This .pdf document is bookmarked Operating Instructions and Parts Manual Model 2700 Shaper Model: 2700 WALTER MEIER (Manufacturing) Inc. 427 New Sanford Road LaVergne, TN 37086 Ph.: 800-274-6848 www.powermatic.com Part No. M-1280100C Revision E3 04/2010 Copyright © 2010 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.
Table of Contents Warranty and Service..........................................................................................................................2 Table of Contents ...............................................................................................................................3 Warnings............................................................................................................................................4 Warning .............................................
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 shaper is designed and intended for use by properly trained and experienced personnel only.
21. Keep visitors a safe distance from the work area. Keep children away. 22. Make your workshop child proof with padlocks, master switches or by removing safety keys. 23. Give your work undivided attention. Looking around, carrying on a conversation and “horse-play” are careless acts that can result in serious injury. 24. 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.
Warning Short stock – Never shape stock less than 12 inches in length without special fixtures. Where practical, shape longer stock and cut to size. 12 inch rule – When shaping, never allow your hands to come closer than 12 inches to the cutters. Hand safety – Never pass the hands directly over, or in front of, the cutters (Figure A). As one hand approaches the 12 inch radius point, remove it (or the push stick) in an arc motion and reposition hands 12 inches beyond the cutters.
Introduction This manual is provided by Walter Meier (Manufacturing) Inc., covering the safe operation and maintenance procedures for a Powermatic Model 2700 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 years of trouble free operation if used in accordance with instructions set forth in this manual.
Unpacking Remove box and wood crating completely from around shaper. Check for shipping damage. Report any damage immediately to your distributor and shipping agent. Do not discard any shipping material until the Shaper is assembled and running properly. Compare the contents of your container with the parts lists on this page to make sure all parts are intact. Missing parts, if any, should be reported to your distributor.
Cleaning Exposed metal surfaces, such as the table top and extension wings, have been given a protective coating at the factory. This should be removed with a soft cloth moistened with kerosene. Do not use acetone, gasoline, or lacquer thinner for this purpose. Do not use solvents on plastic parts, and do not use an abrasive pad because it may scratch the surfaces. Assembly Mounting the Fence Referring to Figure 2: 1.
This machine must be grounded. Grounding provides a path of least resistance to help divert current away from the operator in case of electrical malfunction. Make sure the voltage of your power supply matches the specifications on the motor plate of the machine. The PM2700 Shaper should be connected to a dedicated circuit, and protected by a circuit breaker or time delay fuse, with minimum amp ratings as shown in Table 1. Local codes take precedence over recommendations.
Adjustments Handwheel Adjustments Referring to Figure 5: When changing tools, making adjustments, or doing clean-up and maintenance, always turn the machine off and unplug the machine from its power source.
Coplanar Alignment Follow steps 1–5 to determine if alignment is necessary. Steps 6–9 will guide you through the alignment if required. Figure 6 Verifying that fences are coplanar 1. Remove the guard and spindle attachment. 2. Adjust the fence assembly (A) so it is positioned approximately at midpoint and lock (B). 3. Place a straightedge (F) on the table pressed against the infeed (E1) and outfeed fences (E2). Figure 7 4. Unlock the fence lock knobs (D1, D2). 5.
Ram Dial Calibration The guard and spindle should be removed. Referring to Figure 12: 1. Loosen the infeed fence lock knob (E), then turn the infeed ram dial (D) counterclockwise to bring the infeed fence (F) back all the way until the limiter setscrew (P) touches the head casting (M). Then retighten the lock knob (E). 2. If necessary, loosen two setscrews on the infeed ram dial (D) with a 2mm hex wrench and align the zero on the dial with the indicator mark. Then tighten the setscrews. 3.
Spindle Gib Adjustment Referring to Figure 13: The spindle housing gib on your machine is factory adjusted and initially should not require readjustment. After a period of use the gib may wear and become loose, introducing play and potentially causing the spindle (A) to vibrate. This requires adjustment. To adjust (refer to Figure 13): 1. With a 12mm wrench, loosen four jam nuts (B) that secure the gib setscrews (C). 2.
Spindle Assembly Installation Refer to Figure 15. The fence guard (A) has been removed for clarity. The spindle assembly (B) is mounted to the arbor (C) and secured with a draw bar (J) and nut (E). Use the following procedure to install the spindle assembly. Reverse the order to remove the spindle. When changing tools, making adjustments, or doing clean-up and maintenance, always turn the machine off and unplug the machine from its power source. 1.
Shaper Cutter Installation Note: Spindle installation is described in the previous section. When changing tools, making adjustments, or doing clean-up and maintenance, always turn the machine off and unplug the machine from its power source. Locking the Spindle 1. Locate the spindle lock (F, Fig. 15) accessible through the door on the right side of the cabinet. Pull out and rotate 90º right or left, resetting the knob into the indent. Attempt to turn the spindle (B, Fig.
Changing Cutter Speed Referring to Figure 18: The Model 2700 Shaper is equipped with pulleys that allow you to change the spindle speed. The belt (B) placed on the upper pulleys (as shown in Figure 16) provides 7,500 RPM spindle speed. Placing the belt on the lower pulleys provides 10,000 RPM spindle speed. To change speed (refer to Figure 16): 1. Disconnect the machine from the power source. 2. Open the door of the cabinet. 3.
Precision Miter Gauge Setting the miter gauge angle Referring to Figure 19: 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. Loosen lock handle (A). To adjust the body (B) of the miter gauge to the desired angle: 3. Pull the spring-loaded knob (C) out and turn until the body (B) of the miter gauge is at the desired angle as indicated on the scale. 4. Tighten the lock handle (A).
Start/Stop magnetic, the lock 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. Power Indicator Light – The start switch has a power indicator lamp which is on whenever there is power connected to the shaper, not just when the shaper is running. 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 before use.
Operations Overview Before applying power to the machine, Check the motor and switch wiring diagrams for proper voltage connections. Check that all mounting screws and bolts are tight. Turn on the motor momentarily to check for proper rotation. The spindle should rotate counterclockwise when looking down on the spindle. Correct as required. Run the machine for a short period of time to ensure that the moving parts are working properly with no excessive vibration.
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 25. Figure 25 When the shaping operation removes the entire edge of the work, e.g.
"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). See Figure 28. Note: The "Z" dimension can be either positive or negative. The "Z" dimension is positive if the cutter is larger than the collar bearing.
Edge Shaping When edge shaping, never attempt to hand guide any stock less than 12 inches long, or narrower than 3 inches without the use of a special guide as shown in Figure 30. When edge shaping, the workpiece must be at least 12 inches long unless a special guide is used. 1. Use the hold-ins and hold-downs as shown in Figure 30 to firmly hold the workpiece down and against the fence. If workpiece is too wide for the hold-ins to be used, clamp a scrap board to the table to substitute for the hold-ins. 2.
Straight Line Bevel Shaping Contour Edge Shaping With Collar Bearing To shape a beveled straight edge, use a beveledge shaping jig in combination with the regular fence as shown in Figure 34. To shape contoured edges, the operator must first remove the fence assembly. In order to control the workpiece and limit the depth-of-cut, the operator must use an anti-friction collar with the cutter(s) as shown in Figure 36.
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 39. 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 it. When the workpiece is not contoured all around, start the cut as shown in Figure 45.
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 44. Note: It is advisable to place the cutter as low as possible on the spindle to reduce spindle deflection and ensure the best possible finish. Also make sure that the contacting surfaces of the cutter are smooth, clean and without dents.
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 47. With the entire fence assembly removed, carefully position the jig for desired depth-of-cut and securely clamp to the table. It is important with the arc and circle shapes that the workpiece, prior to being shaped, must be roughly cut to the desired size and curve of the finished piece.
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 49, keep in mind that it serves only as a guide for the cutter. Figure 49 If the workpiece requires all-around shaping, the template can be constructed from several sections pieced together as shown in Figure 50. Securing the Template There are various methods used to secure the template to the workpiece.
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. Stacked Cutters Figure 53 A variety of interesting and timesaving cuts can be made in a single setup by stacking the cutters.
Figure 58 shows BOTH cuts required for a window sash rail end. The first operation at top is a rabbet cut made with a groove cutter. The second operation is performed with a stub spindle and buttonhead screw. Butt Joints All butt-type joints require both work-pieces to be perfectly square and straight-edged. Figure 58 Glue Butt Joint To perform a glue butt joint, both fences are kept inline and adjusted for a depth of cut (Figure 59).
Tenoning The tenoning fixture illustrated in Figure 63 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. Secure the leg to jig and position for cut as shown in Figure 64. Make all first cuts with the same jig setting and spindle height. When the first series of cuts have been made, reposition leg on the jig for each succeeding cut.
Troubleshooting Trouble Possible Cause Shaper will not start. 1. Cord unplugged from the power source. 2. Fuse blown or circuited breaker tripped. 3. Cord damaged. 4. Reversing switch is in the Off position. 5. Overload tripped. 6. Cabinet door is open. Overload kicks frequently. Cuts are unsatisfactory. out 1. Extension cord or wiring inadequate size. 2. Feeding stock too fast. 3. Cutter needs cleaning or replacing. See also Unsatisfactory Cuts below. 1. Dull cutter. 2.
Trouble Possible Cause Remedy Raised areas on shaped edge. 1. Variation of pressure holding work against cutter. 1. Hold work firmly against table and fence. Use hold-downs and push sticks. Work pulled from hand. 1. Feeding in wrong direction. 1. Always feed work against the rotation of the cutterhead. Depth of cut not uniform. 1. Fence misalignment. 2. Side pressure not uniform. 1. Align outfeed fence. 2. Use hold-downs; keep constant pressure against fence and use push sticks. Work burns. 1.
Table – Parts List Index No. Part No. Description Size Qty 1 .............. PM2700-101N .........Insert Ring .......................................................2.55” I.D. .................... 1 2 .............. PM2700-102N .........Insert Ring .......................................................4.16” I.D. .................... 1 3 .............. PM2700-103N .........Insert Ring .......................................................5.75” I.D. .................... 1 4 .............. PM2700-104N ...
Table – Assembly Drawing 35
Fence – Parts List Index No. Part No. Description Size Qty 1 .............. PM2700-201............Knob .................................................................................................. 6 2 .............. PM2700-202............Guard Holder...................................................................................... 1 3 .............. PM2700-203............Cutter Guard ...................................................................................... 1 4 ..............
Fence – Assembly Drawing 37
Frame and Motor – Parts List Index No. Part No. Description Size Qty 1 .............. TS-1503031 ............Hex Socket Cap Screw .....................................M6x12........................ 6 2 .............. TS-2361061 ............Lock Washer ....................................................M6 ........................... 10 3 .............. TS-1550041 ............Flat Washer......................................................M6 ............................. 2 4 .............. PM2700-304....
Frame and Motor – Assembly Drawing Index No. Part No. Description Size Qty 46 ............ PM2700-346............Hex Bushing ....................................................................................... 1 47 ............ TS-1540071 ............Hex Nut............................................................M10 ........................... 1 48 ............ PM2700-348............Belt Tension Handle............................................................................ 1 49 ............
Elevator – Parts List Index No. Part No. Description Size Qty 1 .............. PM2700-501............Lead Screw ........................................................................................ 1 2 .............. PM2700-342............Retaining Ring ..................................................STW-15 ..................... 1 3 .............. PM2700-503............Thrust Bearing ..................................................51202 ........................ 2 4 .............. PM2700-504......
Elevator – Assembly Drawing 41
Caster Assembly – Parts List Index No. Part No. Description Size Qty 1 .............. TS-2342141 ............Nylon Insert Lock Nut ........................................M14 ........................... 4 2 .............. PM2700-602............Sprocket ............................................................................................ 4 3 .............. BB-6002ZZ ..............Ball Bearing......................................................6002ZZ ...................... 4 4 ..............
Caster Assembly Drawing 43
Spindle Assembly – Parts List Index No. Part No. Description Size Qty 1 .............. TS-1505031 ............Socket Head Cap Screw ...................................M10x25 ...................... 4 2 .............. PM2700-702............Pin ..................................................................................................... 2 3 .............. PM2700-703............Special Washer .................................................................................. 1 4 ..............
1-1/4" Spindle 3/4" Spindle 1" Spindle 1/2" Spindle 30mm Spindle Spindle Assembly Drawing- 45
Cabinet and Base – Parts List Index No. Part No. Description Size Qty 1 .............. TS-1533052 ............Phillips Pan Head Machine Screw......................M5x16........................ 8 2 .............. TS-2361051 ............Lock Washer ....................................................M5 ............................. 4 3 .............. TS-1550031 ............Flat Washer......................................................M5 ............................. 4 4 .............. PM2700-404.......
Index No. Part No. Description Size Qty 54 ............ PM2700-454............Motor Cable 3HP, 1Ph ......................................14AWG x 4C .............. 1 ................ PM2700-454A .........Motor Cable 5HP, 1Ph ......................................12AWG x 3C .............. 1 54-1 ......... PM2700-454-1A ......Motor Cable 5HP, 1Ph ......................................12AWG x 2C .............. 1 ................ PM2700-454B .........Motor Cable 5HP, 3Ph .....................................
Cabinet and Base 48
Green Black White Green White White Red Black 49 RED YELLOW Yellow Black WHITE WHITE Green Black White BLACK YELLOW WHITE RED LED White Black 1 White Green Black Green 1 3 White Motor 40UF/125V.AC 600MF D/125V.
5HP, 230V, 3Phase Electrical Schematic - Three Phase 5HP,230V,3Ph X1 Y1 U2 V2 W2 Z1 U1 V1 W1 DRO Motor Black Red White Black White Black Red White White Red Magnetic Switch Green White Black WHITE BLACK Black Green Green White W 14 L1L2L3 13 Red Black Red White Green Yellow Yellow Red White WHITE BLACK Red Red Black Red White Black V U Green Black Black White White Limited switch White White Red Black Green White RED Black Green Red Black Green Electric
5HP, 460V, 3Phase Electrical Schematic - Three Phase 5HP,460V,3Ph DRO X1 Y1 Z1 U2 V2 W2 U1 V1 W1 Motor Black Red White White Black White Red Magnetic Switch Green White Black Red Black WHITE BLACK Black White Green G reen W 14 L1L2L3 13 Red Black Yellow Black Red White Red Green Yellow Yellow Red White BLACK WHITE Red Red Black Red White Black VU White Green Black Black White White Limited switch White White Red Black G reen White RED Black G reen Red Black
WALTER MEIER (Manufacturing) Inc. 427 New Sanford Road LaVergne, TN 37086 Phone: 800-274-6848 www.powermatic.com www.waltermeier.
