Powermatic 209 manual

Operating Instructions and Parts Manual 20-inch Planer Models 209 and 209HH WMH TOOL GROUP 2420 Vantage Drive Elgin, Illinois 60124 Part No. M-0260283 Ph.: 800-274-6848 Revision D1 11/06 www.wmhtoolgroup.com Copyright © WMH Tool Group This Manual is Bookmarked[...]

2 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 Servi ce Center 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[...]

3 Table of Contents Warranty and Service ........................................................................................................... ......................... 2 Table of Contents .............................................................................................................. ............................ 3 Warning .....[...]

4 Warning As with all machines, there is a certain amount of ha zard involved with the use of this planer. Use the machine with the respect and caution d emanded where safety precautions are concerned. When norm al safety precautions are overlooked or ignored, personal injury to the operator ca n result. Read, understand and follo w the safety and [...]

5 Hand safety. Keep hand s outside the machine. NEVER reach under the g uards to try to clear stock that stops feeding. Do not clea r chips and sawdust with hands; use a brush. Do not have any part of the hands under that part of the board that is over the table whe n starting a cut; the infeed roll will engage the board and force it down against t[...]

6 Introduction This manual is provided by WMH Tool Grou p covering the safe operation and maintena nce procedures for a Powermatic Model 209 and 209HH Planer. T his manual contains instructions o n installation, safety precautions, general o perating procedures, mainten ance instructions a nd parts breakd own. This machine has been designed and con[...]

7 Specifications Model Nu mber ....................................................................... 209-1 ....................................................... 209-3 Stock Number .................................................................. 1791296 .......................................... ........ 1791297 Table Area (in.) ..............[...]

8 Unpacking Open shipping container a nd check for shipping damage. Report any damage immediately to your distributor an d shipping agent. Do not discard any shipping material until the Planer i s assembled and running pr operly. Compare the contents of your container with the following parts list to make sure all parts are intact. Missing parts, i[...]

9 Assembly Tools required for assembly: Forklift or hoist with slings Pliers Open-End Wrenches (10,12,19mm) – p rovided Hex Wrenches, 4 and 5mm – provided Remove the screws holding the planer to the pallet and use a forklift or hoist to lift the planer off the pallet. Forks and straps should always be placed under the four lifting handle s when[...]

10 Extension Tables 1. Mount a ca st iron table to the edge of the main table with three M8 x 25 he x cap screws (Figure 9) using a 12mm wrench. Do not fully tighten yet. 2. The extension table must be leveled wit h the main table. Place a straight edge (such as a jointed board) across both t ables. 3. Insert three socket set screws with a 4mm hex [...]

11 Extension Cords The use of an extension cord is not recommended for this machine, bu t if one proves necessary make sure the cord rating is suitable for the amperage liste d on the machine's motor pl ate. An undersize cord will cause a drop in line voltage resulting in loss of power and overheating. The chart in Figure 11 shows the correct [...]

12 When planing smooth sto ck the rollers should be set at low position. NOTE: When raising the roller hi gher above the table, the range is from .003" to .006" (Figu re 14). The table rollers are factory set for average planing and are pa rallel to the table surface. If you desire to adjust the table rollers higher o r lower, proceed as [...]

13 4. If an adjustment to one or more of the knives is necessary, slightly loosen the knife gib (E, Figure 18) by turning the six screws (F, Figure 18) into the gib (i.e. clockwise, when facing the screw heads) with a 12mm hex wrench. Turn the screws just enough to relieve stress in the cutterhead without disturbing the setting of the knives. Do th[...]

14 6. Inspect the cutting edge of the knives for nicks or wire edge. Hone the knives slightly using a stone or if the knive s are to be sharpened, maintain a cutting angle of 35 degrees. 7. Insert springs, knife and gib into slot of cutterhead. Back out screws just en ough to hold the knife in the cutterhead. 8. Place knife setting gauge (Figure 19[...]

15 Work Table Parallel to Cutterhead The work table is set parall el to the cutterhead at the factory and no further adjustment should be necessary. If your machine is planing a taper, first check to see if the knives are set pr operly in the cutterhead. Then che ck to see if the work table is set p arallel to th e cutterhe ad. Proceed as follows: [...]

16 Anti-Kickback Fingers The anti-kickback fingers (A, Figure 23) are an important safety feature, as they help prevent kickback of stock. They operate by gravity and should be inspected frequently to make sure they re free of gum and pitch, so that they move independently and operate correctly. Infeed and Outfeed Roller Spring Tension The infeed r[...]

17 Outfeed Roller Height 1. Disconnect machine from power source. 2. Make sure the knives are set p roperly as previously explained under "Knife Adjustment." 3. Place the gauge block (J, Figure 26) on the table directly beneath the cutterhead (D, Figure 26). 4. Using a 0.02" (0.5mm) feeler gaug e (K, Figure 26) placed on top of the g[...]

18 Pressure Bar Height The pressure bar prevents the stock fro m lifting after it passes under the cutterhead. Check the height of the pressure bar with your gauge block and a .008" (0.2mm) feeler gauge. If ad justment is needed: 1. Remove top cover. 2. Loosen the lock nuts (B, Figure 29) on both ends of the pressure bar and turn the set screw[...]

19 1. Disconnect machine from power source. 2. Remove the three hex cap screws and washers (E, Figure 30). 3. Remove the three sprockets (B, Figure 30) from the infeed roller, outfeed roller and the gear shaft at the same time. 4. When all sp rockets have been removed, replace the gear shaft spro cket (G, Figure 31) and its chain (F, Figu re 31) wi[...]

20 Maintenance Disconnect machine from power source before performing any maintenance. Periodic or regular inspection s are required to ensure that the machine is in prop er adjustment, that all screws are tight , that belts are in good condition, that dust ha s not accumulated in the electrical enclosure s, and that there are no worn or loose elec[...]

21 The item numbers on this chart are refe renced to the surroundi ng illustrations. No. Position Interval Suitable Types of Lubricant Figure No. 1 Drive Chain Frequently Grease 33 2 Gear Box When operated more than 2,500 hours Standard gear oil, 70-90 weight 33 3 Return Rollers Frequently SAE-30 35 4 Worm Gear Frequently Grease 36 5 Lead Screw Fre[...]

22 Troubleshooting: Operating Problems Trouble Probable Cause Remedy Table rollers not set properly. Adjust rollers to proper height. Inadequate support of long boards. Support long boards with extension rollers. Uneven feed roller pressu re front to back. Adjust feed roller pressure. Dull knives or knife inserts. 209: Sharpen or replace knives. 20[...]

23 Troubleshooting: Mechanical and Electrical Problems Trouble Probable Cause Remedy Knife projection from cutterhead is incorrect (209 only) Adjust knife projection. Uneven depth of cut side to side. Table not parallel to cutterhead. Adjust table/cutterhead parallelism. Board thickness does not match depth of cut scale. Depth of cut scale is incor[...]

24 Trouble Probable Cause Remedy Motor starter failure. Examine motor starter for burned or failed components. If damage is found, replace motor starter. If motor starter looks okay but is still suspect, you have two options: have a qualified electrician test the motor starter for function, or purchase a new starter and establish if that was the pr[...]

25 Cutterhead Assembly[...]

26 Parts List: Cutterhead Assembly Index No. Part No. Description Size Qty 1 ............... 6012204 ................... Nut ........................................................................ 5/16-18NC . ................. 2 2 ............... 6292622 ................... Knife Locking Bar * .............................................. .......[...]

27 58 ............. 6292636 ................... Spring ................................................................... .................................... 4 59 ............. 6292635 ................... Bushing ................................................................ ............... ..................... 4 60 ............. 6292638 .....[...]

28 Base Assembly[...]

29 Parts List: Base Assembly Index No. Part No. Description Size Qty 1 ............... 6292649 ................... Ring, Re taining .................................................... STW-12 ............ ........... 1 2 ............... 6292742 ................... Gear ..................................................................... 24T ......[...]

30 Gearbox Assembly[...]

31 Parts List: Gearbox Assembly Index No. Part No. Description Size Qty 1 ............... 6292788 ................... Socket Head Cap Screw ...................................... M6 x 1.0P x 2 5L .......... 5 2 ............... 6292785 ................... Pin ........................................................................ 8 x20 ..... ......[...]

32 Stand Assembly[...]

33 Parts List: Stand Assembly Index No. Part No. Description Size Qty 1 ............... 6292807 ................... Strain Relief.......................................................... .............. ...................... 1 2 ............... 6292804 ................... Key ....................................................................... [...]

34 Parts List: Table Assembly Index No. Part No. Description Size Qty 1 ............... 6292724 ................... Eccent ric Shaft ..................................................... ................. ................... 4 2 ............... 6292679 ................... Bearing ................................................................. 620[...]

35 Electrical Connections – Single Phase, 230 Volt only[...]

36 Electrical Connections – 3 Phase, 230 Volt only[...]

37 Electrical Connections – 3 Phase, 460 Volt only[...]

38 Preventive Maintenance Checklist for Model 209 and 209HH Planers [ ] Work area around machi ne marked off clearly. [ ] Non-skid floor strips in area where op erator normally stands. [ ] Inspect entire machine for loose bolts , nu ts, screws. Tighten and replace as necessary. [ ] Clean table and cutterhead area, removing sawdust and chi ps with a[...]

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40 WMH Tool Group 2420 Vantage Drive Elgin, IL 60124 Phone: 800-274-6848 Website: www.wmhtoolgroup.com[...]