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- Page 1 Operating Instructions and Parts Manual Model PM2500 Series Shaper Model: 2700 Powermatic 427 New Sanford Road LaVergne, TN 37086 Part No. M-708323-RU Ph.: 800-274-6848 Revision A 03/2020 www.powermatic.com Copyright © 2017 Powermatic...
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Page 2: Table Of Contents
Wiring Diagrams ............................46 Wiring Diagrams ............................47 The specifications in this manual are given as general information and are not binding. Powermatic reserves the right to effect, at any time and without prior notice, changes or alterations to parts, fittings,... -
Page 3: Warnings
5. Do not use this shaper 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. - Page 4 24. Check the cutter for cracks or missing teeth. Do not use a cracked cutter or one with missing teeth or improper set. Make sure the cutter is securely locked on the arbor. 25. Keep hands clear of the cutter area. Do not reach past the cutter to clear parts or scrap with the shaper running.
- Page 5 Short stock – Never shape stock less than 12 inches (304.8mm) in length without special fixtures. Where practical, shape longer stock and cut to size. 12 inches (304.8mm) rule – When shaping, never allow your hands to come closer than 12 inches (304.8mm) to the cutters.
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Page 6: Introduction
Introduction This manual is provided by Powermatic covering the safe operation and maintenance procedures for a Powermatic Model PM2500 Series Shaper. 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 consistent, long-term operation if used in accordance with instructions set forth in this manual. -
Page 7: Shipping Contents
Shipping Contents Compare the contents of your container with the parts listings and illustrations on this page 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. -
Page 8: Assembly
Assembly Cleaning Referring to Figure 1: 1. Remove two hex cap screws and flat wash- ers (A) that secure the fence assembly (B) to the table and discard. 2. Set the fence assembly (B) aside to permit cleaning of the table. 3. -
Page 9: Cutter Guard
Electrical Connections Cutter Guard Referring to Figure 2: Electrical connections must Mount the cutter guard (A) to the safety guard made qualified electrician holder (H). Insert two lock knobs (B) through the compliance with all relevant codes. This cutter guard slots and into the threaded mounting machine must be properly grounded to help holes (J) on the safety guard holder (H). -
Page 10: Adjustments
Adjustments When changing tools, making adjustments, or doing clean-up and maint- enance, always turn the machine off and unplug the machine from its power source. Fence Assembly Movement Referring to Figure 4: The adjustment controls of the fence assembly are as follows: A –... - Page 11 Coplanar Alignment Follow steps 1–5 to determine if alignment is necessary. Steps 6–9 will guide you through the alignment if required. Verifying that fences are coplanar 1. Remove the guard and spindle attachment. Figure 6 2. Unlock knobs D and adjust the fence assembly (A) so it is positioned approximately at midpoint;...
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Page 12: Ram Dial Calibration
Fence perpendicular to table The outfeed fence must also be perpendicular to the table. This can be checked as follows: 8. Place a square against the casting (L, Fig. 10) and table. 9. If adjustment is required, adjust setscrews N (Fig. -
Page 13: Spindle Gib Adjustment
Spindle Gib Adjustment Referring to Figure 12: The spindle housing gib on your machine is factory adjusted and initially should not require readjust-ment. After a period of use the gib may wear and become loose, introducing play and potentially causing the spindle (B) to vibrate. This requires adjustment. -
Page 14: Spindle Assembly Installation
Spindle Assembly Installation Referring to Figure 14: The spindle assembly (B) is mounted to the arbor (H) and secured with a draw bar (O) and spindle nut (D). Use the following procedure to install the spindle assembly. Reverse the order to remove the spindle. -
Page 15: Shaper Cutter Installation
2. Loosen the spindle nut (D) then, using the spindle wrench (Inset A) continue to turn until the spindle breaks free of the arbor. Shaper Cutter Installation Note: Spindle installation is described in the previous section. When changing tools, making adjustments, or doing clean-up and maint- enance, always turn the machine off and unplug the machine from its power source. -
Page 16: Changing Spindle Speed
Changing Spindle Speed The PM2500 Shaper is equipped with pulleys that allow you to change the spindle speed. The belt placed on the upper pulleys as shown in position B (Fig. 16) provides a 10,000 RPM spindle speed. Spindle speed for all belt positions are listed in Table 2 below. -
Page 17: Precision Miter Gauge
Precision Miter Gauge Setting the miter gauge angle Referring to Figure 17: The precision miter gauge has a rack and pinion adjustment for setting the angle. To operate: 1. Slide the miter gauge into one of the slots on the table top. 2. -
Page 18: Operating Controls
Operating Controls Safety Key The start/stop switch on the PM2500 Shaper Start/Stop comes equipped with a magnetic safety key. Power Indicator Light – The start switch has a When in place on the switch as shown in Figure 18 the magnetic safety key trips a relay power indicator lamp which is on whenever which will allow the machine to start and stop there is power connected to the shaper, not... -
Page 19: Operations
Operations Overview Deep cuts require excessive Before applying power to the machine, Check the horsepower and pushing force to control the motor and switch wiring diagrams for proper cut. voltage connections. Check that all mounting Deep cuts can also cause the wood to splinter or screws and bolts are tight. - Page 20 Using the Fence Using the fence is the safest and most satisfactory method of shaping, and should always be used when the work permits. Almost all straight work can be used with the fence. For average work, where a portion of the original edge of the work is not to be touched by the cutter, both the front and rear fences are set in a straight line as shown in Figure 22.
- Page 21 "Z" Dimension Before making a template (or using the edge of the workpiece) for shaper cutting, the "Z" dimension must be established in order to determine the shape and size of the finished stock. The "Z" dimension is the difference between the innermost part of the cutter edge and the outside diameter of the ball bearing follower (collar).
- Page 22 Edge Shaping When edge shaping, never attempt to hand guide any stock less than 12 inches (304.8mm) long, or narrower than 3 inches (76.2mm) without the use of a special guide as shown in Figure 27. When edge shaping, the work- piece must be at least 12 inches (304.8mm) long unless a special guide is used.
- Page 23 Straight Line Bevel Shaping Figure 30 To shape a beveled straight edge, use a bevel- Contour Edge Shaping With Collar Bearing edge shaping jig in combination with the regular To shape contoured edges, the operator must first fence as shown in Figure 31. remove the fence assembly.
- Page 24 If the workpiece is to be shaped all around the perimeter, hold it firmly and push the work straight into the cutter until the depth of cut is established by the collar as shown in Figure 36. Continue to feed the work so that the point of contact on the edge is always 90 degrees to the collar (or directly in line with the cutter edge) and held firmly against When the workpiece is not contoured all around,...
- Page 25 3. Using the collar between the two cutters has the advantages and disadvantages of the first two procedures, and is frequently used where both edges of the work are to be molded, Figure 41. Note: It is advisable to place the cutter as low as possible on the spindle to reduce spindle deflection Figure 41 and ensure the best possible finish.
- Page 26 Arcs and Circles Large circular and arc-shaped stock can be shaped as described in Contour Edge Shaping on page 24. However, smaller sized stock requires the use of special shaping jigs similar to those shown in Figure 44. With the entire fence assembly removed, carefully position the jig for desired depth-of-cut and securely clamp to the table.
- Page 27 Templates The template must be thick enough to provide a solid bearing edge against a collar. When constructing a template similar to the one shown in Figure 46, keep in mind that it serves only as a guide for the cutter. Figure 46 If the workpiece requires all-around shaping, the template can be constructed from several sections...
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Page 28: Special Cuts
Special Cuts The illustrations in this section show the profile, or section, views made by the cutter(s). The most efficient cutters are carbide tipped to ensure clean and long-term cutting. Small cutters may be solid carbide, and some use inserts. Since there are such a wide variety of choices, the operator is limited only by his experience and imagination. - Page 29 Butt Joints All butt-type joints require both work-pieces to be perfectly square and straight-edged. Glue Butt Joint To perform a glue butt joint, both fences are kept inline and adjusted for a depth of cut (Figure 56). The cuts on both work-pieces are part-edge cuts which do not reduce the stock width during the cutting procedure.
- Page 30 Tenoning The tenoning fixture illustrated in Figure 60 shows a miter gauge equipped with a hold-down for shaping the ends of narrow work-pieces. The miter gauge can also be adapted to cut square and centered tenons at the ends of legs for tables, chairs, etc.
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Page 31: Troubleshooting
Troubleshooting Trouble Possible Cause Remedy 1. Cord unplugged from the power 1. Plug in power cord. Shaper will not start. source. 2. Fuse blown or circuited breaker 2. Replace fuse or reset circuit tripped. breaker. 3. Cord damaged. 3. Replace cord. 4. - Page 32 Troubleshooting Trouble Possible Cause Remedy 1. Characteristic of this type of cut. 1. Make cross grain cuts first, then Edge splits off on finish cut with the grain. Use scrap cross grain cut. block to support end of cut. 1. Variation of pressure holding work 1.
- Page 33 Table – Parts List Index No. Part No. Description Size 1 ....TS-1521011 ..... Socket Set Screw ..........M4x4 ......3 2 ....JWS35X-102 .... Insert Ring (Small) ................... 1 3 ....TS-2285121 ..... Flat Head Machine Screw ........M5x12 ......3 4 ....
- Page 34 Table – Assembly Drawing...
- Page 35 Fence – Parts List Index No. Part No. Description Size 1 ....PM2500-201 .... Locking Handle ..................4 2 ....PM2700-237 .... Feather Board ..................2 3 ....PM2700-234 .... Bracket ..................... 2 4 ....TS-1550061 ..... Flat Washer ............M8 ....... 4 5 ....
- Page 36 Fence – Assembly Drawing...
- Page 37 Frame and Motor – Parts List Index No. Part No. Description Size 1 ....PM2700-305A ..Spindle Nut............M40x2.5p ....1 2 ....PM2700-306 .... Retaining Ring ............. STW-40 ....... 1 3 ....TS-2246202 ..... Button Head Socket Screw ........M6x20 ......4 4 ....
- Page 38 Frame and Motor – Parts List Index No. Part No. Description Size 55 ..... TS-1551021 ..... Lock Washer ............M4 ....... 3 56 ..... JWS35X-356 .... Cover ......................1 57 ..... PM2700-320E ..Motor Pulley ............Ø 146mm ~ Ø 178mm .. 1 58 .....
- Page 39 Frame and Motor – Assembly Drawing...
- Page 40 ....JWS35X-410AE ..Forward/Reverse Switch (AC-3/25A 250V) ..5HP/3Ph ..... 1 11 ..... PM2700-440 .... Wide Stripe....................1 12 ..... 3520B-140 ....Powermatic Nameplate ................1 13 ..... PM2700-416 .... Bumper ..................... 2 14 ..... PM2500-414 .... Cabinet ..................... 1 15 .....
- Page 41 Cabinet and Base – Assembly Drawing...
- Page 42 Elevator – Parts and Assembly Index No. Part No. Description Size 1 ....JWS35X-501 .... Lead Screw ....................1 2 ....JWS35X-502 .... Key ............... 5x5x12 ......2 3 ....PM2700-342 .... Retaining Ring ............. STW-15 ....... 1 4 ....PM2700-503 .... Thrust Bearing ............. 51202 ......2 5 ....
- Page 43 Spindle Assembly – Parts List- (Standard Equipment) Index No. Part No. Description Size 1 ....TS-1505041 ..... Socket Head Cap Screw ........M10-1.5P x 30 .... 1 2 ....JWS2700-702 ..Pin ................ ø4 x 25 ......2 3 ....JWS2700-703 ..Special Washer ..................1 4 ....
- Page 44 PM2500 Spindle Assembly for 35mm/40mm/50mm (Optional Equipment)
- Page 45 PM2500 Spindle Assembly for 35mm/40mm/50mm (Optional Equipment) Index No. Part No. Description Size 1 ....TS-1505041 ..... Socket Head Cap Screw ........M10-1.5P x 30 .... 1 2 ....JWS2700-702 ..Pin ................ ø4 x 25 ......2 10 ..... PM2700-305A ..Spindle Nut............M40x2.5p ....1 11 .....
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Page 46: Wiring Diagrams
Wiring Diagrams 3HP, 230V, 1Phase... -
Page 47: Wiring Diagrams
Wiring Diagrams 5HP, 400V, 3Phase... - Page 48 427 New Sanford Road LaVergne, TN 37086 Phone: 800-274-6848 www.powermatic.com...
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