Powermatic PJ1696 User Manual
Operating Instructions and Parts Manual
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16-inch Jointer
Model PJ1696
For machines with serial no. 12061696217 and higher
Powermatic
427 New Sanford Road
LaVergne, Tennessee 37086 Part No. M-0460269
Ph.: 800-274-6848 Revision D1 05/2014
www.powermatic.com Copyright © 2014 Powerm atic
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 provi d e pr o 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 Information
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.
2
Table of Contents
SectionPage
Warranty and Service ............................................................................................................................................ 2
Table of Contents .................................................................................................................................................. 3
Warning ................................................................................................................................................................. 4
Safety Label .......................................................................................................................................................... 6
Features: PJ1696 Jointer ...................................................................................................................................... 7
Introduction ........................................................................................................................................................... 8
Specifications ........................................................................................................................................................ 8
Receiving the Jointer ............................................................................................................................................. 9
Installation and Assembly ..................................................................................................................................... 9
Fence Installation .............................................................................................................................................. 9
Dust Hood ....................................................................................................................................................... 10
Start/Stop Switch ............................................................................................................................................. 10
Electrical Connection ....................................................................................................................................... 10
Adjustments ........................................................................................................................................................ 11
Drive Belt ......................................................................................................................................................... 11
Replacing Knife Inserts ................................................................................................................................... 11
Setting Outfeed Table ..................................................................................................................................... 11
Table Raising Limit Blocks .............................................................................................................................. 12
Infeed Table Adjustment ................................................................................................................................. 12
Fence Adjustments .......................................................................................................................................... 13
Operating Instruction ........................................................................................................................................... 13
Hand Placement .............................................................................................................................................. 13
Edge Jointing ................................................................................................................................................... 13
Surfacing ......................................................................................................................................................... 13
Rabbeting ........................................................................................................................................................ 14
Jointing Warped Surfaces ............................................................................................................................... 14
Jointing Short or Thin Work ............................................................................................................................. 14
Direction of Grain ............................................................................................................................................ 14
Beveling ........................................................................................................................................................... 15
Taper Cuts ....................................................................................................................................................... 15
Maintenance ........................................................................................................................................................ 15
Lubrication ....................................................................................................................................................... 15
Cutterhead Repairs ......................................................................................................................................... 15
Blade Inserts ................................................................................................................................................... 16
Replacement Parts .............................................................................................................................................. 17
Parts List: Cutterhead Assembly (PJ1696 Jointer) .......................................................................................... 18
Cutterhead Assembly (PJ1696 Jointer) ........................................................................................................... 19
Parts List: Fence Assembly (PJ1696 Joi n ter) ................................................................................................. 20
Fence Assembly (PJ1696 Jointer) .................................................................................................................. 21
Parts List: Stand Assembly (PJ1696 Jointer) .................................................................................................. 22
Stand Assembly (PJ1696 Jointer) ................................................................................................................... 23
Parts List: Bed Assembly (PJ1696 Jointer) ..................................................................................................... 24
Bed Assembly (PJ1696 Jointer) ...................................................................................................................... 25
Parts List: Cutterhead Guard Assembly (PJ1696 Jointer) ............................................................................... 26
Cutterhead Guard Assembly (PJ1696 Jointer) ................................................................................................ 27
Parts List: Infeed Table Assembly (PJ1696 Jointer) ....................................................................................... 28
Infeed Table Assembly (PJ1696 Jointer) ........................................................................................................ 29
Parts List: Outfeed Table Assembly (PJ1696 Jointer) ..................................................................................... 30
Outfeed Table Assembly (PJ1696 Jointer) ...................................................................................................... 31
Parts List: Motor Assembly (PJ1696 Jointer) .................................................................................................. 32
Electrical Connections ..................................................................................................................................... 33
Preventive Maintenance ...................................................................................................................................... 34
3
Warning
Read the manual. Read, understand, and follow the safety instructions found in this manual. Know the
limitations and hazards in using the model PJ1696 Jointer. Decals are placed on each machine as reminders
of good safety practice.
Installation. If mounting machine to the floor, use high quality anchor bolts through the mounting holes on the
base. If using a mobile base, be sure to lock the wheels.
Location. Use extra care in the location of the jointer in the shop. Place the machine so that potential
kickback area is not in line with aisles, doorways, wash stations, or other work areas.
Electrical grounding. Make certain that the machine frame is electrically grounded and that a ground lead is
included in the incoming electrical service. If a cord and plug are used, make certain the grounding lug
connects to a suitable ground. Follow the grounding procedure indicated in the National Electric Code.
Eye safety. Always wear approved safety goggles, glasses, or a face shield when operating this machine.
(Note: common eyeglasses are only impact-resistant, they are not safety glasses.)
Personal protection. Before operating the machine, remove tie, rings, watch and other jewelry and roll up
sleeves above the elbows. Remove all loose clothing and confine long hair. Protective type footwear should
be used. Where the noise exceeds the level of exposure allowed in Section 1910.95 of the OSHA Regulations,
use hearing protective devices. Do not wear gloves.
Guards. Be sure machine guards are in place and in good working order. Use them at all times on operations
where they can be used. If a guard must be removed for any operation, make sure it is replaced immediately
following completion of that operation.
Work area. Keep the floor around the machine clean and free of scrap material, saw dust, oil and other liquids
to minimize the danger of tripping or slipping. Be sure the table is free of all scrap, foreign material and tools
before starting to cut. Make certain the work area is well lighted and that a proper exhaust system is used to
minimize dust. Powermatic recommends the use of anti-skid floor strips on the floor area where the operator
normally stands and that each machine's work area be marked off. Provide adequate work space around the
machine.
Disconnect machine before performing any service or maintenance. A machine under repair should be RED
TAGGED to show it should not be used until the
maintenance is complete.
Housekeeping. Before turning on machine, remove
all extra equipment such as keys, wrenches, scrap,
stock, and cleaning rags away from the machine.
Power on. On machines equipped with a manual
starter make sure the starter is in "OFF" position
before connecting power to machine.
Three inch rule. When working a piece of wood on
the jointer, follow the 3 inch radius rule. The hands
must never be closer than 3 inches to the cutterhead.
See Figure 1.
Always use a hold-down or push block when
surfacing stock less than 12" inches long, or 3 inches
wide, or 3 inches thick.
Do not pe rform jointing operations on material shorter than 8", narrower than 3/4" or less than 1/4" thick.
Depth of cut. Do not make cuts deeper than 3/4" when rabbeting. On other cuts such as edging, surfacing,
etc., depth of cut should not be over 1/16" to avoid overloading the machine and to minimize chance of
kickback.
Avoid tip-in. Never apply pressure to stock directly over the cutterhead. This may result in the stock tipping
into the cutterhead along with the operator's fingers. Follow the 3 inch rule. Position hands away from extreme
ends of stock, and push through with a smooth, even motion. Never back workpiece toward the infeed table.
4
Avoid Kickback. "Pull-out" and the danger of kicked back stock can occur when the work piece has knots,
holes, or foreign materials such as nails. It can also occur when the stock is fed against the grain on the
jointer. The grain must run in the same direction you are cutting. Before attempting to joint, or plane, each
work piece must be carefully examined for stock condition and grain orientation.
NOTE: At certain times it may be necessary to plane
against the grain when working with a swirl grain
wood or burls. With this type work the operator must
use a lesser depth of cut and a slow rate of feed.
Hand safety. It is good practice to move the hands in
an alternate motion from back to front as the work
continues through the cut. Never pass the hands
directly over the cutter knife. As one hand
approaches the knives remove it from the stock in an
arc motion and place it back on the stock in a position
beyond the cutter knife (Figure 2). NOTE: At all times
hold the stock firmly.
Misuse. Do not use this jointer for other than its
intended use. If used for other purposes, Powermatic
disclaims any real or implied warranty and holds itself harmless for any injury or damage which may result from
that use. Do not equip or use this jointer with a motor larger than 7-1/2 Horsepower at 5,200 R.P.M. Use of a
larger horsepower motor or higher cutterhead speed voids the warranty and Powermatic holds itself harmless
for any injury which may result.
If you are not thoroughly familiar with the operation of jointers, obtain advice from your supervisor, instructor or
other qualified person.
Drugs, alcohol, medication. Do not operate tool while under the influence of drugs, alcohol, or any
medication.
Health hazards. Some dust created by power sanding, sawing, grinding, drilling and oth er constructi on
activities contains 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 and cement and other masonry pro ducts.
• Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures 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
those dust masks that are specifically designed to filter out microscopic particles.
5
Familiarize yourself with the following safety notices used in this manual:
Thismeansthatifprecautionsarenotheeded,itmayresultinminorinjuryand/orpossible
machinedamage.
Thismeansthatifprecautionsarenotheeded,itmayresultinseriousinjuryorpossiblyeven
death.
- - SAVE THESE INSTRUCTIONS - -
Safety Label
Familiarize yourself with the location and content of this decal on your machine.
Figure3
6
Features: PJ1696 Jointer
1. Outfeed table
2. Fence
3. Fence Handle
4. Lock Lever
5. Cast Housing
6. Control Handle - Forward/Backward
7. Rack Column
8. Cutterhead Guard Plate
9. Eccentric Shaft
10. Base
11. Eccentric Shaft
12. Rabbeting Ledge
13. Cutter Guard
Figure 4
14. Guard Bracket Block
15. Pushbutton Switch
16. Cabinet
17. Table Lock
18. Door Latch
19. Cabinet Door
20. Table Raising/Lowering Handle
21. Infeed Table
22. Eccentric Shaft
23. Fence Base
24. Junction Box
25. Drive Belt Cover
7
Introduction
This manual is provided by Powermatic Inc. covering the safe operation and maintenance procedures for a
Powermatic Model PJ1696 Jointer. This manual contains instructions on installation, safety precautions,
general operating procedures, maintenance instructions and parts breakdown. This machine has been
designed and constructed to provide years of trouble free operation if used in accordance with instr uctions set
forth in this manual. If there are any questions or comments, please contact either your local supplier or
Powermatic. Po wermatic can also be reached at our web site: www.powermatic.com.
Specifications
Model No. ...................................................................................................................................... PJ1696
Stock No. .....................................................................................................................................1791283
Motor ........................................................................................................ 7-1/2HP, 3Ph, 230/460V*, 60Hz
Maximum width cutti ng c apac ity............................................................................................ 16" (406 mm)
Maximum depth cutti ng c apac ity ............................................................................................ 3/4" (19 mm)
Cuts per minute .............................................................................................................................. 20,800
Table size ............................................................................................ 16" W x 96" L (406mm x 2438 mm)
Table he ig h t from floor .................................................................................................... 3 7-1/2" (800 mm)
Fence size ........................................................................................47-1/4" L x 5-1/4" H (1200 x 133 mm)
Fence tilt .................................................................................. 45 degrees forward, 45 degrees backward
Positive stops ....................................................................................................45 deg., 90 deg., 135 deg.
Cutterhead speed ...................................................................................................................... 5200 RPM
Number of knife inserts ............................................................................................. 56 standard, 2 rabbet
Cutterhead diameter ................................................................................................................. 4" (98 mm)
Rabbeting capacity ................................................................................................................ 3/4" (19 mm)
Dust connection diameter ....................................................................................................... 6" (152 mm)
Overall dimension ............................................................ 46" L x 96" W x 43" H (1168 x 2438 x 1092 mm)
Packing dimension ...................................................... 39" L x 102" W x 29-1/2" H (991 x 2591 x 749 mm)
Net weight ...................................................................................................................1280 lbs. (582 kgs.)
Gross weight ...............................................................................................................1400 lbs. (636 kgs.)
* pre-wired 230 volt NOTE: For 460V operation, magnetic swit c h ( part no.PJ1696-205D) must be
purchased separately and ins talled. A qualified elect r ic ian is r ec om m ended.
The above specifications were current at the time this manual was published, but because of o ur policy of
continuous improvement, Powermatic reserves the right to change spec ifications at any time and wit hout prior
notice, without incurring obligations.
8
Receiving the Jointer
Carefully unpack the jointer and all loose items
from the wood crate and inspect for damage. Any
damage should be reported to your distributor a nd
shipping agent immediately. Before proceeding
further, read your manual t horoughly to familiarize
yourself with proper assembly, set-up,
maintenance, safety and operating procedures.
Exposed metal parts such as the table and fence
have been given a protective coating at the factory.
This should be removed with a soft cloth moistened
with a solvent (such as kerosene). Do not use
acetone, gasoline or lacquer thinner for this
purpose. Do not use an abrasive pad. After
cleaning, it is recommended that you cover all
unpainted surfaces with a good quality paste wax.
Crate contents:
1 jointer
1 dust chute
1 fence assembly
4 hex wrenches (3, 5, 8 and 10mm)
3 open-end wrenches (10-12mm, 12-14mm,
17-19mm)
2 push pads
1 helical cutt er head t ool pac k age:
2 rabbet knives
8 two-sided standard knives
7 gibs
7 gib nuts
7 gib screws
1 hex wrench 5mm (L type)
3 hex wrenches 5mm (T type)
1 manual
1 warranty card
Installation and Assembly
Figure 5
Figure 6
The jointer should be mounted to a solid, level
foundation, preferably a concrete floor. The
machine area should be clean, dry, well ventilated
and well lighted, with sufficient space around the
machine for operation and maintenance work.
This machine is equipped with noise-reducing table
lips. The work site should, however, be one which
minimizes reverberant sound from walls, ceilings
and other equipment.
Tools required
10mm hex wrench (provided)
Phillips screwdriver
The supplied tools are shipped inside the bottom of
the stand, and can be removed through the dust
outlet (A, Figure 5) on the left side of the machine.
Remove the bolts holding the jointer to the skid,
and lift the machine from the skid using a hoist.
The strap should be suitable to lift 1320 pounds of
weight, and should be placed under the base
casting as shown in Figure 6. DO NOT place strap
under the tables.
Fence Installation
Mount the fence (A, Figure 7) to the holes on the
jointer table with the two socket head cap screws
(B, Figure 7), using a 10mm hex wrench. Tighten
the screws (B, Figure 7) securely.
9
Figure 7
Dust Hood
Mount the dust hood (C, Figure 8), to the left side
of the jointer using the seve n 1/4-20 x 1/2 screws
(D, Figure 8) provided on the machine. Before
mounting the dust hood, make sure the hole in the
base is covered by t he dust chute cover ( shown in
Figure 5).
It is recommended a dust collection system of
appropriate size (at least 800 CFM) be c onnected
to the dust outlet via a 6" diameter hose.
Figure 8
Start/Stop Switch
The arm (E, Figure 9) on which the pushbutton
switch is located is shipped in the down position.
The screws (F, Figure 9) should be loosened with a
10mm hex wrench and the arm pivoted to upright
position. Re-tighten screws.
Figure 9
Electrical Connection
Electrical connections must
be made by a qualified electrician. The machine
must be properly grounded to help avoid
electric shock and possible death.
IMPORTANT: Make sure the electrical
characteristics are the same between the motor
nameplate and the power source, and make sure
the circuit on which the jointer will be used is
properly fused and that the wire size is correct.
It is recommended that the jointer when operated
at 230 volts, be connected to a dedicated,
minimum 40 amp circuit with a 40 amp circuit
breaker or time delay fuse. When operated at 460
volts, connect the jointer to a dedicated, minimum
20 amp circuit with 20 amp circuit breaker or t ime
delay fuse. Local codes take precedence over
recommendations.
1. Connect wires from the power source to the
motor junction box. Refer to diagram inside the
motor junction box cover (a similar diagram
appears at the back of this manual). The green
wire (ground) must be properly grounded.
2. After wiring is complete, turn motor on
momentarily to check for proper direction of
rotation (cutterhead should rotate toward
infeed table). If rotation is in the wrong
direction, disconnect machine and switch any
two of the hot leads. Reconnect power and
confirm proper rotation.
3. Run the machine without cutting for a short
time to check that all powered functions are
operating properly.
460VConversion
The Jointer is pre-wired for 230 volt operation. If
460 volt operation is required, proceed as follows:
1. Re-connect the motor leads according to the
wiring diagram.
10
2. Replace the installed magnetic switch with the
switch rated for 460V operation (stock no.
PJ1696-205D; separate purchase).
3. Change the dial on the overload relay to the
appropriate setting for 460V operation.
4. Check for proper direction of rotation
(cutterhead should rotate toward infeed table).
If rotation is in the wrong direction, disconnect
machine and switch any two of the hot leads.
Reconnect power and confirm proper rotation.
Adjustments
Tools required
17mm/19mm wrench
Drive Belt
Remove the three crown nuts and washers (A,
Figure 10) on the be lt cover with a 17m m wrench,
and remove the cover. Use a 19mm wrench to
adjust the nuts in the motor support (B, Figure 11).
Raise or lower motor support to obtain proper
tension, then re-tighten n uts.
NOTE: Proper tension will be achieved when there
is a small amount of deflection in the belt when
using moderate finger pressure. See Figure 12.
Figure 12
Replacing Knife Inserts
The cutterhead on the PJ1696 is a solid steel
helical insert design with 56 two-sided standard
knives, and two rabbet knives on the outboard end
of the cutterhead. Replacing knives is a simple
process, and they will seat themselves properly
without having to be set with a knife gauge.
After a period of use, dull knives should be flipped
over, replaced or re-ground. To change a knife:
1. Loosen the gib screw (C, Figure 13) and
remove the knife (D, Figure 13) from the slot.
2. Flip t he knife 180 degrees and re-insert it, then
tighten the gib screw (C, Figure 13). To ensure
optimal cutting, all knives in the cutterhead
should be flipped at the same time.
Figure 10
Figure 11
Tighten gib screws firmly.
Loose gib screws can result in knives being
thrown out of the cutterhead, causing severe
damage to the machine and possible serious or
fatal injury to the operator or bystanders.
Figure 13
Setting Outfeed Table
For accurate work in most jointing operations, t he
outfeed table must be exactly level with the knives
at their highest point of revolution.
1. Raise the outfeed table to its highest point,
and place a straight edge across it.
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