hand to hold the work piece.

27. T ur n off the machi ne before cleaning. Use a brush or compressed air to remove chips or debri s — do not use your hands.

28. Do not stand on the machine. Serious injury c ould oc c ur if the mac hine tips over.

29. Never leave the machine runni ng unatt ended. T urn off the electrical power and t he air supply, and do not leave the machine until cutter comes to a complete stop.

30. Remove loose items and unnecessary work piec es from the area before starting the machine.

Familiariz e you rself 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 Powermati c covering the safe operat ion and maintenance pr ocedures for a Model DT65 Si ngle End Dov etailer. T his manual cont ains instr uctions on i nstallat ion, saf ety precauti ons, general operating procedures, maintenance instructions and parts breakdown. This machine has been designed and const ructed to pr ovide years of trouble free oper ation if used in accor dance to i nstructions set fort h in t his manual . If there are any que sti ons or c om m ents, please co ntac t ei ther your l ocal suppli er or Powermatic. Powermatic can also be reached at our web site: www.powermatic.com.

Description

The Model DT65 Dov etailer will make cleanly cut half-bl ind dovetails for drawer or box constr uction. A four-si ded template allows any of four pi tches, from 1” up to 2-1/2”. T he use of different dovetail pitches will give a unique custom appearance to your work. The cutter is carbide-tipped. The machine has a magnetic star ter, and is built to last wit h c ast iron and steel construction. The pneum atic clamping system is quick and easy to use.

Specifications

Model Number ...................................................................................................................................DT65

Stock Number...............................................................................................................................1791305

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

Maximum work piece size (in.) .................................................................................................. 59 x 16-1/2

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

Maximum dovetai l height (in.) ............................................................................................................... 3/4

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

Maximum front thickness (in.) ............................................................................................................ 2-3/8

Minimum side thickness (in.) ................................................................................................................. 3/8

Maximum side thi ckness (in.) ........................................................................................................... 1-3/16

Number of spindl es .................................................................................................................................. 1

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

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

Table he ig h t from floor (in .) .................................................................................................................... 45

Overall dimensions (L x W x H) (in.) ........................................................................................ 37 x 44 x 63

Motor ........................................................................................................... TEFC, 1HP, 1Ph, 230V, 60Hz

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

Dust collection minimum CFM required ................................................................................................ 50 0

Approximate Weight, Shipping/Net (lbs.) ....................................................................................... 510/420

The above specifications were current at the time t his manual was published, but bec ause of our policy of continuous im provement, Powerm atic reserves the right t o change specific ations at any time and without prior notic e, wit hout incurring obligations.

Features of the DT65 Dovetailer

Terminology

Below are the term s used in t his manual to identify types of cuts and measurement s.

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 shi pping material unt il the Dovetail er is assembled and r unning pr oper ly.

Remove the box from inside the cabinet. Compare the c ontent s of y our cont ainer wit h t he 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

1 Dovetail Machine 2 Fixed Chasers (2-1/2” and 3” pitches) 1 Indication Template 1 Set of Open-Ended W r enc hes (8-10, 11-13,

12-14, and 17-19mm) 1 Combination Wrench, 30mm 1 Set of Hex Wrenches (1.5 to 6mm) 1 Dust Chute 2 Sample Dovetailed B oar ds 1 Owner's Manual 1 Warranty Card

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

or operation! Failure t o co mply may cause serious injury.

Installation & Assembly

Tools requi red for assemb ly

forklift or hoist with straps/slings 14mm wrench (provided)

[NOTE: A socket set wi th ratchet wrench may

speed assembly ] 4mm hex wrench (provi ded) knife or wire cutter flat head screwdriver

1. Remove the four screws and flat washers

holding the machine to the pallet with a 14mm wrench, as shown in Figur e 1.

2. Place lifti ng st r aps thr ough the two eyebolts

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

3. 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.

4. A group of cords holds the headstock

secure to the machine frame to prevent it from moving duri ng shipping. These cords should now be cut and removed (see Figure 3).

5. Exposed metal areas of the Dovetailer

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

Figure 1

Figure 2

Figure 3

Attaching Dust Hose

1. Slide the upper end of the hose over the

chute on the dust hood (Fi gur e 4) .

2. Tighten the hose clamp with the attached

screw, using a fl at head screwdriver.

Figure 4

Installing Dust Chute

Remove the four socket head cap screws at the rear of the cabinet, using a 4mm hex wrench. Place the 4” diam eter dust c hute (Fi gure 5) ov er the hole, and re-insert and tighten the four socket head cap screws.

Dust Collection

The use of a du st collection system is strongly recommended f or this machi ne. It will help k eep your shop clean as well as mi nimize any healt h risks caused by wood dust. Mak e sure your dust collector has a capacity of at least 500 cubic feet per minute (CFM).

Connect the intake hose of your dust c ollector to the 4” diameter dust chute at the back of the cabinet (Figure 5) .

NOTE: A variet y of dust coll ection systems are available from Powermatic. Call customer service at 1-800-274-6848 or visit our website for mo re inform ation.

Grounding Instructions

Figure 5

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.

This mac hine m ust be grounded. I n the event of a malfuncti on or break down, groundi ng prov i des a path of least r esistance f or electri c current to reduce the ri sk of el ectri c shock .

Improper connection of the equipmentgrounding conductor can result in a risk of electric shock. The conductor, with insulation having an outer surface that is green with or without yellow stripes, is the equipmentgrounding conduct or . If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conduc tor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool i s properly grounded. Us e only three wire extensi on c or ds that have three-prong grounding plugs and three- pole recept acles that accept the tool ’s pl ug.

Repair or replace a damaged or worn cord immediately.

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

230 Volt Operation

As received from the factory, the DT65 Dovetail er is designed to run on 230 volt power only. You may either connect a UL/CSA listed 230V plug (similiar to the one shown in Figure 6) or “hard-wire” the machine directly to a control panel. If hard-wired to a panel, make sure a disconnect is available for the operator. The dovetailer must comply with all local and national codes after being wired.

1. If it is to be hard- wired, m ak e sure the f uses

have been removed or the breakers have been tripped in the circuit to which the dovetailer will be connected. Place a warning placard on t he fuse holder or circuit breaker to prevent it being turned on while the machine is being wired.

2. Refer to “Elec trical Connections” on page 36

for connecting the motor leads.

3. The Dovetail er with a 230 v olt plug should

only be connected to an outlet having the same confi guration. No adapter is av ailable or should be used with the 230 v olt plug.

Figure 6

Recommended Gauges (AWG) of Extension Cords

Extension Cord Length *

100

150

200

feet

Amps

feet

Extens ion cords

If an extensi on c or d is necessary, make sure t he cord rating i s suitable for the am perage listed on the machine’s motor plate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating.

Use the chart in Fi gure 7 as a general guide in choosing the c orrect size cord. If in doubt, use the next heavi er gauge. The smaller the gauge number, the heavier the cord.

Air Connection

Connect the air supply hose to the coupli ng on the air uni t (Figure 8). The air i s turned ON by rotating the valve lever 90 degrees counterclockwise (until it is parallel with the hose), and turned OFF by rotating the valve lever 90 degrees cl oc k wise.

Even after the air has been

turned off to the machine, there may be residual air inside the lines, and the clamping cyl ind ers can sti ll p rovid e a hazard to fingers. After shutting off the air, always bleed residual air from the system by pushing the rel ief valve pin at the bottom of the air cup, shown in Figure 8. Keep the relief valve open until all air in the system has been removed.

< 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 lin e voltage dr op to 5V at 15 0% of the rated amp eres.

NR: Not Recommended.

Figure 7

Figure 8

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