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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.

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Summary of Contents for Single End Dovetailer DT45

Page 1: ...tions 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 ...

Page 2: ...or 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 o...

Page 3: ... 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 Part...

Page 4: ...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 influen...

Page 5: ...ctions 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 ...

Page 6: ...ork 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...

Page 7: ...7 Features of the DT45 Dovetailer Terminology Below are the terms used in this manual to identify types of cuts and measurements ...

Page 8: ...ure 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 War...

Page 9: ...can be further stabilized by securing it to the floor using lag screws through the four holes at the bottom of the cabinet 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 th...

Page 10: ...lling 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 When the clamping handles are screwed in completely tighten the hex nuts against the hubs with a 19mm wrench Dust Colle...

Page 11: ...face that is green with or without yellow stripes is the equipment grounding 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...

Page 12: ...ed 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 2...

Page 13: ...ght out on the locking handle and rotate it then release making sure it seats properly 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...

Page 14: ... 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 hea...

Page 15: ...e used as the basis for locating the vertical fence 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 templa...

Page 16: ...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 correc...

Page 17: ...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 counter cl...

Page 18: ...s 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 m...

Page 19: ...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...

Page 20: ...rds 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 This problem is resolved simply by taking a 2 inch plus wide back up board of the same thickness as your workpi...

Page 21: ... 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 t...

Page 22: ...ons 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 Motor starter failure 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 mo...

Page 23: ...tise and tenon cuts The mortise depth or tenon thickness is set incorrectly 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 Boards not square when clamped Make sure the initial cuts on the board ripping and or crosscutting have been done squarely and that the board is flush ag...

Page 24: ...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 S...

Page 25: ...25 Base Assembly ...

Page 26: ...r 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 S...

Page 27: ...27 Headstock Assembly ...

Page 28: ...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 ...

Page 29: ...29 Electrical Connections 115 volt ...

Page 30: ...30 Electrical Connections 230 volt ...

Page 31: ...31 ...

Page 32: ...32 WMH Tool Group Inc 2420 Vantage Drive Elgin Illinois 60124 Phone 800 274 6848 www wmhtoolgroup com ...

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