Manual - Rockler.com
Contents
1. Socket Set SCrew su Ve a KE 13 c Pee ener DT65 104 e TT 1 Ds TS 1550041 STT oetheltae NO na 5 Gi TS 1503041 Socket Head Cap Screw nanne enen Ven a E 2 Per DT65 107 VE Lett EE 1 Brass TS 1501041 Socket Head Cap Screw nanne MATZ souno 2 S ETEA DT65 109 O ee 2 loss DT65 110 SE 2 DIC intend at 1 dr RAR Let E Fed CASSE si ia te i PION EEN EH DI65 1 Eal E e e E POR sil line TS 1503061 Socket Head Cap Screw nanne enen MGX25 sens 3 las ALE e A O S 1 NSS EE DT45 105 MOCKING FANG saninin US 2 A DT65 114 SEI Bar E 2 Done eee TS 2361061 Lock Washer eee IE See eee 4 IE TS 1503081 Socket Head Cap Screw eee MOXI Oui 4 AAA DT65 117 Indication Template eee e ee eee ee 1 TS assa DT65 118 Cla ee T 2 Sen DIOS KE SE 4 EEN DT45 120 LOCKING FANS arena eentiende MIS X2 rieneke 5 Olen OOS KEE ia D A Soret ne renee erent 4 EE TS 1550061 Flat WAS NCR t de deeman MIS une 8 ZO mens TS 1490031 Hex GAP SEW an ant id MSK20 vce ne es 8 zn DT45 126 Adjustmment el EE 1 PAS RENTREE TS 1504061 Socket Head Cap Screw eee eee VE 1 PIS DEEE DT45 128 Knurled KNOB WEE 1 PT DT45 129 Adjustment oeat ainean aa 1 Po et DT452. 2M roll 28 Hold Down Assembly 8 M mm 29 Parts List Headstock Assembly Index No Part No TS 1550061 TS 1490031 15155003 ian TS 1502041 Ba 28 lisses TS 1540031 1S 1502081 Description Size Qty Spindle Assembly Index 2 thru 10 naan oenen eneen eenen 1 Spindle Bearing HOUSING 0000000 lis 1 Ball Bearing special 6005 TB P63 2 Fe DUN NUL A EE is 1 ECGEntrie ele 1 Socket Set Screw aaan annen eenen VE a LA 2 EE EE ee 1 DISC SOA D O A A 4 EAN DEE 1 Si A 1 Spindle S Ide Seat tri a dede 1 E O II os 1 Flat Was herria id I 1 HEX CAD OCW tisdale MOX20 2 1 clamping PIECE RD et nets 1 BUS DIRE eege Ee dee 1 Socket Head Cap Screw nanne VE 1 PON eegene 1 A eternet A A tenet net 1 SEU MIO Taen 1 ONU as a e ide err ee nar ee Mis 1 Hex Head Boll ui deelden O A 1 INGICATION Brackel ita e ais 1 Flat Wee Eeer tikel MO cuts 6 Socket Head Cap Screw nanne MEXT Oene 2 Adjustment PIECE senteerd da 1 Socket Head Cap Screw nanne MAIO soil 2 OW ce on SR RS Nm meer eres 1 Adjustment SCENE rer 1 LOCKING Handle iras Wl e RE 1 Guide ROG ee e D sn te nda 2 Sockel Sel SChEW EE Ve a KEE 4 CEL eN 1 Linear BUS Raman ie one VOW as 4 D S SN EE TOO amas 4 Retaining RING licita Sr ni n 4 Linear BUS ONG EE EME coat 4 a dit PEXAOX ee 4 o marmottes D tacita 4 AP E A A
3. Figure 9 Figure 10 The clamping cylinders can also be adjusted laterally for better support of workpieces with differing widths Simply loosen the locking handle Figure 11 and slide the clamping cylinder to position Re tighten locking handle Clamping Pressure The pressure exerted by the cylinder clamps against the workpiece can be adjusted at the air regulator shown in Figure 12 The hardness or softness of the wood will determine the amount of clamping pressure desired Enough pressure should be used to prevent the workpiece from slipping during operations Forty 40 psi is suitable for clamping most wood going above that is not recommended To change the clamping pressure pull up on the knob A Figure 12 and rotate it clockwise to increase pressure counterclockwise to decrease pressure The attached needle indicator B Figure 12 shows the air pressure Lock the setting by pushing the knob A Figure 12 back down Locking Handles All locking handles such as those shown in Figure 11 can be rotated out of the way if they interfere with other machine parts Simply lift straight out on the locking handle and rotate it then release making sure it seats properly Template Bar The four sided template bar shown in Figure 14 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
4. Ww Q 7 ks LL wi l 3015 LHOIH apisul O LC ee A 1stcut C NT D B 2nd cut C 3rd cut D 4th cut Figure 28 Bottom groove mm Figure 29 20 Activate the clamping cylinder in front of the RIGHT SIDE workpiece Place the drawer BACK on the horizontal table and against the horizontal fence Slide it flush against the RIGHT SIDE workpiece The bottom groove on the BACK should face downward and opposite the fence See Figure 30 Activate the clamping cylinder above the BACK workpiece The BACK is now butting against the RIGHT SIDE so they are flush with the RIGHT SIDE overlapping the edge of the BACK Both workpieces should be firmly and evenly against the fences Turn on the machine at the switch and slide the headstock to the left edge of the workpiece Move the cutter in sequence left to right allowing the tracer pin to move in and out of the template slots See Figure 31 You can watch the progress of the cutter through the window of the dust hood NOTE Do not rush the cut allow the cutting unit to do the work When finished slide the headstock out of the way and unclamp the workpieces by turning the clamping cylinder levers to off 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 fo
5. 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 First notice how the notches on the template bar are grouped toward the right side of the machine The template bar should always be oriented in this fashion 2 Release one end of the spring on the left side of the headstock Figure 13 and pull the headstock forward until the tracer pin Figure 14 is clear of the template bar 3 Loosen and remove the locking handles on each end of the template bar Figure 15 4 Pull out the template bar flip it to the desired side then reinstall it NOTE The pitch dimension is inscribed on each side of the template bar The side of the template bar that you have chosen should face downward when mounted on the machine 5 Insert and tighten both locking handles Figure 12 Figure 14 6 Push the headstock back and re connect the spring Figure 13 You must now also shift the indication template Figure 16 See Indication Template Indication Template Because the tracer pin is not easily observed while the machine is in operation the indication template A Figure 16 provides the operator with a visual record of the progress of the hidden tracer pin The bracket B Figure 16 slides in and out of the notches on the indication template echoing the tracer pin as it slides in and out of the notches on the template bar be
6. 142 SIE 0 A0 tte SR A a ane mca Ree 2 ie EREN TS 1550041 PAU NV A A ee ea cs MO aten 2 SO TS 1503051 Socket Head Cap Screw nanne enen Ve EE 2 Sl TS 2361081 Beie Ar uti o eid iced Monda ne 1 DA TS 1503031 Socket Head Cap Screw eee eee MOXI lis 2 26 Base Assembly Parts List Hold Down Assembly Index No Part No Description Size Qty EPEE EA DT65 301 Cylinder Assembly Index 2 thru 16 aanne 4 EE DT65 302 CYINder BOY ser a ce dette 4 die DT65 303 Be E 4 E DT65 304 WV CAVING etui 4 dennen DT65 305 PRISON BACKING zet near nee donnee 4 Css DT65 306 PISTON ROO EE 4 lon TS 2361121 LOCK Washer ici sante MTZ tro aan 4 AAA TS 1540081 FAA A A Deeg 4 Dee DT65 309 Reena ALE 4 NO eneen DT65 310 ORRI PR nee eae Me nee eee errant Sree nek ee eer ere ee tener erent 4 A DT65 311 CR eee eae ee nee eee enna Seamer nek eae eer ere eee rte erent 4 eege DT65 312 Ene ere PP eRe SY ORT Renee eee nr nee tere 4 AA DT65 313 IMPI DI C eme 4 14 TS 1550061 PIAUVVASINGR ss ermede ne Vu 4 los TS 1490021 Hex Cap SEW Sragen eR Rodi Rre NS Ornette dende 4 10 DT65 316 Male e eet Te EE 9 IE tenen DOI SI
7. Locking handle Template bar Figure 15 top edge must match pitch of template bar Figure 16 Figure 17 14 1 To replace the fixed chaser remove the three M6 socket head cap screws and flat washers using a 5mm hex wrench as shown in Figure 17 Remove the fixed chaser 2 Install the new fixed chaser and make sure It is level with the main table 3 Re insert and tighten the socket head cap screws against the flat washers After mounting the fixed chaser make sure it will correspond to your chosen pitch on the template bar With the machine power off slide the headstock across the length of the fixed chaser allowing the cutter to move in and out of the spaces If there is any interference between the cutter and one of the fingers on the fixed chaser then try a different fixed chaser or change the pitch of the template bar Horizontal and Vertical Fences 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 buffer pad Move the headstock to the left edge of the workpiece then slide
8. See Figure 22 10 This adjustment will cause the vertical work piece to be slightly offset to the right of the horizontal piece as viewed from front of machine thus ensuring the dovetails will correspond when the two pieces are assembled 11 Tighten the locking handle on the vertical fence _ Groove not in center of mortise Groove visible Figure 20 Groove not visible _ Groove in center of mortise Figure 21 Vertical vi fence offset 1 2 pitch lt gt ee Horizontal Greg fence a t Wi o ag MMT tien i Figure 22 view from rear of machine 16 There are a total of four fences on the DT65 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 Buffer Pads The polyethylene buffer pads shown in Figure 22 have slots through which they are secured to the fences by screws These buffer pads can be re positioned if needed To adjust a buffer pad loosen the two hex cap screws shown in Figure 22 with a 13mm wrench Slide the buffer pad as necessary Re tighten both hex cap screws when finished Cutter Height This adjustment will change the height of the tail on the tenon male cut and how deep the mortise female cut goes into the thicknes
9. 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 d W L Figure 24 Figure 25 18 NOTE One notch of the scale equals 1mm 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 spring on the headstock and re install the dust hood 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 26 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 Replacing cutter AWARNING The cutter is very sharp use caution when working with or around cutter Disconnect machine from power source Failure to comply may cause seriou
10. en tn MS ar ne abre 2 Socket Head Cap Screw nanne Ge CLE 1 SPANG EE RE ER RE EP E 1 Socket Head Cap Screw eee eee Ve EEE 1 Gets ea es nen 1 Motor PUEY AR tete 1 FINE NAS IA 1 Hex Cap Screw eee M6X20O ss 1 Socket Set Screw aaan eaen MB5X1O Raha 1 HIA BOI st edere ie 670725 sans 1 Belt Tension Adjustment Holder 1 FIA MAS EEN MS 3 LOCK Washer criada Vu 2 Socket Head Cap Screw nanne MOS E 2 Socket Head Cap Screw nanne MSX100 a aaa 1 A Meten A ES 1 Sponge COOLING maison NT rs ne sie ne cent 1 Socket Head Cap Screw eee M6x30 4 30 USE leie Everett A E Ve ele EEN Machine Screw nnen eneen eneen d EEN EE EE Socket Head Cap Screw annae eenen M5x12 31 Headstock Assembly 32 Parts List Cabinet Assembly Index No Part No DT45 311 Description Lock Washer Socket Head Cap Screw Socket Set Screw Dust Chute Socket Head Cap Screw 33 X U d X 7 i ae vm m gt gt gt Y A A i U K ER Lu o VI d i Size Qty 4 4 4 M ca 6 MIXO 2 6 MONTO ss sete 6 EE 1 Peer E 2 Mio pisto ne cadc 2 2 1 MOXI ccoo cidcid 4 Electrical Connections 34 39 THE GOL STANDARD POWERMATIC WALTER MEIER Manufacturing Inc 427 New Sanford Road LaVergne Tennessee 37086 Phone 800 274 6848 www powermatic com www waltermeier com
11. 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 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 24 Cutter not cutting Cutter in wrong position Turn cutter towards the or mark page 18 properly Cutter dull or Cutter dull or damaged Sharpen or replace cutter page 19 or replace cutter page 19 Dovetailed parts fit a not adjusted ee set screws and turn cutter toward the too tightly properly mark Retighten set screws page 18 Dovetailed parts fit Cutter not adjusted Loosen set screws and turn cutter toward the too loosely properly mark Retighten set screws page 18 Cutter sometimes Drive belt tension incorrect Adjust drive belt tension page 19 slips and misses revolutions Dovetailed parts fit The mortise depth or tenon Change depth of mortise cut or thickness of tenon side to side but thickness is set incorrectly cut by using the adjustment screw page 17 amp 18 have depth gaps between the mortise and tenon cuts A gap between Bo
12. is resolved simply by taking a two inch plus wide back up board of the same thickness as the 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 33 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 3 Plywood has a tendency to chip out on exposed edges A back up board may be necessary see Figure 33 exposed edge on SIDE _ Back up FRONT BACK board 22 P renr EE and gt pa on vz ZA l Figure 33 view from rear of machine Maintenance AWARNING Before doing maintenance on the machine disconnect it from the electrical supply and the air supply and release any residual air from the lines Failure to comply may cause serious injury If the power cord is worn cut or damaged in any way have it replaced immediately The horizontal and vertical
13. it to the right allowing the tracer pin to slide just a little into the template recesses while observing through the dust hood window the progress of the cutter 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 19 and slide the horizontal fence into position Tighten both locking handles A amp B Figure 19 3 There is also a micro adjustment on the horizontal fence loosen locking handle A Figure 19 but leave locking handle B tight Loosen the screw C Figure 19 with a 6mm hex wrench and rotate the knurled knob D Figure 19 as needed for precise positioning of the horizontal fence 4 When finished tighten screw C Figure 19 and locking handle A Figure 19 Template Bar Fixed Chaser 1 pitch used with 1 1 2 pitch 2 pitch 2 1 2 pitch 2 pitch 3 pitch 2 pitch 2 1 2 pitch used with used with used with Figure 18 Figure 19 NOTE Make sure locking handles A amp B Figure 19 will not interfere with the headstock during operation 5 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
14. of the way of clamping cylinders Failure to comply may cause serious injury Both vertical and horizontal clamping cylinders can be adjusted to match the thickness of your workpieces To change the thickness capacity of the clamping cylinders proceed as follows 1 To increase the clamping capacity loosen the top two hex nuts A and B Figure 10 on the stud at the end of the holder bracket with a 30mm wrench Do the same for the stud at the opposite end of the holder bracket 2 Tighten the lower hex nut C Figure 10 You can do this without a wrench This will raise the holder bracket Do this incrementally on both studs until the desired height is reached When finished tighten top hex nuts A amp B Figure 10 on both studs with the wrench NOTE Make equal adjustment on both studs at each end of the holder bracket to ensure the clamps are parallel to the table To check this measure from the bottom edge of the holder bracket down to the table Measure at each end of the holder bracket the measurements should be equal Figure 10 shows the horizontal clamping assembly the procedure is identical for the vertical clamping assembly 3 To decrease the clamping capacity back off the lower hex nut C Figure 10 and tighten the top hex nut B Figure 10 This will lower the holder bracket 4 When finished tighten the lower hex nut C against the holder bracket and bring hex nut A down against hex nut B
15. table Never use your hand to hold the work piece Turn off the machine before cleaning Use a brush or compressed air to remove chips or debris do not use your hands Do not stand on the machine Serious injury could occur if the machine tips over Never leave the machine running unattended Turn off the electrical power and the air supply and do not leave the machine until cutter comes to a complete stop 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 ACAUTION This means that if precautions are not heeded it may result in minor injury and or possible machine damage AWARNING This means that if precautions are not heeded it may result in serious injury or possibly even death SAVE THESE INSTRUCTIONS Introduction This manual is provided by Walter Meier Manufacturing Inc covering the safe operation and maintenance procedures for a Model DT65 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 Walter Meier Walter Meier can also be reached a
16. 1 13 12 14 and 17 19mm Combination Wrench 30mm Set of Hex Wrenches 1 5 to 6mm Dust Chute Sample Dovetailed Boards Owner s Manual Warranty Card ND sech Indication Template Dust Chute Hex wrenches Read and understand the entire contents of this manual before attempting set up or operation Failure to comply may cause serious injury Installation amp Assembly Tools required for assembly forklift or hoist with straps slings 14mm wrench provided NOTE A socket set with ratchet wrench may speed assembly 4mm hex wrench provided knife or wire cutter flat head screwdriver Remove the four screws and flat washers holding the machine to the pallet with a 14mm wrench as shown in Figure 1 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 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 A group of cords holds the headstock secure to the machine frame to prevent it from moving during shipping These cords should now be cut and removed see Figure 3 Exposed metal areas of the dovetailer such as the ta
17. P ss FOILS eet RS D la eens he 1 On DT65 318 Special WaS NOR nd Cod eue 4 55 TR BALS Ee orea Beie lee el MOSS Rs land 4 20 sachs dias DITOS 320 antenne de eE ET 4 A eee TS 2310201 HE NU edn M20 ane sr le a 16 Desk TS 1550111 Flat NAS tene M20 Ann per ee 8 Se DT65 328 aiie Holder aT EE 1 PA RE DT65 324 FIXING Bracke ica E cts 4 o iles TS 1502031 Socket Head Cap Screw Ver dE 8 DO enen DT65 326 CONO VaVe a a a E 4 LN DIOS EE Si al 4 Se TS 1522011 Socket Set crew MISO ran ede 4 EN TS 1502101 Socket Head Cap Screw MEXA irna aback 8 Dre DT65 330 Male COME PIO OO nin 8 CN EE DT65 331 0 LES e ee ee a sd Aisne PI VO ais 3 AA DT65 332 Ale Dieren TEE 1 On DT65 333 Air Control Valve nnn AA T 1 CT RE DT65 334 EE SAR Ain ne JO Ads ce 1 Oden DT65 335 Male Coupling anne PIE RE 1 A DT65 336 Male Elbow Connector PIS AA 1 ads TS 1550041 Fab NAS a en aia Y annee 2 SO nem TS 1503041 Socket Head Cap Screw MO Oneness tenen 2 GE JPUOD406Z Air Hose Black not shown 6mm x 4mm 5M roll on eg JPU0406W Alr Hose Clear not shown 6mm x 4mm
18. S MDN rendent E ee ct once eran 29 Paris List Headstock ASSEIMDIY ssl nee 30 Site EE e EE 32 Parts Lis elt E ue EE 33 Sege e ee Leet ele 34 Warnings 10 11 12 13 14 15 16 17 18 19 20 Read and understand the entire owners manual before attempting assembly or operation 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 Replace the warning labels if they become obscured or removed 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 Do not use this dovetailer for other than its intended use If used for other purposes Walter Meier Manufacturing Inc disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use Always wear approved safety glasses face shields while using this dovetailer Everyday eyeglasses only have impact resistant lenses they are not safety glasses 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 Wear ear protectors plugs or muffs during extended periods o
19. This pdf document is bookmarked PO WERMATIC Operating Instructions and Parts Manual Single End Dovetailer Model DT65 a ut A kel l L N F H d WALTER MEIER Manufacturing Inc 427 New Sanford Road LaVergne Tennessee 37086 Part No M 1791305 Ph 800 274 6848 Revision A3 11 2011 www powermatic com Copyright 2011 Walter Meier Manufacturing Inc Warranty and Service Walter Meier Manufacturing 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 Walter Meier Authorized Service Centers can authorize warranty repair assist you in obtaining parts or perform routine maintenance and major repair on your POWERMATIC tools For the name of an Authorized Service Center in your area call 1 800 274 6848 MORE INFORMATION Walter Meier is consistently adding new products to the line For complete up to date product information check with your local Walter Meier distributor or visit powermatic com WARRANTY POWERMATIC products carry a limited warranty which varies in duration based upon the product Industrial Products Non Industrial Products Horizontal Panel Saws Belt Sanders Tablesaws Disc Sanders Cut Off Saws Shapers Vertical Panel Saws Edge Sanders Rip Saws Power Feeders Bandsaws Drum Sanders Bandsaws Mortisers Jointers shapers Jointers Dovet
20. ailers Planers Drill Press s WARRANTY Planers ES Planer Molder Mortisers Oscillating Edge Sanders Dust Collection Dovetailers 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 pro
21. and millimeters is mounted to both horizontal and vertical tables if you need more precise measurements for the location of the dovetail cuts 6 Again make sure the locking handles on the horizontal fence A amp B Figure 19 are tightened The position of the horizontal fence will now be used as the basis for locating the vertical fence 7 Loosen the locking handle on the vertical fence 8 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 tail 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 Figures 20 and 21 Important To make proper dovetail cuts the two fences must always be offset from each other by half the pitch of the template bar T hat is offset 1 2 when using the one inch template 3 4 when using the 1 1 2 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 horizontal and vertical tables are marked in 1 16 increments and millimeters 9 Line up the vertical fence with the horizontal fence then offset the vertical fence by exactly half the pitch of the template bar
22. ards not square when Make sure the initial cuts on the board ripping mortise and tenon clamped and or crosscutting have been done squarely and cuts increases that the board is flush against the stop before along the clamping dovetailed corner Side piece edge is Fences not set correctly Offset the vertical fence from the horizontal fence not aligned with by half the pitch of the cut page 16 front back piece edge Workpiece slips Clamping cylinder not Position clamping cylinder to take advantage of its during the cut positioned over center of full surface area page 13 workpiece Clamping cylinder too high Lower clamping cylinder in relation to thickness of to properly contact workpiece page 12 workpiece Clamping pressure too low Adjust pressure at air regulator page 13 Surface area of workpiece Use larger workpiece too small to achieve adequate coverage from clamping cylinder 29 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 Parts List Base Assembly Index No Part No Description Size Qty Mas DT 65 101 WE WOE DIG nanne ede ee de deken eel 1 Are BAS 102 SEET Te e EE 1 ee TS 1523041
23. ble template bar cylinder clamps 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 Attaching Dust Hose 1 Slide the upper end of the hose over the chute on the dust hood Figure 4 Tighten the hose clamp with the attached screw using a flat head screwdriver Remove screws sf Figure 1 Use eyebolts to lift machine SCH teg d Figure 4 Installing Dust Chute Remove the four socket head cap screws at the rear of the cabinet using a 4mm hex wrench Place the 4 diameter dust chute Figure 5 over the hole and re insert and tighten the four socket head cap screws Dust Collection The use of a dust collection system is strongly 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 cubic feet per minute CFM Connect the intake hose of your dust collector to the 4 diameter dust chute at the back of the cabinet Figure 5 NOTE A wide variety of dust collection systems are available from Walter Meier Manufacturing Inc Call customer service at 1 800 274 6848 or visit www waltermeier com for more information Grounding Instructions WARNING Electrical connections m
24. duct 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 WALTER MEIER MANUFACTURING INC 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 WALTER MEIER MANUFACTURING INC 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 Walter Meier sells through distributors only The specifications in Walter Meier catalogs are given as general information and are not binding Members of Walter Meier reserve the right to effect at any time without prior notice those altera
25. er reserves the right to change specifications at any time and without prior notice without incurring obligations Features of the DT65 Dovetailer Pneumatic clamping system NN Za Magnetic starter Air and Oil Regulator Indication template Dust hood Headstock Terminology Below are the terms used in this manual to identify types of cuts and measurements MORTISE CUTS TENON CUTS made on Front and Back drawer pieces also called pins or sockets HEIGHT THICKNESS TAIL TENON CUTS made on Side drawer pieces also called tails MORTISE CUTS n n Half Blind Dovetails PIN i show on one side of joint only SOCKET 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 POWERMATIS ATEN aU AWARNING Sample Boards Open ended wrenches Contents of the Shipping Container 1 Dovetail Machine 2 Fixed Chasers 2 1 2 and 3 pitches 1 Indication Template Set of Open Ended Wrenches 8 10 1
26. f operation 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 Do not operate this machine while tired or under the influence of drugs alcohol or any medication Make certain the switch is in the OFF position before connecting the machine to the power supply Make certain the machine is properly grounded Make all machine adjustments or maintenance with the machine unplugged from the power source 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 Keep safety guards in place at all times when the machine is in use lf removed for maintenance purposes use extreme caution and replace the guards immediately 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
27. llows Insert the LEFT SIDE piece and clamp it in vertical position and against the fence NOTE The bottom groove on the LEFT SIDE will face outward and toward the fence Turn the BACK 180 degrees and clamp it in the horizontal position against the fence NOTE The bottom groove on the BACK workpiece will still be face down but toward the fence Make the cut then continue the dovetailing procedure with the FRONT piece making cuts C and D Figure 28 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 32 ly e Figure 31 Full tenon Half tenon Figure 32 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 33 This may result in an unsatisfactory cut at the edge of the SIDE This problem
28. low The pitch of the indication template must match the pitch of the template bar Therefore when turning the template bar for a new pitch you must also change the indication template 1 First notice how the notches on the indication template are grouped toward the right side of the machine The indication template should always be oriented in this fashion 2 Remove the socket head cap screw C Figure 16 at each end of the indication template with a 5mm hex wrench 3 The indication template that came installed on your machine contains the 1 and 2 pitch The other indication template has the 1 1 2 and 2 1 2 pitch Either flip the indication template or replace it with the other one as needed to match the pitch of the template bar 4 Re insert and tighten the socket head cap screws C Figure 16 Fixed Chaser The fixed chaser Figure 17 provides a support on which the workpieces rest The spacing between the fingers of the fixed chaser allows clearance for the cutter The DT65 Dovetailer comes standard with three fixed chasers at 2 2 1 2 and 3 pitches Pitch IS the distance between the centers of the fingers see Figure 18 NOTE If you wish to use the 1 1 2 or 2 1 2 pitch on the template bar you must replace the fixed chaser on the machine with one of the others provided Figure 18 explains how the avallable fixed chasers correspond to the pitch of the template bar
29. lt 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 a qualified electric motor repair shop and
30. n in Figure 6 r hard wire the machine directly to a control panel If hard wired to a panel make sure a disconnect is available for the operator The dovetailer must comply with all local and national codes after being wired 1 If it is to be hard wired make sure the fuses have been removed or the breakers have been tripped in the circuit to which the dovetailer will be connected Place a warning placard on the fuse holder or circuit breaker to prevent it being turned on while the machine is being wired 2 Refer to Electrical Connections on page 36 for connecting the motor leads 3 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 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 7 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 Air Connection Connect the air supply hose to the coupling on the air unit Figure 8 The air is turned ON by rotating the valve lever 90 degrees counterclockwise until it is parallel with the hose and turned OFF by rotating the valve lever 90 degrees cl
31. nd BACK pieces are placed horizontally on top the machine s table SIDE pieces are placed vertically 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 28 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 IMPORTANT Make sure the workpiece has been cut square before making dovetails An out of square workpiece will result in poor dovetail joints 1 Check that all the following have been set correctly See Adjustments above e proper pitch of Template Bar e proper Indication Template e Vertical and Horizontal Fence positions offset from each other by half the pitch of the template bar e height of Clamping Cylinders for workpiece thickness e proper Fixed Chaser with no cutter interference e height of Cutter 2 Move the headstock all the way to the right and out of the way 3 Connect the air supply and the electrical power to the machine AWARNING Keep fingers clear of clamping cylinders 4 Place the drawer RIGHT SIDE against the vertical table and on top the fixed chaser The RIGHT SIDE should be flush against the fence with the bottom groove facing outward and opposite the fence Figure 29 Inside B BACK A ss CO gt a 3 ui Ze
32. ockwise AWARNING Even after the air has been turned off to the machine there may be residual air inside the lines and the clamping cylinders can still provide a hazard to fingers After shutting off the air always bleed residual air from the system by pushing the relief valve pin at the bottom of the air cup shown in Figure 8 Keep the relief valve open until all air in the system has been removed 11 150 230 VOLTS 3 Grounding Prong 240 volt Grounded Outlet Figure 6 Recommended Gauges AWG of Extension Cords Extension Cord Length 50 15 100 150 200 feet feet feet feet 12 to 15 15 to 20 21 to 30 based on limiting the line voltage drop to 5V at 150 of the rated amperes NR Not Recommended Figure 7 S Valve lever a 7 K K F De L SCH e G CH en in X 4 Q 3 d mem a y 4 L i Relief valve Figure 8 Adjustments AWARNING Disconnect machine from power source shut off air supply and bleed residual air from system before making adjustments Failure to comply may cause serious injury Clamping Cylinders The workpieces are clamped to the table by pneumatically operated aluminum cylinders A Figure 9 Each cylinder has its own air on off lever Simply turn the lever B Figure 9 to on position to activate the cylinder the cylinder will respond immediately by clamping the workpiece against the table AWARNING Always keep fingers out
33. r pin A Figure 24 1 Disconnect machine from power source 2 Loosen the locking handle B Figure 24 3 Insert a 5 5mm hex wrench into the end of the adjustment screw C Figure 24 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 B Figure 24 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 headstock Release one end of the spring on the headstock see Figure 13 and pull the headstock away from the machine until the cutter becomes more accessible 3 You will notice the cutter shown in Figure 25 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 AWARNING The cutter is very sharp Use caution when working with or around it 4 Loosen both set screws on the spindle Figure 25 by turning them counter clockwise with a 4mm hex wrench 5 scale is located just above the cutter with a plus and minus sign Moving the cutting edge of the
34. s injury 1 To replace the cutter loosen both set screws Figure 25 and carefully pull up on the cutter until it is free from the spindle 2 Slide the new cutter down into the spindle and align the cutting edge with your previous setting on the spindle scale 3 Tighten both set screws Oil Output Oil is distributed through the air lines for constant lubrication of the clamping system The oil output can be adjusted by rotating the oil regulator knob A Figure 27 Turn the knob counterclockwise to increase oil output clockwise to decrease oil output The level of oil should be checked occasionally and re filled as necessary A minimum level is marked on the window of the oil cup C Figure 27 Refill by removing the screw B Figure 27 and pouring oil into the fill hole When finished re install screw B Figure 27 Use standard air tool oil This is available from your local distributor or can be found in most hardware and tool stores 19 Cap screw for belt tensioning Figure 26 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 a
35. s of the workpiece 1 Disconnect machine from power source 2 Loosen the spindle lock screw Figure 23 by turning it counterclockwise with a 6mm hex wrench 3 Turn the spindle height adjustment screw Figure 23 with a 5 5mm hex wrench either clockwise to raise the cutter increase the cutter depth or counterclockwise to lower the cutter decrease 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 adjustment bolt shown in Figure 23 limits how far forward the headstock 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 adjustment bolt Figure 23 by turning the hex nut counterclockwise with a 17mm wrench Mortise depth adjustment Auer SCH Spindle height _ adjustment mmer Ce Figure 23 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 Thickness of Tenon Cut To adjust the thickness of the tenon male cuts you will change the depth of the trace
36. t our web site www waltermeier com Description The Model DT65 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 has a magnetic starter and is built to last with cast iron and steel construction The pneumatic clamping system IS quick and easy to use Specifications Model Number a Se ee lele DT65 SLOT EE 1791305 Minimum Work pi ce size MJ at ae Ud 7 7 8 x 2 3 8 Maximum WORK EIER ee io lis 59 x 16 1 2 Minimum dovetail MEE N ss ner e do o ela o ea ced 3 16 Maximum dovetall neiO ts EE 3 4 Minimum front aler KN SS Ne EE 9 32 Maximum front TAIGKINCSS DEE 2 3 8 ll Ee TR gle 251 EE 3 8 Maximum side le nt DEE 1 3 16 Number eg elle e EE 1 eil e speed RPM EE 18 500 Center to center dovetail spacing in ensen enrens nnee neren 1 1 1 2 2 and 2 1 2 Table height gel TOO D EE EE 45 Overallsdimensions EE WX Fy IS EE 37 x 44 x 63 MOTO EE la TEFC 1HP 1Ph 230V 60Hz DUStcolection ports diameter IA asar A AA era es el front 2 1 2 rear 4 Dust collection minimum GEM Ke quired BEE 500 Approximate Weight Shipbing Net 1DS EE 510 420 The above specifications were current at the time this manual was published but because of our policy of continuous improvement Walter Mei
37. tables and other exposed metal parts should be kept clean and free of rust A coat of paste wax will help protect the tables from tarnishing After each day s use brush or blow out dust and debris from the cutter table motor etc Keep the clamping cylinders clean to prevent debris adhering to them which can scar workpieces 23 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 VG 120 grease through the grease nipple on the spindle 10 in the exploded view on page 32 Occasionally check the oil level in the oll regulator cup see Figure 27 Add more oil as needed Use standard air tool oil Troubleshooting the DT65 Dovetailer Machine will not start restart or repeatedly trips circuit breakers or blows fuses 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 On off switch failure Machine not plugged in Verify machine is connected to power Bae ak Replace fuse or reset circuit breaker breaker tripped p Cord damaged Replace cord If the Dovetailer overloads on the circuit breaker bui
38. tions to parts fittings and accessory equipment which they may deem necessary for any reason whatsoever 2 Table of Contents ET ge ANd Kee e 2 WANO ME 4 o PS en nee En eed eer renee haere ery 6 A O O E AA 6 JA A A 6 Features of the DT65 Dovetailer iii 7 A nt nes O CR es dde ein nt 7 IGE en ee a ed E E ata D E 8 Contents of the Shipping Container 8 TAS FANON Bc AS SCD EE 9 PAC IMC SU IO Se ui dere 9 Je Ma e DUST CA a e a dd O 10 Dust gelen WEE 10 Eroundina a ye eiee e dde to samencter 10 230 VO e tee a o os 11 XI NSION COO terende a dns 11 Golan eden TTT 11 PAA SUNS TMS eer a et le nue 12 Glampina MONA lo tasa Dee uate al Een 12 clamping Press UG EE 13 k ckiNg Gel 13 Tompo EE 13 Je allez weie Templates Ea E E TE E A ate noceusaaens 14 SK beier 14 Fi rizontal ANA We e e Seoca siina a a sltunae aliinisanausnculcuhatnsus miata ueveuiareuSaetas 15 UPS can et de ni de eee 17 Cuter le a RU ise AeA aiuto RAA US AL RE cube A te lat site 17 Moriss DEP aaa A ad 17 TMICKMESS or TENNIS da aida acaba 18 Tighthess Of Morse Reial GE 18 Drive oe Tenson PR laa a dai 19 al Su ni huts Me wise hats nr a anion alive tania A 19 EE 19 CD SiO THT 20 me MeN Cena Ship EE 22 VO VC AS IPN OCR rm nee den uta Moats ele ie a aan 22 MANG aca rc ae ca ade lora 23 A ane den de cu en Re A de on E 23 Replacement l SR ee enten Sean et ta ne nt 26 PAS WISE BASS ASSE MDN EE 26 BASS MON EE 27 Parts LISE G elle DOWMASSCMIDIY usais 28 Fold DOWN AS
39. ust 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 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 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 Dovetailer 10 Socket head cap screw Dust chute Figure 5 230 Volt Operation As received from the factory the DT65 Dovetailer is designed to run on 230 volt power only You may either connect a UL CSA listed 230V plug similiar to the one show
40. 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 Provide for adequate space surrounding work area and non glare overhead lighting Keep the floor around the machine clean and free of scrap material oil and grease Keep visitors a safe distance from the work area Keep children away Make your workshop child proof with padlocks master switches or by removing starter keys Warnings 21 22 23 24 20 26 27 Give your work undivided attention Looking around carrying on a conversation and horse play are careless acts that can result in serious injury 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 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 Use recommended accessories improper accessories may be hazardous Maintain tools with care Keep cutters sharp and clean for the best and safest performance Follow instructions for lubricating and changing accessories Make sure the work piece is securely clamped to the
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