Operating Instructions and Parts Manual
Single End Dovetailer
Model DT45
WMH TOOL GROUP, Inc.
2420 Vantage Drive
Elgin, Illinois 60124 Part No. M-1791304
Ph.: 800-274-6848 Revision A1 11/07
www.powermatic.com Copyright © 2007 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.
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Table of Contents
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
3
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.
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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 - -
5
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.
6
Features of the DT45 Dovetailer
Terminology
Below are the terms used in this manual to identify types of cuts and measurements.
7
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.
8
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
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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
10
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.
This machine must be grounded. In the event of
a malfunction or breakdown, grounding provides
a path of least resistance for electric current to
reduce the risk of electric shock. This dovetailer
is equipped with an electric cord having an
equipment-grounding conductor and a
grounding plug similar to the one illustrated in
Figure 8. The plug must be inserted into a
matching outlet that is properly installed and
grounded in accordance with all local codes and
ordinances.
Do not modify the plug provided. If it will not fit
the outlet, have the proper outlet installed by a
qualified electrician.
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 conductor. If repair or replacement of
the electric cord or plug is necessary, do not
connect the equipment-grounding conductor 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 is properly grounded. Use only
three wire extension cords that have three-prong
grounding plugs and three-pole receptacles that
accept the tool’s plug.
Repair or replace a damaged or worn cord
immediately.
Make sure the voltage of your power supply
matches the specifications on the motor plate of
the machine.
Figure 8
115 Volt Operation
As received from the factory, your dovetailer is
ready to run at 115 volt operation. This
dovetailer, when wired for 115 volts, is intended
for use on a circuit that has an outlet and a plug
that look like the ones illustrated in Figure 8. A
temporary adapter, which looks like the adapter
as illustrated in Figure 9, may be used to
connect this plug to a two-pole receptacle, as
shown in Figures 8 and 9, if a properly grounded
outlet is not available.
Figure 9
11
The temporary adapter should only be used until
a properly grounded outlet can be installed by a
qualified electrician. This adapter is not
applicable in Canada. The green colored rigid
ear, lug, or tab, extending from the adapter,
must be connected to a permanent ground such
as a properly grounded outlet box, as shown in
Figure 9.
230 Volt Operation
If 230 volt, single-phase operation is desired, the
following instructions must be followed to
convert from 115 to 230:
1. Disconnect machine from power source.
2. This dovetailer is supplied with six motor
leads that are connected for 115 volt
operation, as shown in Figure 10.
Reconnect these six motor leads for 230
volt operation, also shown in Figure 10.
3. The 115 volt attachment plug (Figure 8),
supplied with the dov etailer, must be
replaced with a UL/CSA listed plug suitable
for 230 volt operation, similar to the one
illustrated in Figure 11. Contact your local
authorized WMH Tool Group service center
or qualified electrician for proper procedures
to install the plug. The dovetailer must
comply with all local and national codes
after the 230 volt plug is installed.
4. The dovetailer with a 230 volt plug should
only be connected to an outlet having the
same configuration. No adapter is available
or should be used with the 230 volt plug.
Important: In all cases (115 or 230 volts),
make certain the receptacle in question is
properly grounded. If you are not sure, have
a registered electrician check the receptacle.
Extension cords
If an extension cord is necessary, make sure the
cord rating is suitable for the amperage 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 Figure 12 as a general guide in
choosing the correct size cord. If in doubt, use
the next heavier gauge. The smaller the gauge
number, the heavier the cord.
Figure 10
Figure 11
AWG (American Wire Gauge)
Cord Length
240 Volt Lines 120 Volt Lines
0-50 Feet No. 16 No. 16
50-100 Feet No. 14 No. 14
Over 100 Feet No. 14 No. 12
Figure 12
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Adjustments
Disconnect machine from
power source before making adjustments.
Failure to comply may cause serious injury.
Lower Work Support
Inside the cabinet is a lower work support
(Figure 13) which is used to support work pieces
in the vertical position. To move this support up
or down, loosen the locking handle (A, Figure
13). Tighten locking handle when finished.
To set the work support at level position, loosen
the socket head cap screw (B, Figure 13) with a
6mm hex wrench, and loosen the locking handle
(C, Figure 13). When finished adjusting, tighten
locking handle (C, Figure 13) and socket head
cap screw (B, Figure 13).
Locking Handles
All locking handles (such as C, Figure 13) can
be rotated if they are in the way of other
machine parts. Simply lift straight out on the
locking handle and rotate it, then release,
making sure it seats properly.
Figure 13
Clamping Bars
The workpieces are clamped to the table by
eccentric bars. Simply rotate the handle (A,
Figure 14) until the workpiece is secured. Do not
overtighten the clamping bars to prevent denting
the workpiece.
Both upper and lower clamping bars must be
adjusted to match the thickness of your
workpieces. Thickness is indicated on the
adjoining scales mounted to the machine frame.
1. Loosen the two locking handles on the front
edge of the frame (B, Figure 14).
2. Rotate the knurled adjustment pieces (C,
Figure 14) on both sides of the machine
until the indicator line on the adjustment
piece matches the desired thickness on the
adjoining scale. It is important that both
knurled adjustment pieces be rotated the
same to ensure the clamping bar is parallel
to the table.
3. Tighten locking handles (B, Figure 14).
Figure 14
(shows adjustment of lower clamping bar)
13
Template Bar
The four-sided template bar, shown in Figure
16, will allow you to create “half-blind” dovetails,
where the dovetails are visible on only one side
of the joint. It will create dovetails in one of four
different “pitches” or centerlines. The available
pitches are 1”, 1-1/2”, 2” and 2-1/2”. To change
the pitch of a dovetail cut, proceed as follows:
1. Release one end of the spring on the left
side of the headstock (Figure 15) and pull
the headstock toward the front of the
machine until the tracer pin is clear of the
template bar as shown in Figure 16.
2. Loosen and remove the locking handle on
each end of the template bar.
3. Pull out the template bar as shown in
Figure 16, flip it to the desired side, then reinstall it. NOTE: The pitch dimension is
inscribed on each side of the template bar.
4. Insert and tighten both locking handles.
5. Push the headstock back and re-connect
the spring (Figure 15).
Horizontal and Vertical Fences
Figure 15
The workpieces will lie flush against the fences
during cutting to ensure squareness. Two buffer
pads made of polyethylene material are
mounted to the fences – these provide a
“chipbreaker” effect to prevent chip-out on the
left edges of the workpieces. They are designed
so the cutter can bite into them without any
damage to the cutter.
To adjust these fences, proceed as follows:
1. Place your FRONT/BACK workpiece on the
horizontal table and against the fence. Move
the headstock to the left edge of the
workpiece, then slide it to the right, allowing
the tracer pin to slide just a little into the
template recesses. This will give you an
idea where the cuts will be made and how
they will be spaced across the width of the
workpiece.
2. For broad movement of the horizontal fence,
loosen both locking handles on the
horizontal fence (A and B, Figure 17) and
slide the horizontal fence into position.
There is also a micro adjustment on the
horizontal fence; loosen locking handle (A,
Figure 17), but leave locking handle (B)
tight. Loosen the screw (C, Figure 17) with a
6mm hex wrench and rotate the knurled
knob (D, Figure 17) as needed for precise
positioning of the horizontal fence. When
finished, tighten screw (C, Figure 17) and
locking handle (A, Figure 17).
Figure 16
Figure 17
14
3. Continue to check the spacing by sliding the
headstock across, until the dovetail cuts will
be distributed evenly across the width of the
workpiece. NOTE: This is an approximate
method of determining by eye where to
place the workpiece. A scale in inches and
millimeters is mounted to the table if you
need more precise measurements for the
location of the dovetail cuts.
4. As noted, the position of the horizontal
fence will affect the position of the vertical
fence. Therefore, if you are making a drawer
that has a bottom groove, the vertical fence
should be set so that the bottom groove in
the drawer piece to be tenoned will go
through the center of a dovetail. That means
the bottom groove of the mortised piece will
go through the center of a mortise. This will
prevent the groove from being visible on the
outside of the assembled drawer. See
Figure 18 and 19.
5. Tighten the locking handles on the
horizontal fence to secure it in position. The
position of the horizontal fence will be used
as the basis for locating the vertical fence.
Figure 18
6. Loosen the locking handle on the vertical
fence.
Important: To make proper dovetail cuts, the
two fences must always be offset from each
other by half the pitch of the template bar. That
is, offset 1/2” when using the one-inch template;
3/4” when using the 1-1/2 inch template; 1”
when using the two-inch template, and 1-1/4”
when using the 2-1/2 inch template. The
measuring scales on the table are marked in
1/16” increments.
7. Line up the vertical fence with the horizontal
fence, then offset the vertical fence by
exactly half the pitch of the template. See
Figure 20.
8. This adjustment will cause the vertical work
piece to be slightly offset to the right of the
horizontal piece, thus ensuring the dovetails
will correspond when the two pieces are
assembled.
9. Tighten the locking handle on the vertical
fence.
There are a total of four fences on the DT45
Dovetailer – two vertical and two horizontal.
These allow two sets of workpieces to be cut at
the same time. If this is desired, position the
other two fences in the same manner as the first
two fences, remembering again to offset the
vertical fence by half the pitch.
Figure 19
Figure 20
15
Buffer Pads
The polyethylene buffer pads (shown in Figure
20) have slots through which they are secured
to the fences by screws. These buffer pads at
times may need to be re-positioned; for
example, if a clamping bar is adjusted for a
different thickness of workpiece, the buffer pad
may need to be adjusted out of the way to
prevent obstructing the clamping bar.
To adjust a buffer pad, loosen the two hex cap
screws (Figure 20) with a 13mm wrench. Slide
the buffer pad as necessary. Retighten both hex
cap screws when finished.
Cutter Height
This adjustment will change the height of the
tails on the tenon (male) cut, and how deep the
mortise (female) cut goes into the thickness of
the workpiece.
1. Disconnect machine from power source.
2. Loosen the spindle lock screw (Figure 21)
by turning it counterclockwise with a 6mm
hex wrench.
3. Turn the spindle height adjust screw (Figure
19) with a 5.5mm hex wrench, either
clockwise to raise the cutter (decrease the
cutter depth), or counterclockwise to lower
the cutter (increase the cutter depth).
4. Tighten spindle lock screw by turning it
clockwise.
Mortise Depth
This adjustment ensures that the side pieces of
your drawer will remain flush with the front and
back pieces of the drawer. The correct fit will
have the sides flush with the front and back of
the drawer, without showing any of the mortise
cut on the inside of the drawer.
The mortise depth adjust bolt, shown in Figure
19, limits how far forward the cutting unit will go,
and thus limits the length of your mortise cut.
1. Disconnect machine from power source.
2. Loosen the hex nut on the mortise depth
adjust bolt (Figure 21) by turning the hex nut
counterclockwise with a 17mm wrench.
3. To decrease the depth of the mortise
(female) cut, turn the bolt clockwise. To
increase the depth of the mortise cut, turn
the bolt counterclockwise.
4. Re-tighten the hex nut.
Figure 21
16
Thickness of Tenon Cut
To adjust the thickness of the tenon (male) cuts,
you will change the depth of the tracer pin
(Figure 22).
1. Disconnect machine from power source.
2. Loosen the locking handle on top the tracer
pin (Figure 22) by turning it counter
clockwise.
3. Insert a 5.5mm hex wrench into the end of
the adjustment screw (Figure 22) and turn
the adjustment screw as needed. To
decrease the thickness of the tenon cut, turn
the adjustment screw counterclockwise. To
increase the thickness of the tenon cut, turn
the adjustment screw clockwise.
4. Tighten locking handle.
Figure 22
Tightness of Mortise/Tenon Fit
A proper dovetail fit should be snug with no
gaps showing, but not overly tight as glue must
later fill the joints. If the cuts seem correct, but
the joint is simply too tight, or the joint is too
loose, proceed as follows.
1. Disconnect machine from power source.
2. Remove the dust hood from the front of the
machine.
3. You will notice the cutter, shown in Figure
23, is slightly off center of the spindle. The
spindle is eccentric and allows the cutter to
be turned to a different position on the
spindle.
The cutter is very sharp! Use
caution when working with or around it.
4. Loosen both set screws on the spindle
(Figure 23) by turning them counterclockwise with a 4mm hex wrench.
5. A scale is located just above the cutter, with
a plus (+) and minus (-) sign. Moving the
cutting edge of the cutter toward the plus (+)
side of the scale will increase the size of the
mortise cut and decrease the size of the
tenon cut. Moving the cutting edge of the
cutter toward the minus (-) side will
decrease the size of the mortise cut and
increase the size of the tenon cut.
Figure 23
6. With your fingers on the shank portion of the
cutter, carefully rotate the cutter toward the
plus (+) or minus (-) position as needed.
7. When satisfied with the adjustment, tighten
both set screws firmly.
8. Re-attach the dust hood.
17
Drive Belt Tension
The tightness of the belt that drives the spindle
has been adjusted at the factory. Further
adjustment may be necessary after the machine
receives some use, as the belt may stretch
slightly during the “breaking in” process.
Belt tension can be adjusted by a socket head
cap screw at the rear of the headstock (Figure
24) which slides the motor toward or away from
the spindle. To tighten the belt, rotate this cap
screw clockwise with a 6mm hex wrench. To
loosen the belt, rotate the cap screw
counterclockwise. The belt should be just tight
enough to prevent it slipping on the spindle
during operation.
Figure 24
Replacing Cutter
The cutter is very sharp; use
caution when working with or around cutter.
Disconnect machine from power source!
Failure to comply may cause serious injury.
To replace the cutter, loosen both set screws
(Figure 23) and carefully pull down on the cutter
until it is free from the spindle. Place the new
cutter in the spindle and tighten both set screws.
Operation
NOTE: The following are basic dovetailing
procedures as they apply to this machine, and
are not intended to be a full course of instruction
in making dovetails. Refer back to the
terminology on page 7 if needed.
The Dovetailer can be used to make joints in
drawers, boxes, cabinets, etc. Instructions in this
manual are based upon making a drawer
consisting of FRONT and BACK pieces, and two
SIDE pieces. FRONT and BACK pieces are
placed horizontally on top the machine’s table;
SIDE pieces are placed vertically in front of the
machine’s table. The insides of the boards
always face outward when they are placed on
the machine.
No matter the project, prevent mistakes by
laying out the pieces beforehand according to
how they will be assembled. Place them with the
inside facing up, and label the mating edges, as
shown in Figure 25.
Before cutting on what is to be the finished
piece, the operator should make test cuts on
scrap wood to make sure all settings and
adjustments are correct.
Figure 25
18
IMPORTANT: Make sure the workpiece has
been cut square before making dovetails. An
out-of-square workpiece will result in poor
dovetail joints.
1. Set the appropriate template size, fence
positions, clamping bar thickness, and cutter
depth for your particular job. Refer to
“Adjustments” section starting on page 13.
2. Move the headstock all the way to the right
and out of the way.
3. Place the drawer BACK on top the table and
flush against the fence, with the bottom
groove facing up and toward the fence. See
Figure 26.
Figure 26
4. Place the drawer RIGHT SIDE in the vertical
position on top the lower work support and
against the fence. Adjust the lower work
support as necessary. The bottom groove
on the RIGHT SIDE should be toward the
fence and facing the operator, as shown in
Figure 26.
5. Make the BACK butt against the RIGHT
SIDE so they are flush, with the RIGHT
SIDE overlapping the edge of the BACK.
See Figure 26. Both pieces should be firmly
and evenly against the fences with their
edges flush as shown. You may need to
loosen and tighten each clamping bar
several times as you adjust the two drawer
pieces into position. When the drawer
pieces are positioned correctly, tighten
upper and lower clamping bars. Do not
overtighten the clamping bars.
6. Slide the headstock all the way to the left.
Turn on the machine and move the cutter in
sequence, left to right, allowing the tracer
pin to move in and out of the template slots.
See Figure 27. You can watch the progress
of the cut through the window of the dust
hood. NOTE: Do not rush the cut; allow the
cutting unit to do the work.
7. When finished, slide the headstock out of
the way and unclamp the workpieces.
8. Fit the BACK and RIGHT SIDE together and
examine the joint. If the joint is not
satisfactory, make any needed corrections
to your settings as explained under
“Adjustments.” If the joint is satisfactory,
proceed with the next cut as follows.
9. Turn the BACK 180 degrees and clamp it in
the horizontal position against the fence.
Figure 27
(Dust hood removed for clarity only; always use
dust hood when operating dovetail machine.)
19
10. Insert the LEFT SIDE piece and clamp it in
vertical position on the lower work support
and against the fence. (NOTE: The bottom
grooves on both pieces will be face up, but
will now be opposite the fences.) Again,
make sure the edges are flush with the
LEFT SIDE overlapping the edge of the
BACK.
11. Continue the dovetailing procedure with the
FRONT piece, making cuts “C” and “D”
(Figure 25) until all four joints of the drawer
have been cut.
TIP: When using drawer side widths that are not
“whole inch” sizes, you may wish to gauge off
the top of the drawer rather than the bottom
when placing workpieces in the machine. Doing
this will improve the look of the drawer by
providing a full tenon near the top of the drawer
and the half-tenon will end up at the bottom. See
Figure 28.
Preventing Chip Out
As noted previously, when the SIDE and
FRONT/BACK pieces are inserted into the
machine, they are offset a bit so they’ll match
correctly when assembled. In other words, the
SIDE will rest slightly to the right of the
FRONT/BACK in the machine. This leaves the
right edge of the SIDE exposed without the
“chipbreaker” effect that the FRONT/BACK
provides for the rest of the SIDE (see Figure
29). This may result in an unsatisfactory cut at
the edge of the SIDE.
Figure 28
This problem is resolved simply by taking a 2inch-plus wide “back-up” board, of the same
thickness as your workpiece, and clamping it
horizontally next to the FRONT/BACK piece so
that it backs up the exposed edge of the SIDE,
as shown in Figure 29. You can use this piece
over and over again.
Dovetails in Plywood
Because plywood handles a bit differently than
solid stock, here are some tips to follow:
1. When using plywood, the layers tend to be
more fragile. Therefore, the operator should
keep the movement of the cutting unit
consistent and proceed relatively slowly.
2. On the rounded arcs of the tenon cuts, you
may lose a bit of the top layer. This is to be
expected with plywood, and does not affect
either the look or the strength of the
assembled dovetail joint. Rather, the
strength of the dovetailed corner comes
from the flat side of the tenons.
Figure 29
20
3. Plywood has a tendency to chip out on
exposed edges. A back-up board should be
used as needed (see Figure 29).
Maintenance
Before doing maintenance
on the machine, disconnect it from the
electrical supply. Failure to comply may
cause serious injury.
If the power cord is worn, cut, or damaged in
any way, have it replaced immediately.
The table and other exposed metal parts should
be kept clean and free of rust. A coat of paste
wax will help protect the table from tarnishing.
After each day’s use, brush or blow out dust and
debris from the cutter, table, motor, etc.
Keep the clamping bars clean to prevent debris
adhering to them, which can scar workpieces.
Keep clean the travel rods upon which the
headstock slides.
Lubrication
The linear bushings by which the headstock
travels on the rods are pre-lubricated and
sealed; they do not require additional lubrication.
The spindle bearing should be lubricated as
needed, according to machine usage. Apply VG120 grease through the grease nipple on the
spindle (#10 in the exploded view on page 27).
21
Troubleshooting the DT45
Trouble Probable Cause Remedy
Machine will not
start/restart or
repeatedly trips
circuit breakers or
blows fuses.
Machine not plugged in. Verify machine is connected to power.
Fuse blown, or circuit
breaker tripped.
Cord damaged. Replace cord.
Overload automatic reset
has not reset.
Dovetailer frequently trips.
Building circuit breaker trips
or fuse blows.
Loose electrical
connections.
Motor starter failure.
Motor failure.
Miswiring of the unit.
Replace fuse, or reset circuit breaker.
If the Dovetailer overloads on the circuit breaker
built in to the motor starter, it takes time for the
machine to cool down before restart. Allow unit to
adquately cool before attempting restart. If problem
persists, check amp setting on the motor starter
inside the electrical box.
Check the amp setting on the overload relay.
Match the full load amps on the motor as noted on
the motor plate. If amp setting is correct then there
is probably a loose electrical lead or a failed
component. See below.
Verify that dovetailer is on a circuit of correct size.
If circuit size is correct, there is probably a loose
electrical lead. Check amp setting on motor starter.
Go through all of the electrical connections on the
dovetailer including motor connections, verifying
the tightness of each. Look for any signs of
electrical arcing which is a sure indicator of loose
connection or circuit overload.
If you have access to a voltmeter, you can
separate a starter failure from a motor failure by
first, verifying incoming voltage at 220+/-20 and
second, checking the voltage between starter and
motor at 220+/-20. If incoming voltage is incorrect,
you have a power supply problem. If voltage
between starter and motor is incorrect, you have a
starter problem. If voltage between starter and
motor is correct, you have a motor problem.
If electric motor is suspect, you have two options:
Have a qualified electrician test the motor for
function or remove the motor and take it to a
qualified electric motor repair shop and have it
tested.
Check to make certain all electrical connections
are correct and properly tight. The electrical
connections other than the motor are
preassembled and tested at the factory. Therefore,
the motor connections should be checked as the
highest probability for error. If problems persist,
double check the factory wiring.
22
Trouble Probable Cause Remedy
Machine will not
start/restart or
repeatedly trips
circuit breakers or
blows fuses.
(continued)
Cutter not cutting
properly.
Dovetailed parts fit
too tightly.
Dovetailed parts fit
too loosely.
Cutter sometimes
slips and misses
revolutions.
Dovetailed parts fit
side to side, but
have depth gaps
between the
mortise and tenon
cuts.
On/off switch failure. If the on/off switch is suspect, you have two
options: Have a qualified electrician test the switch
for function, or purchase a new on/off switch and
establish if that was the problem on changeout.
Cutter in wrong position. Turn cutter towards the (+) or (-) mark [page 17].
Cutter dull or damaged. Sharpen or replace cutter.
Cutter not adjusted
properly.
Cutter not adjusted
properly.
Spindle belt tension
incorrect.
The mortise depth or tenon
thickness is set incorrectly.
Loosen set screws and turn cutter toward the (+)
mark. Retighten set screws [page 17].
Loosen set screws and turn cutter toward the (-)
mark. Retighten set screws [page 17].
Adjust spindle belt tension [page 18].
Change depth of mortise cut or thickness of tenon
cut by using the adjustment screw [pages 16 & 17].
A gap between
mortise and tenon
cuts increases
along the
dovetailed corner.
Side piece edge is
not aligned with
front/back piece
edge.
Workpiece slips
during the cut.
Boards not square when
clamped.
Fences not set correctly. Offset the vertical fence from the horizontal fence
Clamping bar not properly
adjusted for thickness of
workpiece.
Make sure the initial cuts on the board (ripping
and/or crosscutting) have been done squarely, and
that the board is flush against the stop before
clamping.
by half the pitch of the cut.
Position clamping bar according to workpiece
thickness. Make sure both ends of clamping bar
have been adjusted equally.
Replacement Parts
Replacement parts are listed on the following pages. To order parts or reach our service department, call
1-800-274-6848, Monday through Friday (see our website for business hours, www.powermatic.com).
Having the Model Number and Serial Number of your machine available when you call will allow us to
serve you quickly and accurately.
23
Parts List: Base Assembly
Index No. Part No. Description Size Qty
1............... DT45-101.................Worktable.............................................................................................. 1
2............... DT45-102.................Base Guide Rod.................................................................................... 2
3............... TS-1523041.............Socket Set Screw ...............................................M6x12 ...................... 15
4............... DT45-104.................Copying Template ................................................................................. 1
5............... DT45-105.................Locking Handle...................................................M6x35........................ 2
6............... DT45-106.................Scale..................................................................................................... 2
7............... DT45-107.................Scale..................................................................................................... 2
8............... DT45-108.................Adjustment Piece................................................................................... 2
9............... DT45-109.................Clamp Bar ............................................................................................. 2
10............. DT45-110.................Key.....................................................................6x6x30 ....................... 2
11............. DT45-111.................Hub ....................................................................................................... 2
12............. TS-1540081.............Hex Nut..............................................................M12............................ 2
13............. DT45-113.................Lever..................................................................................................... 2
14............. DT45-114.................Handle................................................................................................... 2
15............. DT45-115.................Locking Handle...................................................M6x25........................ 2
16............. DT45-116.................Locking Handle...................................................M6x45........................ 2
17............. DT45-117.................Sliding Rod............................................................................................ 2
18............. DT45-118.................Adjustment Piece...................................................................................2
19............. DT45-119.................Fence.................................................................................................... 2
20............. DT45-120.................Locking Handle...................................................M8x25........................ 6
21............. TS-1504061.............Socket Head Cap Screw.....................................M8x30........................ 1
22............. DT45-122.................Buffer Pad ............................................................................................. 2
23............. TS-1550061.............Flat Washer........................................................M8.............................. 9
24............. TS-1490031.............Hex Cap Screw ..................................................M8x20........................ 8
25............. DT45-125.................Buffer Pad ............................................................................................. 2
26............. DT45-126.................Adjustment Screw..................................................................................1
27............. TS-1504071.............Socket Head Cap Screw.....................................M8x35........................ 2
28............. DT45-128.................Knurled Knob......................................................................................... 1
29............. DT45-129.................Adjustment Seat.................................................................................... 1
30............. DT45-130.................Guide Rod............................................................................................. 1
31............. DT45-131.................Clamping Seat....................................................................................... 1
32............. DT45-132.................Locking Handle...................................................M8x35........................ 1
33............. DT45-133.................Adjustment Plate ................................................................................... 1
34............. TS-1504041.............Socket Head Cap Screw.....................................M8x20........................ 1
35............. DT45-135.................Switch Box ............................................................................................ 1
36............. TS-1550041.............Flat Washer........................................................M6.............................. 2
37............. TS-1503041.............Socket Head Cap Screw.....................................M6x16........................ 2
38............. DT45-138.................Contactor ..............................................................................................1
39............. DT45-139.................Switch Cover......................................................................................... 1
40............. TS-1502031.............Socket Head Cap Screw.....................................M5x12........................ 2
41............. DT45-141.................Scale..................................................................................................... 2
42............. DT45-142.................Buffer Pad ............................................................................................. 2
43............. TS-1550041.............Flat Washer........................................................M6.............................. 2
44............. TS-1503051.............Socket Head Cap Screw.....................................M6x20........................ 2
45............. TS-1524041.............Socket Set Screw...............................................M8x16........................ 1
46............. TS-2361081.............Lock Washer ......................................................M8.............................. 3
47............. DT45-147.................Fence.................................................................................................... 2
24
Base Assembly
25
Parts List: Headstock Assembly
Index No. Part No. Description Size Qty
1............... DT45-201.................Spindle Assembly (Index #2 thru #10).................................................... 1
2............... DT45-202.................Spindle Bearing Housing ....................................................................... 1
3............... DT45-203.................Ball Bearing (special)..........................................6005 B.P63 ................ 2
4............... DT45-204.................Fixing Nut.............................................................................................. 1
5............... DT45-205.................Eccentric Spindle................................................................................... 1
6............... TS-1524021.............Socket Set Screw ...............................................M8x10 ........................ 2
7............... DT45-207.................Spacer................................................................................................... 1
8............... DT45-208.................Disc Spring............................................................................................ 4
9............... DT45-209.................Fixing Nut.............................................................................................. 1
10............. DT45-210.................Grease Nipple ....................................................................................... 1
11............. DT45-211.................Spindle Slide Seat ................................................................................. 1
12............. DT45-212.................Gear Shaft............................................................................................. 1
13............. TS-1550061.............Flat Washer........................................................M8 ............................. 1
14............. TS-1490031.............Hex Cap Screw ..................................................M8x20 ....................... 1
15............. DT45-215.................Clamping Piece ..................................................................................... 1
16............. DT45-216.................Bushing................................................................................................. 1
17............. TS-1504121.............Socket Head Cap Screw.....................................M8x60........................ 1
18............. DT45-218.................Panel..................................................................................................... 1
19............. DT45-219.................Plug....................................................................................................... 1
20............. TS-1550071.............Flat Washer........................................................M10............................ 1
21............. TS-1540071.............Hex Nut..............................................................M10............................ 1
22............. DT45-222.................Hex Head Bolt ....................................................M10x185 .................... 1
23............. DT45-223.................Guide Rod............................................................................................. 2
24............. TS-1523041.............Socket Set Screw...............................................M6x12........................ 4
25............. DT45-225.................Carriage ................................................................................................ 1
26............. DT45-226.................Linear Bushing ...................................................LM16UU..................... 4
27............. DT45-227.................Seal....................................................................16x28x7 ..................... 4
28............. DT45-228.................Retaining Ring....................................................R28............................ 4
29............. DT45-229.................Linear Bushing ...................................................LM25UU..................... 4
30............. DT45-230.................Seal....................................................................25x40x7 ..................... 4
31............. DT45-231.................Retaining Ring....................................................R40............................ 4
32............. TS-1540031.............Hex Nut..............................................................M5.............................. 2
33............. TS-1502051.............Socket Head Cap Screw.....................................M5x20........................ 1
34............. DT45-234.................Spring.................................................................................................... 1
35............. DT45-235.................Motor..................................................................................................... 1
36............. DT45-236.................Motor Pulley .......................................................................................... 1
37............. DT45-237.................Fixing Washer .......................................................................................1
38............. TS-1482041.............Hex Cap Screw ..................................................M6x20........................ 1
39............. TS-1522031.............Socket Set Screw...............................................M5x10........................ 1
40............. DT45-240.................Flat Belt..............................................................670-25........................ 1
41............. DT45-241.................Belt Tension Adjustment Holder............................................................. 1
42............. TS-1550061.............Flat Washer........................................................M8.............................. 3
43............. TS-2361081.............Lock Washer ......................................................M8.............................. 2
44............. TS-1504071.............Socket Head Cap Screw.....................................M8x35........................ 2
45............. TS-2238911.............Socket Head Cap Screw.....................................M8x100...................... 1
46............. DT45-246.................Locking Handle...................................................M6x20........................ 1
47............. DT45-247.................Tracer Pin..............................................................................................1
48............. DT45-248.................Adjustment Screw..................................................................................1
49............. DT45-249.................Handle................................................................................................... 1
50............. DT45-250.................Sponge Coating..................................................................................... 1
51............. TS-1503071.............Socket Head Cap Screw.....................................M6x30........................ 4
52............. DT45-252.................Dust Hood ............................................................................................. 1
53............. TS-1550031.............Flat Washer........................................................M5.............................. 2
54............. TS-1502031.............Socket Head Cap Screw.....................................M5x12........................ 2
55............. DT45-255.................Window ................................................................................................. 1
56............. TS-2171012.............Machine Screw...................................................M4x6.......................... 4
57............. DT45-257.................Cutter.................................................................................................... 1
58............. TS-1502081.............Socket Head Cap Screw.....................................M5x35........................ 1
26
Headstock Assembly
27
Parts List: Cabinet Assembly
Index No. Part No. Description Size Qty
1............... DT45-301.................Cabinet.................................................................................................. 1
2............... DT45-302.................Door...................................................................................................... 1
3............... DT45-303.................Door Latch.............................................................................................1
4............... TS-2361081.............Lock Washer ......................................................M8.............................. 6
5............... TS-1504061.............Socket Head Cap Screw.....................................M8x30........................ 6
6............... TS-1524021.............Socket Set Screw ...............................................M8x10 ........................ 6
7............... DT45-307.................Flexible Hose......................................................2-1/2” .........................1
8............... DT45-308.................Hose Clamp .......................................................2-1/2” .........................2
9............... DT45-309.................Eye Bolt..............................................................M10............................ 2
10............. DT45-310.................Pin.........................................................................................................2
11............. DT45-311.................Dust Chute ............................................................................................ 1
12............. TS-1502031.............Socket Head Cap Screw.....................................M5x12........................ 4
28
Electrical Connections – 115 volt
29
Electrical Connections – 230 volt
30
31
WMH Tool Group, Inc.
2420 Vantage Drive
Elgin, Illinois 60124
Phone: 800-274-6848
www.wmhtoolgroup.com
32
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