POWERMATIC PM2000B 10 Inch Saw Cabinet Instruction Manual

POWERMATIC PM2000B 10 Inch Saw Cabinet Instruction Manual

Model: PM2000B & PM2000BT

1.0 Safety Warnings

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 table saw 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 table saw, do not use until proper training and knowledge have been obtained.
5. Do not use this table saw for other than its intended use. If used for other purposes, Powermatic disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use.
6.   Model PM2000BT has an industrial-grade lowfriction corrosion-resistant coating on the table and table extensions. While this coating is durable, it can be damaged if metal or other hard and/or sharp objects strike, gouge, or scratch the surface. Significant damage to the coating may affect its performance.
7. Always wear approved safety glasses or face shield while using this table saw. Everyday eyeglasses only have impact resistant lenses; they are not safety glasses.
8.  Before operating this table saw, remove tie, rings, watches, and other jewelry, and roll sleeves up past the elbows. Do not wear loose clothing. Confine long hair. Non-slip footwear or anti-skid floor strips are recommended. Do not wear gloves.
9. Wear ear protectors (plugs or muffs) during extended periods of operation.
10. Do not operate this machine while tired or under the influence of drugs, alcohol, or any medication.
11. Make certain the machine is properly grounded.
12.  Make all machine adjustments or maintenance with the machine unplugged from the power source. A machine under repair should be RED TAGGED to show it must not be used until maintenance is complete.
13. 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.
14.  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.
15.  Check the alignment of the riving knife, fence, and miter slot to the blade. A caution decal is installed on each guard to remind the operator of the dangers of improper machine operation.
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 safety keys.
21. Give your work undivided attention. Looking around, carrying on a conversation and “horseplay” 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 blade 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 blade sharp and clean for the best and safest performance. Follow instructions for lubricating and changing accessories.
26. Check the saw blade for cracks or missing teeth. Do not use a cracked or dull blade or one with missing teeth or improper set. Make sure the blade is securely locked on the arbor.
27.  Keep hands clear of the blade area. Do not reach past the blade to clear parts or scrap with the saw blade running. Never saw freehand. Avoid awkward operations and hand positions where a sudden slip could cause your hand to contact the blade.
28.  Do not attempt to saw boards with loose knots or with nails or other foreign material, on its surface. Do not attempt to saw twisted, warped or bowed stock unless one edge has been jointed for guiding purposes prior to sawing. Excessively warped stock should not be used.
29.  Do not attempt to saw long or wide boards unsupported where spring or weight could cause the board to shift position.
30.  Always use the riving knife, blade guard, push stick and other safety devices for all operations where they can be used. On operations such as dadoing or molding where the blade guard cannot be used, use feather boards, fixtures and other safety devices, and use extreme caution. Reinstall the riving knife and blade guard immediately after completing the operation that required their removal.
31.  Be sure the saw blade rotates clockwise when viewed from the motor side (left side) of the machine.
32.  Turn off the machine before cleaning. Use a brush or compressed air to remove chips or debris — do not use bare hands. 33. Do not stand on the machine. Serious injury could occur if the machine tips over.
33. Never leave the machine running unattended. Turn the power off and do not leave the machine until it comes to a complete stop.
34.  Remove loose items and unnecessary work pieces from the area before starting the machine.
35.  Blade should have minimum exposure during cuts. Adjust blade to approximately 1/8” inch above surface of workpiece.

1.1 Kickback

The most common accidents among table saw users, according to statistics, can be linked to kickback, the high-speed expulsion of material from the table that can strike the operator. Kickback can also result in the operator’s hands being pulled into the blade.

Kickback Prevention

Tips to avoid the most common causes of kickback:

• Make sure the riving knife is always aligned with the blade. A workpiece can bind or stop the flow of the cut if the riving knife is misaligned, and result in kickback.
• Use a riving knife during every cut. The riving knife maintains the kerf in the workpiece, which will reduce the chance of kickback.
• Never attempt freehand cuts. The workpiece must be fed parallel to the blade, otherwise kickback will likely occur. Always use the rip fence or miter gauge to support the workpiece.
• Make sure that rip fence is parallel to blade. If not, the chances of kickback are very high. Take the time to check and adjust the rip fence.
• Feed cuts through to completion. Anytime you stop feeding a workpiece that is in the middle of a cut, the chance of binding, resulting in kickback, is greatly increased.

Tips for Kickback Protection

Kickback can happen even if precautions are taken to prevent it. Listed below are some tips to protect you if kickback does occur:

•  Stand to the side of the blade when cutting. An ejected workpiece usually travels directly in front of the blade.
• Wear safety glasses or a face shield. Your eyes and face are the most vulnerable part of your body.
• Never place your hand behind the blade. If kickback occurs, your hand will be pulled into the blade.
• Use a push stick to keep your hands farther away from the moving blade. If a kickback occurs, the push stick will most likely take the damage that your hand would have received.

Familiarize yourself with the following safety notices used in this manual:

  CAUTION This means that if precautions are not heeded, it may result in minor injury and/or possible machine damage.
  WARNING This means that if precautions are not heeded, it may result in serious or possibly fatal injury.

2.0 About This Manual

This manual is provided by Powermatic covering the safe operation and maintenance procedures for Powermatic
Model PM2000B & PM2000BT Cabinet Saws. This manual contains instructions on installation, safety precautions, general operating procedures, maintenance instructions and parts breakdown. Your machine has been designed and constructed to provide consistent, long-term operation if used in accordance with the instructions set forth in this document.

This manual is not intended to be an exhaustive guide to table saw operational methods, use of jigs or aftermarket accessories, choice of stock, etc. Additional knowledge can be obtained from experienced users or trade articles. Whatever accepted methods are used, always make personal safety a priority.

If there are questions or comments, please contact your local supplier or Powermatic. Powermatic can also be reached at our web site: www.powermatic.com.
Retain this manual for future reference. If the machine transfers ownership, the manual should accompany it.

  WARNING Read and understand the entire contents of this manual before attempting assembly or operation! Failure to comply may cause serious injury!

4.0 Terminology

Arbor: Metal shaft that connects the drive mechanism to the blade.
Bevel Edge Cut: Tilt of the saw arbor and blade between 0° and 45° to perform an angled cutting operation.
Blade Guard: Mechanism mounted over the saw blade to prevent accidental contact with the cutting edge.
Crosscut: Sawing operation in which the miter gauge is used to cut across the grain of the workpiece.
Dado Blade: Blade(s) used for cutting grooves and rabbets. A stacked dado set can be used for wider grooves.
Dado Cut: Flat bottomed groove in the face of the workpiece made with a dado blade.
Featherboard: Device used to keep a board against the rip fence or table that allows the operator to keep hands away from saw blade.
Freehand: Moving the workpiece into the blade using only the hands, without a fixed positioning device. (This is a dangerous, unacceptable procedure – always use appropriate devices to feed the workpiece through the saw blade during cutting operations.)

Kerf: The resulting cut or gap made by a saw blade.
Kickback: An event in which the workpiece is lifted up and thrown back toward an operator, caused when a workpiece binds on the saw blade or between the blade and rip fence (or other fixed object). To minimize or prevent injury from kickbacks, see the Operations section.
Miter Gauge: A component that controls the workpiece movement while performing a crosscut of various angles.
Non-Through Cut: A sawing operation that requires the removal of the blade guard and
standard riving knife, resulting in a cut that does not protrude through the top of the workpiece (includes dado and rabbet cuts).
The blade guard and riving knife must be re-installed after performing a non- through cut to avoid accidental contact with the saw blade during operation.

Parallel: Position of the rip fence equal in distance at every point to the side face of the saw blade.
Perpendicular: 90° (right angle) intersection or position of the vertical and horizontal planes such as the position of the saw blade (vertical) to the table surface (horizontal).
Push Board/Push Stick: An instrument used to safely push the workpiece through the cutting operation by keeping the operator’s hands at a distance.
Rabbet: A cutting operation that creates an L-shaped channel along the edge of the board.
Rip Cut: A cut made along the grain of the workpiece.
Riving Knife: A metal plate fixed relative to the blade, which moves with the blade as cutting depth is adjusted. Thus, it maintains not only the kerf opening in the workpiece, but also the knife-to-blade distance. A low-profile riving knife sits lower than the top edge of the blade, for making a non- through cut.
Splitter (Spreader): A stationary metal plate to which the blade guard is attached that maintains the kerf opening in the workpiece during a cutting operation. (Powermatic table saws use the superior riving knife system instead.)
Standard Kerf: 1/8″ gap made with a standard blade.

Straightedge: A tool used to check that a surface is flat or parallel.
Through Sawing: A sawing operation in which the workpiece thickness is completely sawn through.
Proper blade height usually allows 1/8″ of the top of blade to extend above the wood stock. Keep the blade guard down, the anti-kickback pawls down, and the riving knife in place over the blade.

5.0 Specifications

Table 1

1 Note: For 460V operation, an overload relay (Part No. PM2000B-2107BORA) must be purchased separately and installed. A qualified electrician is recommended.
2 subject to local/national electrical codes.
3 The specified values are emission levels and are not necessarily to be seen as safe operating levels. As workplace conditions vary, this information is intended to allow the user to make a better estimation of the hazards and risks involved only.
L = length, W = width, H = height, D = depth
n/a = not applicable

5.1 Kit Configurations

Table 2

The specifications in this manual were current at time of publication, but because of our policy of continuous improvement, Powermatic reserves the right to change specifications at any time and without prior notice, without incurring obligations.

6.0 Setup and Assembly

7.0 Electrical Connections

WARNING 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.

A power plug is not provided with this table saw. You may either connect the proper UL/CSA listed plug or “hardwire” the machine directly to your electrical panel provided there is a disconnect near the machine for the operator. Consult electrical drawings in sect. 15.0 for further clarification of wiring setup.

Before connecting to power source, be sure switch is in off position.

It is recommended that the 3HP 1-phase, and 5HP 3-phase table saws be connected to a dedicated 20- amp circuit with breaker or fuse.

The 5HP 1-phase saw should be connected to a 30- amp circuit with breaker or fuse.

If connected to a circuit protected by fuse, use time delay fuse marked “D”. Local codes take precedence over recommendations.

7.1 Grounding Instructions

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 tool is equipped with an electric cord having an equipment-grounding conductor. A plug is not provided. A proper UL/CSA listed plug may be installed or the machine may be “hard-wired” to a circuit panel. If hard-wired, make sure a disconnect is available to the operator.

Improper connection of the equipment-grounding 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 equipment-grounding conductor. If repair or replacement of the electric cord or a plug is necessary, do not connect the equipment-grounding conductor to a live terminal.

  WARNING 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. Failure to comply may cause serious or fatal injury.
Repair or replace damaged or worn cord immediately.

7.2 Voltage Conversion (3-phase model only)

1. Remove transformer cover at back of machine and move fuse from 230V position to 460V position on transformer.
2. Switch the incoming power leads to the motor for 460-volt operation, according to wiring diagram on inside cover of motor junction box.
A similar diagram is found in sect. 15.0 of this manual. (In case of discrepancy, diagram in junction box takes precedence.)
3. Replace the 230V overload relay with a 460V overload relay (additional purchase, part number PM2000B-2107BORA).
4. If using a plug, the 230V plug must be replaced with a UL/CSA listed plug rated for 460V.

7.3 Extension Cords
USE PROPER EXTENSION CORD. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw.
An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Table 3 shows correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

7.4 Magnetic switch and Safety Key

Refer to Figure 7-2.
Power Indicator Light – The start switch has a power indicator lamp which is on whenever there is power connected to the saw, not just when the saw is running. Always check before use.

  WARNING Do not assume that no light means there is no power to the machine. If the bulb is bad, there will be no indication. Always check for power first. Failure to comply may cause serious injury!
To Start – Press green start switch.
When power is connected to the machine, the green light is always on regardless of whether the saw is running or not.
To Stop – Press red switch to stop.

Reset – If the saw stops without pressing the stop button, as the result of a tripped fuse or circuit breaker:
1. Press red button to reset.
2. Press green button to restart machine.
7.4.1 Safety Key
The switch is equipped with a magnetic safety key.
When in place on the switch as shown in Figure 7-
2, the safety key trips a relay which will allow the machine to start and stop when the respective switches are pressed. Being magnetic, the key can be removed to make the machine inoperable and can be hidden for safe storage by attaching it underneath the rail or another magnetic surface.
When using the saw, place the key on the switch cover lining up the arrow on the key with the REMOVE arrow on the cover. Then rotate the key so the arrow lines up with the LOCK arrow. This prevents the safety key from vibrating loose when machine is in use.

8.0 Adjustments

  CAUTION Model PM2000BT has an industrial-grade low-friction corrosion- resistant coating on the table and table extensions. While the coating is durable, it can be damaged if metal or other hard and/or sharp objects strike, gouge, or scratch the surface. Significant damage to the coating may affect its performance. Use care when making adjustments to this saw.

8.1 Tools Required for Adjustments
Hex keys: 2.5mm, 3mm, 4mm
Wrenches: 13mm, 19mm, 22mm (or adjustable)
Straight edge
Square

8.2 Fence Alignment
Before using the Accu-Fence®, verify that it is properly aligned with the blade. Consult manual no.
M-2195079B that accompanied the fence.
8.3 Blade Raising and Tilting
See Figure 8-1.
To raise or lower blade, loosen lock knob (A, Figure
8-1) and turn handwheel (B) on front of saw until desired height is reached. Tighten lock knob (A).
The blade should be raised about 1/8″ above top surface of material being cut.

To tilt blade, loosen lock knob (C) and turn handwheel (D) until desired angle is obtained, as shown on tilt scale or DRO. Retighten lock knob (C).

The DRO, or digital readout (E) displays the angle for quick positioning. See sect. 8.10 for calibration of the DRO.

Reference pointers (F) can be positioned at any point along scale; loosen knob and slide pointer to position, then tighten knob. These provide a quick reference point for aligning the angle indicator.

8.4 Caster Mechanism
To engage caster system, pump handle (G, Figure 8-1) about 4 or 5 times.

Disengage caster system by turning handle (H) counterclockwise. Casters must be disengaged before operating saw.

Note: It is recommended that saw be lowered to resting position after being moved to desired location. If left in raised position for an extended period, saw will gradually settle back to floor – this is normal.

8.5 Miter Gauge
Refer to Figures 8-2, 8-3, 8-3B, and 8-3C.
For model PM2000BT: The miter gauge has non-marring bottom surfaces to protect the table coating. To prevent damage to the table coating, only use the miter gauge supplied with this machine.

Setting Miter Angle (model PM2000B)

The miter gauge has rack and pinion adjustment for setting angle. To operate:
1. Slide miter gauge into table slot.
2. Loosen lock handle (H, Figure 8-2) by turning counterclockwise.
3. Pull out spring-loaded knob (J) and rotate knob until body (K) of miter gauge is at desired angle as indicated on scale.
4. Tighten lock handle (H).

Indent Settings (model PM2000B)
There are indents at 0º, 30º and 45º right and left positions. At these settings, release knob (J) to engage indent. Then tighten lock handle (H).

Note: Do not rely solely on the indents for an accurate setting. After stop rod engages at the 0º, 30º and 45º positions, make a fine adjustment with the knob (J) if necessary, setting it against the scale indicator (L).

Miter Gauge Fence (model PM2000B)
The miter gauge fence (M, Figure 8-2) can be adjusted by sliding to right or left or removed entirely.

To adjust, loosen two lock handles (N), slide fence and retighten lock handles. Make sure end of fence and lock handle are not in blade path.

NOTE: The lock handles (N) are adjustable. Pull out on handle, rotate it to different position, then release, making sure it seats itself upon the pin.
To remove miter gauge fence, slide it completely off and remove lock handles (N) and mounting hardware.

Squaring Miter Gauge (model PM2000B)

1. Place miter gauge into table slot.

2. Set miter gauge at 90º to blade (0º setting on scale) by loosening lock handle (H, Figure 8-2), then pulling out spring-loaded knob (J) and turning body (K) until 0º is indicated on scale.

3. Measure accuracy of miter gauge against slot with a square.
   If adjustment is needed:

4. Adjust body (K) until it is square (90º) to miter slot.

5. Tighten lock handle (H).

6. Verify that scale indicator (L) reads 0º. If it does not, loosen screw (P) and adjust indicator (L) until it reads 0º. Retighten screw (P).

7. If the above procedure does not satisfactorily align the miter gauge, loosen two screws (R, Figure 8-3) beneath mounting block and shift block as needed. Retighten screws when finished.

NOTE: The miter gauge bar has two slots with set screws (S, Figure 8-2). Adjust these set screws to eliminate any play between bar and miter slot.

Squaring Miter Gauge (model PM2000BT):

1. Place a square against miter gauge face, and against flat of blade. (Place square against flat of blade, not against the teeth which are set wider than the blade body).
2. Loosen screws A and B as shown in Figure 8- 3C.
3. Adjust the miter gauge fence to make it square to the blade. Tighten screws A and B.
4. After squaring, if the red pointer (C) is not pointing at 0°, loosen the pointer setscrew (see
   Figure 8-3B), rotate the pointer to 0°, and retighten the pointer setscrew.

Figure 8-3B

Adjusting Miter Gauge Angle for Operations (model PM2000BT, refer to Figure 8-3C):

1. Unscrew handle (D) just enough to loosen it.
2. Press black tab (E) to release it from stop 0°.
3. Rotate gauge body until red pointer (C) lines up with desired angle on scale.
4. Tighten handle (D).
5. There are 13 stops at 0°, 15°, 22.5°, 30°, 45°, 60°, and 67.5° left and right. Each of these can be adjusted to by allowing the spring stop to lock into each location. Press black tab (E) to move past each stop location.

8.6 Blade Tilt Stop Adjustment
The stops for 90°, 45° blade tilt, and elevation settings have all been factory set, and should require no immediate adjustment. The settings should be confirmed by the operator, however, and especially if cuts become inaccurate. Both tilt stops are located on the trunnion.

8.6.1 Tilt Stop 90°

1. Disconnect machine from power source.

2. Make sure table insert has been leveled with table surface (sect. 6.8).

3. Raise blade to highest position and place a square on table and against blade (Figure 8-4).
   Make sure that a blade tooth does not obstruct the actual reading.

4. Tilt blade with handwheel until square and blade are flush.

5. If adjustment is required, loosen nut on 90° stop screw (Figure 8-5) with 13mm wrench, and turn screw to proper height. Verify setting and retighten nut against trunnion.

6. Check pointer position on scale (Figure 8-5). If needed, loosen screw and adjust pointer to zero. Retighten screw.

Sect. 8.10.1 describes general calibration procedure. Sect. 8.10.2 describes mandatory calibration procedures if the PCB sensor is ever replaced in the table saw.

8.10.1 General Calibration

1. Blade tilt stops must be correctly set. See sect. 8.6.

2. Connect machine to power source. DRO will be illuminated.

3. If saw blade is relatively close to 0°, set blade to exactly 0° and press “SET 0” button. Readout will display 0.00. See Figure 8-13.
   Or, if saw blade is relatively close to 45°, set blade to 45°, and press “SET 45” button. Readout will display 45.0.

4. Calibration is complete.
   NOTE: If power is disconnected, digital display will reset to 0.00. When power is restored, repeat above procedure.

Figure 8-13

8.10.2 PCB Replacement Calibration

1. Blade tilt stops must be correctly set. See sect. 8.6.
2. Connect machine to power source. DRO will be illuminated.
3. Tilt saw blade to 0°.
4. Press and hold both SET buttons until display shows “—“ (Figure 8-14).
5. Release buttons and display will show “00.0”.
6. Calibration at 0° is complete. (If “00.0” does not display, disconnect from power, reconnect, and repeat above procedure.)
7. Tilt blade to 45°.
8. Press and hold both SET buttons until display shows “—“ (Figure 8-14).
9. Release buttons and display will show “45.0”.
10. Calibration at 45° is complete. (If “45.0” does not display, disconnect from power, reconnect, and repeat above procedure.)

9.0 Operations

  Model PM2000BT has an industrial-grade low-friction corrosion-resistant coating on the table and table extensions. While the coating is durable, it can be damaged if metal or other hard and/or sharp objects strike, gouge, or scratch the surface. Significant damage to the coating may affect its performance. Use care when operating the machine.

Familiarize yourself with the location and operation of all controls and adjustments and the use of accessories such as miter gauge and rip fence.

Note: The following figures are general in nature and may not show your particular saw model.

9.1 Kickback Prevention

Serious injury can result from kickbacks which occur when a workpiece binds on the saw blade or binds between the blade and rip fence or other fixed object. This binding can cause the workpiece to lift up and be thrown toward the operator.

Listed below are conditions which can cause kickbacks:

•  Confining the cutoff piece when crosscutting or ripping.
•  Releasing workpiece before completing operation or not pushing workpiece all the way past saw blade.
• Not using splitter/riving knife when ripping or not maintaining alignment of splitter/ riving knife with saw blade.
•  Using dull saw blade.
• Not maintaining alignment of rip fence so that it tends to angle toward rather than away from saw blade front to back.
• Applying feed force when ripping to the cutoff (free) section of workpiece instead of the section between saw blade and fence.
• Ripping wood that is twisted (not flat), or does not have a straight edge, or has twisted grain.

To minimize or prevent injury from kickbacks:

•  Avoid conditions listed above.
• Wear a safety face shield, goggles, or safety glasses.
• Do not use miter gauge and rip fence in the same operation unless provision is made by use of a facing board on the fence, to allow the cutoff section of workpiece to come free before the actual cut begins (See Figure 9-8).
• As the machine receives use, the operation of the anti-kickback pawls should be checked periodically (Figure 9-1). If the pawls do not stop the reverse motion of a workpiece, resharpen all the points.
• Where possible, keep your face and body out of line with potential kickbacks, including when starting or stopping the machine.
• Dull, badly set, improper, or improperly filed cutting tools, and cutting tools with gum or resin adhering to them can cause accidents. Never use a cracked saw blade. The use of a sharp, well maintained, and correct cutting tool for the operation will help avoid injuries.
• Support the work properly and hold it firmly against gauge or fence. Use a push stick or push block when ripping short, narrow (6″ width or less), or thin work. Use a push block or miter gauge hold-down when dadoing or molding.
• Never use the fence as a length stop when crosscutting. Do not hold or touch the free end or cutoff section of a workpiece. On throughsawing operations, the cutoff section must NOT be confined.
•  Always keep your hands out of line of the saw blade and never reach back of the cutting blade with either hand to hold the workpiece.
• Bevel ripping cuts should always be made with the fence on the right side of saw blade so that the blade tilts away from the fence and minimizes possibility of the work binding and the resulting kickback.

9.2 Rip Sawing

Ripping is feeding the workpiece with the grain into the saw blade using the fence or other positioning device as a guide to ensure desired width of cut (Figure 9-2).

Always use a push stick or similar device when ripping narrow pieces.

Before starting a rip cut, verify that fence is clamped securely and aligned properly.

• Never rip freehand or use miter gauge in combination with the fence.
• Never rip workpieces shorter than the saw blade diameter.
• Never reach behind the blade with either hand to hold down or remove the cutoff piece with the saw blade rotating.

anti-kickback pawls. Make sure splitter/riving knife is properly aligned. When wood is cut along the grain, the kerf tends to close and bind on the blade and kickbacks can occur.

Note: A warning decal is affixed to the guard to remind the operator of some basic safety procedures.

The rip fence should be set for the width of the cut by using the scale on the front rail, or by measuring the distance between blade (A) and fence (B). Stand out of line with saw blade and workpiece to avoid sawdust and splinters coming off the blade or a potential kickback.

If the workpiece does not have a straight edge, nail an auxiliary straight edged board on it to provide one against the fence. To cut properly, the board must make good contact with the table. Do not attempt to cut warped boards.

In ripping, use one hand to hold the board down against the fence or fixture, and the other to push it into the blade between blade and fence. If workpiece is narrower than 6″ or shorter than 12″, use a push stick or push block to push it through between fence and blade (Figure 9-4). Never push in a location such that the pushing hand is in line with the blade. Move the hand serving as a holddown a safe distance from blade as cut nears completion.

For very narrow ripping where a push stick cannot be used, use a push block or auxiliary fence. Always push the workpiece completely past the blade at the end of a cut to minimize the possibility of a kickback.

When ripping long boards, use a support at front of table (C, Figure 9-5), such as a roller stand, and a support or “tailman” at the rear (D).

Never use the rip fence beyond the point where the carriage is flush with the end of the rails.

Have the blade extend about 1/8″ above top of workpiece. Exposing the blade above this point can be hazardous.

9.3 Resawing

Resawing is a ripping operation in which thick boards are cut into thinner ones. Note: A band saw is the ideal tool for resawing.

****If the table saw is used for resawing, take precautions such as using an auxiliary fence, resaw barrier or similar devices to stabilize the workpiece and provide operator safety.

Narrow boards up to 3″ can be resawn in one pass. Wider boards up to 6″ must be resawn in two passes.

In resawing wider boards, adjust the blade height so as to overlap the two cuts by 1/2″ as shown in Figure 9-6. Too deep a first cut can result in binding and possible kickbacks on the second cut. Always use the same side of the board against the fence for both cuts.

9.4 Crosscutting

Crosscutting is where the workpiece is fed cross grain into the saw blade using the miter gauge to support and position the workpiece (Figure 9-7).

Crosscutting should never be done freehand, nor should the fence be used as an end stop unless an auxiliary block (E, Figure 9-8) is clamped to the front of the blade area such that the cutoff piece comes free of the block before cutting begins.

Length stops should not be used on the free end of
the workpiece in the cutoff area.

Do not crosscut workpieces shorter than 6″. Before starting a cut, be sure the miter gauge is securely clamped at the desired angle. Hold the workpiece firmly against the table and back against the miter gauge. Always use the saw guard and riving knife and make sure the riving knife is properly aligned.

For 90-degree crosscutting, most operators prefer to use the left-hand miter gauge slot. When using it in this position, hold the workpiece against the gauge with the left hand and use the right hand to advance the workpiece. When using the right-hand slot for miter and compound crosscutting so that the blade tilts away from the gauge, the hand positions are reversed.

When using the miter gauge, the workpiece must be held firmly and advanced smoothly at a slow rate. If the workpiece is not held firmly, it can vibrate causing it to bind on the blade and dull the saw teeth.

To augment the effectiveness of the miter gauge in crosscutting, some users mount an auxiliary wood extension face (F, Figure 9-9) with a glued-on strip of sandpaper (G) to help grip the workpiece.

Provide auxiliary support for any workpiece extending beyond the table top with a tendency to sag and lift up off the table.

Have the blade extend about 1/8″ above the top of the workpiece. Exposing the blade above this point can be hazardous.

9.5 Bevel and Miter Operations

Bevel cut – A bevel cut is a special type of operation where the saw blade is tilted at an angle less than 90-degrees to the table top (Figure 9-10).

Operations are performed in the same manner as ripping or crosscutting, except the fence or miter gauge should be used on the right-hand side of the blade to provide added safety in avoiding a binding action between blade and table top. When beveling with the miter gauge, the workpiece must be held firmly to prevent creeping.

  Never use a zero- clearance insert with saw blade in tilted position.

Mitering – Crosscuts made at an angle to the edge of the workpiece are called miters (Figure 9-11). Set the miter gauge at the required angle and make the cut the same as a normal crosscut except the workpiece must be held extra firmly to prevent creeping.

Note: When making compound miters (with blade tilted) use the miter gauge in the right-hand slot to provide more hand clearance and safety.

Have the blade extend only 1/8″ above the top of the workpiece. Exposing the blade above this point can be hazardous.

9.6 Dado Cutting

Dadoing is cutting a wide groove into a workpiece or cutting a rabbet along the edge of a workpiece. A dado insert (optional accessory, shown in Figure 9- 12) is necessary for this type of operation.

  Do not use the standard table insert for dadoing operations.

The process of cutting 1/8″ to 13/16″ grooves in workpieces is accomplished by the use of a stacked dado blade set or an adjustable-type blade mounted on the saw arbor. By using various combinations of stacked dado blades, or properly setting the dial on an adjustable blade, an accurate width dado can be made. This is very useful for shelving, making joints, tenoning, etc.

The guard, riving knife, and anti-kickback pawls supplied with the saw should be used for all cutting operations where they can be used.

When performing operations where the guard cannot be used, as in some dadoing operations, alternative safety precautions should be taken. These include push sticks, feather boards, filler pieces, fixtures, jigs and any other appropriate device that can be utilized to keep operators’ hands away from the blade.

Upon completion of the operation requiring removal of the guard, the entire guard assembly must be placed back on the machine in its proper working order.

  CAUTION Never use a dado head in a tilted position. Never operate the saw without the blade guard, riving knife and anti-kickback pawls for operations where they can be used.

10.0 Safety Devices

10.1 Feather Board
Feather boards, or “combs,” can be purchased at most tool stores, or made by the operator to suit particular applications. The feather board (Figure 9- 13) should be made of straight grain hardwood approximately 1″ thick and 4″ to 8″ wide depending on the size of the machine. The length is developed in accordance with intended use.

Feather boards can be fastened to the table or rip fence by use of C-clamps. Alternatively, drilled and tapped holes in the table top allow the use of wing nuts and washers as a method of clamping. If this method of fastening is used, provide slots in the feather board for adjustment. (The illustration shows a method of attaching and use of the feather board as a vertical comb. The horizontal application is essentially the same except that the attachment is to the table top.)

Figure 9-13: feather board

10.2 Push Stick and Push Block
The use of a push block or push stick provides an added level of safety for the operator. A push stick is included with your table saw, but you may wish to make others personalized for different cutting procedures. The templates in Figures 9-15 and 9-15 offer construction details.

Figure 9-14: push block template

Figure 9-15: push stick template

11.0 Maintenance

  WARNING Always disconnect power to machine before performing maintenance.
Failure to comply may result in serious personal injury.

  CAUTION Model PM2000BT has an industrial-grade low-friction corrosion- resistant coating on the table and table extensions. While the coating is durable, it can be damaged if metal or other hard and/or sharp objects strike, gouge, or scratch the surface. Significant damage to the coating may affect its performance. Use care when cleaning and maintaining the machine.

11.1 General Inspection
Always be aware of the condition of your machine.
Routinely check the condition of the following items and repair or replace as necessary:

• Mounting bolts
• Power switch
• Saw blade
• Blade guard assembly

11.2 Cleaning
Note: The following maintenance schedule assumes the saw is being used daily.

DAILY:

• Model PM2000B: Wipe down the table surface and T-slots with a rust preventive.
• Model PM2000BT: Wipe down the table surface and T-slots.
• Clean pitch and resin from saw blade.

WEEKLY:

• For Model PM2000B Only: Table surface must be kept clean and free of rust for best results.
  To facilitate this, apply a coat of paste wax to the surface. Alternatively, commercial spray protectants are available from local hardware and tool stores. A good protectant should provide rust protection for the surface without staining workpieces.

• Clean the motor fan housing with compressed air.

• Wipe down fence rails with a dry silicon lubricant.

PERIODICALLY:

• Keep cabinet interior and trunnion area clean. Vacuum dust and chips.
• Check for excessive play in tilting and raising mechanism and in saw arbor and adjust as required.
• Check belt for proper tension, and for wear, cracks, frays, etc.

11.3 Lubrication

• Grease the tilting worm gear, raising worm gear, and the trunnion areas with a good grade non-hardening grease.
• Check all adjustments after lubricating, such as handwheel action, blade stops, DRO setting, etc.

11.4 Arbor/Arbor Bearing Removal
The saw arbor is press fitted in the saw raising arm housing. If the arbor needs to be removed for bearing replacement, it should be done by a qualified service technician. Contact Powermatic customer service.

11.5 Additional Servicing
Any additional servicing should be performed by authorized service personnel.

12.0 Optional Accessories

These accessory items (purchased separately) can enhance the functionality of your table saw. Contact your dealer to order or call Powermatic at the phone number on the cover. Additional accessories may be available; see our website.

13.0 Troubleshooting

13.1 Motor and Electrical Problems

13.2 Mechanical and Operational Problems

14.0 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.

Non-proprietary parts, such as fasteners, can be found at local hardware stores, or may be ordered from Powermatic.

Some parts are shown for reference only and may not be available individually.

14.1.1 Table and Cabinet Assembly I – Exploded View

14.1.2 Table and Cabinet Assembly II – Exploded View

14.1.3 Table and Cabinet Assembly – Parts List

14.2.1 Motor and Trunnion Assembly I – Exploded View

14.2.2 Motor and Trunnion Assembly II – Exploded View

14.2.3 Motor and Trunnion Assembly – Parts List

14.3.2 Blade Guard Assembly – Parts List

• for models with serial no. 22022000B2889 and higher.

14.4.1 PM2000B Miter Gauge Assembly – Exploded View

14.4.2 PM2000B Miter Gauge Assembly – Parts List

14.5.1 PM2000BT Miter Gauge Assembly – Exploded View

14.5.2 PM2000BT Miter Gauge Assembly – Parts List

14.6.1 Motor Cover Assembly – Exploded View

14.6.2 Motor Cover Assembly – Parts List

15.0 Electrical Connections

15.1 Wiring diagram – 3HP, 230V, 1PH

15.2 Wiring diagram – 5HP, 230V, 1PH

15.3 Wiring diagram – 5HP, 230V, 3PH

15.4 Wiring diagram – 5HP, 460V, 3PH

16.0 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 Covered
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. Powermatic woodworking machinery is designed to be used with Wood. Use of these machines in the processing of metal, plastics, or other materials outside recommended guidelines may void the warranty. The exceptions are acrylics and other natural items that are made specifically for wood turning.

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

How to Get Technical Support
Please contact Technical Service by calling 1-800-274-6846. Please note that you will be asked to provide proof of initial purchase when 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 State 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

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.

427 New Sanford Road
LaVergne, Tennessee 37086
Phone: 800-274-6848
www.powermatic.com

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References

• powermatic.com

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