Operating Instructions and Parts Manual
20-inch Planer
Models 209 and 209HH
Powermatic
427 New Sanford Road
LaVergne, TN 37086 Part No. M-0460283
Ph.: 800-274-6848 Revision H1 11/2018
www.powermatic.com Copyright © 2017 Powermatic
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2
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
90 Days – Parts; Consumable items
1 Year – Motors, Machine Accessories
2 Year – Woodworking Machinery used for industrial or commercial purposes
5 Year – Woodworking Machinery
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.
3
Table of Contents
Warranty and Service .................................................................................................................................... 2
Table of Contents .......................................................................................................................................... 3
Warning ......................................................................................................................................................... 4
Introduction ................................................................................................................................................... 6
Features ........................................................................................................................................................ 6
Specifications ................................................................................................................................................ 7
Unpacking ..................................................................................................................................................... 8
Assembly ....................................................................................................................................................... 9
Knife Gauge (model 209 only) ................................................................................................................... 9
Handwheel ................................................................................................................................................. 9
Extension Tables ..................................................................................................................................... 10
Dust Hood ................................................................................................................................................ 10
Electrical Connections ............................................................................................................................. 10
Extension Cords ...................................................................................................................................... 11
Adjustments ................................................................................................................................................ 11
Belt Tension ............................................................................................................................................. 11
Table Rollers ........................................................................................................................................... 11
Cutterhead ............................................................................................................................................... 12
Knife Adjustments (Model 209 only) ........................................................................................................ 12
Replacing and Re-setting Knives (Model 209 only) ................................................................................ 13
Replacing or Rotating Knife Inserts (Model 209HH only) ........................................................................ 14
Work Table Parallel to Cutterhead .......................................................................................................... 15
Anti-Kickback Fingers .............................................................................................................................. 16
Infeed and Outfeed Roller Spring Tension .............................................................................................. 16
Height of Infeed Roller, Chipbreaker, Pressure Bar and Outfeed Roller ................................................ 16
Infeed Roller Height ................................................................................................................................. 17
Chipbreaker Height .................................................................................................................................. 17
Pressure Bar Height ................................................................................................................................ 18
Chip Deflector .......................................................................................................................................... 18
Feed Speed Control ................................................................................................................................ 18
Changing Accessories for Lowest Feed Speed ...................................................................................... 18
Return Rollers .......................................................................................................................................... 19
Depth of Cut ............................................................................................................................................ 19
Know the Transmitting Rollers of Your Planer ........................................................................................ 15
Maintenance ................................................................................................................................................ 20
Lubrication ............................................................................................................................................... 20
Troubleshooting: Operating Problems ........................................................................................................ 22
Troubleshooting: Mechanical and Electrical Problems ............................................................................... 23
Optional Accessories .................................................................................................................................. 24
Replacement Parts ...................................................................................................................................... 24
Cutterhead Assembly .............................................................................................................................. 25
Parts List: Cutterhead Assembly ............................................................................................................. 26
Base Assembly ........................................................................................................................................ 28
Parts List: Base Assembly ....................................................................................................................... 29
Gearbox Assembly .................................................................................................................................. 30
Parts List: Gearbox Assembly ................................................................................................................. 31
Stand Assembly ....................................................................................................................................... 32
Parts List: Stand Assembly ..................................................................................................................... 32
Parts List: Table Assembly ...................................................................................................................... 34
Electrical Connections – Single Phase, 230 Volt only ................................................................................ 35
Electrical Connections – 3 Phase, 230 Volt only ........................................................................................ 36
Electrical Connections – 3 Phase, 460 Volt only ........................................................................................ 37
Preventive Maintenance .............................................................................................................................. 3 8
4
Warning
As with all machines, there is a certain amount of hazard involved with the use of this planer. Use the
machine with the respect and caution demanded where safety precautions are concerned. When normal
safety precautions are overlooked or ignored, personal injury to the operator can result.
Read, understand and follow the safety and operating instructions found in this manual. Know the
limitations and hazards associated with this machine.
Electrical grounding. Make certain that the machine frame is electrically grounded and that a ground
lead is included in the incoming electrical service. In cases where a cord and plug are used, make certain
that the grounding plug connects to a suitable ground. Follow the grounding procedure indicated in the
National Electrical Code.
Eye safety. Wear an approved safety shield, goggles, or glasses to protect eyes. (NOTE: Common
eyeglasses are only impact-resistant, they are not safety glasses.)
Personal protection. Before operating the machine, remove tie, rings, watch and other jewelry and roll
up sleeves above the elbows. Remove all loose outer clothing and confine long hair. Protective type
footwear should be used. Where the noise exceeds the level of exposure allowed in Section 1910.95 of
the OSHA Regulations, use hearing protective devices. Do not wear gloves.
Guards. Keep the machine guards in place for every operation for which they can be used. If any guards
are removed for maintenance, DO NOT OPERATE the machine until the guards are reinstalled.
Placement. Place machine so that potential kickback area is not in line with aisles, doorways, wash
stations, or other work areas.
Work area. Keep the floor around the machine clean and free of scrap material, saw dust, oil and other
liquids to minimize the danger of tripping or slipping. Be sure the table is free of all scrap, foreign material
and tools before starting to cut. Make certain the work area is well lighted and that a proper exhaust
system is used to minimize dust. It is recommended that anti-skid floor strips are used on the floor area
where the operator normally stands and that each machine’s work area be marked off. Provide adequate
work space around the machine.
Avoid accidental starting: Make certain motor switch is in off position before connecting power to the
machine.
Operator position. Maintain a balanced stance and keep your body under control at all times. Stand to
one side out of line with the table and make sure no one else is standing in line with the table.
Housekeeping. Before turning on machine, remove all extra equipment such as keys, wrenches, scrap,
and cleaning rags away from the machine
Careless acts. Give the work you are doing your undivided attention. Looking
around, carrying on a
conversation, and “horseplay” are careless acts that can result in serious injury.
Disconnect machine before performing any service or maintenance or when changing blades. A
machine under repair should be RED TAGGED to show it should not be used until the maintenance is
complete.
Maintain tools in top condition. Keep tools sharp and clean for safe and best performance. Dull tools
increase noise levels and can cause kickbacks and glazed surfaces. Check the condition and adjustment
of the tools before making any cuts. Follow the sharpening instructions on knife grinding and jointing,
installing and adjustments.
5
Hand safety. Keep hands outside the machine. NEVER reach under the guards to try to clear stock that
stops feeding. Do not clear chips and sawdust with hands; use a brush. Do not have any part of the
hands under that part of the board that is over the table when starting a cut; the infeed roll will engage the
board and force it down against the table causing a pinching action. Do not operate machine while the
gear cover is open.
Cutterhead rotation: Be sure cutterhead rotates under power in a counterclockwise direction when
viewed from the main drive motor side.
Material condition: Do not plane boards with loose knots or with nails or any foreign material on its
surface. Knife impact on these objects can cause the knives to be pulled out and cause them to shatter
against the chipbreaker or pressure bar. Twisted, warped, or in wind stock should first be jointed on one
surface before attempting to plane a parallel surface on the planer. Serious stock flaws cannot be
removed by use of a planer alone.
Machine adjustments: Make all machine adjustments with power off except feed rate.
Job completion. If the operator leaves the machine area for any reason, the planer should be turned
"off" and the cutterhead should come to a complete stop before his departure. In addition, if the operation
is complete, he should clean the planer and the work area. Never clean the planer with power "on" and
never use the hands to clear sawdust and debris; use a brush.
Replacement parts. Use only Powermatic or factory authorized replacement parts and accessories;
otherwise the warranty and guarantee is null and void.
Misuse. Do not use this planer for other than its intended use. If used for other purposes, Powermatic
disclaims any real or implied warranty and holds itself harmless for any injury or damage which may result
from that use.
If you are not thoroughly familiar with the operation of planers, obtain advice from your supervisor,
instructor or other qualified person.
Drugs, alcohol, medication. Do not operate this machine while under the influence of drugs, alcohol, or
any medication.
Familiarize yourself with the following safety notices used in this manual:
This means that if precautions are not heeded, it may result in minor injury and/or
possible machine damage.
This means that if precautions are not heeded, it may result in serious injury or possibly
even death.
WARNING: Drilling, sawing, sanding or machining wood products generates wood dust and other
substances known to the State of California to cause cancer. Avoid inhaling dust generated from
wood products or use a dust mask or other safeguards for personal protection.
Wood products emit chemicals known to the State of California to cause birth defects or other
reproductive harm. For more information go to http://www.p65warnings.ca.gov/wood.
WARNING: This product can expose you to chemicals including lead which is known to the State
of California to cause cancer and birth defects or other reproductive harm. For more information go to
http://www.p65warnings.ca.gov.
6
Introduction
This manual is provided by Powermatic covering the safe operation and maintenance procedures for a
Powermatic Model 209 and 209HH Planer. 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. If there are any questions or comments, please contact either your
local supplier or Powermatic. Powermatic can also be reached at our web site: www.powermatic.com.
Features
Figure 1
7
Specifications
Model Number ....................................................................... 209-1 ....................................................... 209-3
Stock Number .................................................................. 1791296 .................................................. 1791297
Table Area (in.) ............................................................ 25-3/4 x 20 .............................................. 25-3/4 x 20
Maximum Planing Width (in.) ..................................................... 20 ............................................................ 20
Maximum Planing Thickness (in.) ................................................ 8 .............................................................. 8
Minimum Planing Thickness (in.) .............................................. 1/8 ........................................................... 1/8
Full Width Cutting Depth (in.) .................................................. 3/32 ......................................................... 3/32
Minimum Planing Length (in.) ................................................ 6-3/4 ........................................................ 6-3/4
Knives ........................................................................................... 4 .............................................................. 4
Blade Size (in.) ............................................................ 20 x 1 x 1/8 ............................................. 20 x 1 x 1/8
Cutterhead Speed (RPM) ...................................................... 5,000 ....................................................... 5,000
Cuts per Minute ................................................................... 20,000 ..................................................... 20,000
Cutterhead Diameter (in.) ..................................................... 3-3/16 ...................................................... 3-3/16
Sound Rating @ 2” distance (dB) ..................................... 82 to 85 ................................................... 82 to 85
Feeding Speed (FPM) .................................................... 24 and 31 ................................................ 24 and 31
Motor ................................................ TEFC, 5HP, 1Ph, 23A, 230V ....... TEFC, 5HP, 3Ph, 14/7A, 230/460V*
Dust Chute Diameter (in.) ............................................................ 5 .............................................................. 5
Overall Dimensions (LxWxH)(in.) ................... 26 x 36-5/8 x 41-3/8 ................................ 26 x 36-5/8 x 41-3/8
Net Weight (lbs.) ...................................................................... 770 .......................................................... 770
Shipping Weight (lbs.) .............................................................. 880 .......................................................... 880
Model Number ................................................................. 209HH-1 .................................................. 209HH-3
Stock Number .................................................................. 1791315 .................................................. 1791316
Table Area (in.) ............................................................ 25-3/4 x 20 .............................................. 25-3/4 x 20
Maximum Planing Width (in.) ..................................................... 20 ............................................................ 20
Maximum Planing Thickness (in.) ................................................ 8 .............................................................. 8
Minimum Planing Thickness (in.) .............................................. 1/8 ........................................................... 1/8
Full Width Cutting Depth (in.) .................................................. 3/32 ......................................................... 3/32
Minimum Planing Length (in.) ................................................ 6-3/4 ........................................................ 6-3/4
Cutterhead number of rows......................................
.................... 5 .............................................................. 5
Knives .......................................................... 100 four-sided inserts ............................. 100 four-sided inserts
Cutterhead Speed (RPM) ...................................................... 5,000 ....................................................... 5,000
Cuts per Minute ................................................................... 20,000 ..................................................... 20,000
Cutterhead Diameter (in.) ..................................................... 3-1/16 ...................................................... 3-1/16
Knife Insert Screw Max. Torque (pound force–inch) ........ 45 to 55 ................................................... 45 to 55
Sound Rating @ 2” distance (dB) ..................................... 80 to 84 ................................................... 80 to 84
Feeding Speed (FPM) .................................................... 24 and 31 ................................................ 24 and 31
Motor ................................................ TEFC, 5HP, 1Ph, 28A, 230V ....... TEFC, 5HP, 3Ph, 14/7A, 230/460V*
Dust Chute Diameter (in.) ............................................................ 5 .............................................................. 5
Overall Dimensions (LxWxH)(in.) ................... 26 x 36-5/8 x 41-3/8 ................................ 26 x 36-5/8 x 41-3/8
Net Weight (lbs.) ...................................................................... 801 .......................................................... 801
Shipping Weight (lbs.) .............................................................. 911 .......................................................... 911
*
pre-wired 230 volt NOTE: For 460V operation, magnetic switch (part no.209-5016G) must be
purchased separately and installed. A qualified electrician is recommended.
The above specifications were current at the time this manual was published, 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.
8
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 Planer is
assembled and running properly.
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.
Crate Contents (Figure 2):
Models 209 and 209HH:
1 Planer (not shown)
1 Dust Hood
2 Cast Iron Extension Tables
1 Handwheel
1 Handle
1 Low Speed Gear Kit (#6292822) containing:
1 50P Chain
1 12T Sprocket
3 Open-End Wrenches (8-10,12-14,17-19mm)
4 Hex Wrenches (3,4,5 and 6mm)
2 Hardware Bags*
(*Contents of hardware bags are drawn full
scale in Figure 3.)
1 Owner’s Manual (not shown)
1 Warranty Card (not shown)
Model 209 ONLY:
1 Knife Setting Gauge
Model 209HH ONLY:
1 1/4” Drive Screwdriver
1 T25P Torx Plus Drive Socket Adaptor
1 Set of 10 Knife Inserts
Figure 4
Figure 2
Figure 3
9
Assembly
Tools required for assembly:
Forklift or hoist with slings
Pliers
Open-End Wrenches 10,12,13,19mm
Hex Wrenches, 4 and 5mm – provided
Remove the screws holding the planer to the
pallet and use a forklift or hoist to lift the planer
off the pallet. Forks and straps should always be
placed under the four lifting handles when lifting
this machine (Figure 5). The lifting handles can
be pushed back in when not in use.
The planer should be operated in a well-lit area
with a sturdy floor and good ventilation. It can be
rolled on its casters to the desired location.
Tighten the lock knob (Figure 6) to prevent
movement during operation or adjustments.
Exposed surfaces, such as tables, rollers,
cutterhead, etc., have been given a protective
coating at the factory. This should be removed
with a soft cloth moistened with a good
commercial solvent. Do not use acetone,
gasoline, lacquer thinner, or other solvents with
a low flash point. Do not use an abrasive pad
because it may scratch the polished cast iron
surfaces.
Use care when cleaning
around the cutterhead area – knives are
extremely sharp!
Knife Gauge (model 209 only)
Place the two gauge blocks on the ends of the
shaft (Figure 7) and use a pliers to press the
four e-rings into the grooves on each side of the
blocks.
Handwheel
1. Remove the nut and washer from the
gearbox shaft, and place the handwheel
onto the shaft (Figure 8), making sure it is
oriented so the handwheel slips over the
key.
2. Place flat washer and hex nut on shaft and
tighten with 19mm wrench.
3. Mount the handle into the threaded hole in
the handwheel, and tighten with a 12mm
wrench placed over the flat on the handle.
Figure 5
Figure 6
Figure 7 – Model 209 only
Figure 8
10
Extension Tables
1. Mount a cast iron table to the edge of the
main table with three M8 x 25 hex cap
screws (Figure 9) using a 13mm wrench. Do
not fully tighten yet.
2. The extension table must be leveled with the
main table. Place a straight edge (such as a
jointed board) across both tables.
3. Insert three socket set screws with a 4mm
hex wrench, and screw them in or out as
needed until tables are level.
4. Securely tighten the hex cap screws.
5. Mount the second extension table to the
opposite side of the planer table, using the
same procedure.
Dust Hood
Mount the hood to the rear of the head casting
with six M6 x 12 hex cap screws and six 1/4" flat
washers (Figure 10), with a 10mm wrench.
It is recommended that you use a dust collection
system with this planer. If you are not using a
dust collection system, do not attach the dust
hood to the planer, as the accumulation of dust
inside the hood may create a safety hazard, or
eventually cause jamming of the rollers.
Electrical Connections
Electrical connections must
be made by a qualified electrician in
compliance with all relevant codes. The
machine must be properly grounded to help
prevent electrical shock and possible fatal
injury.
A power plug is not provided with the 209
planer. You may either connect one or "hard-
wire" the machine directly to your electrical
panel provided there is a disconnect near the
machine. Consult electrical schematics on
pages 35-37 for further clarification of wiring
setup.
The 209 Planer 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.
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.
Figure 9
Figure 10
209 Plane
r
Recommended circuit*
5HP 1PH 230V 40 Amp
5HP 3PH 230V 30 Amp
5HP 3PH 460V 15 Amp
*subject to local codes
Table 1
If converting from 230 to 460 volt operation:
1. Change leads in motor junction box, as
shown in electrical diagrams.
2. Replace 230V magnetic switch with 460V
magnetic switch (part no. 209-5016G;
separate purchase). A qualified electrician is
recommended.
11
Extension Cords
The use of an extension cord is not
recommended for this machine, but if one
proves 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.
The chart in Figure 11 shows the correct size
cord to use based on cord length and motor
plate amp rating. If in doubt, use the next
heavier gauge. The smaller the gauge number
the heavier the cord.
Adjustments
Tools required for adjustments:
3, 5, 6, and 10mm hex wrenches
12, 14 and 19mm open-end wrenches
Feeler gauges
Straight edge
Gauge block or dial gauge
Cross-point (Phillips) screwdriver
Disconnect machine from
power source before making any adjust-
ments (except feed rate).
Belt Tension
Inspect the tension of the belts frequently during
the first few times you use the planer. Belts often
stretch during this trial period. If they require
tightening, proceed as follows:
1. Remove the belt guard and the rear panel.
2. Loosen the bottom nuts on the motor
adjustment screws (Figure 12) with a 19mm
wrench.
3. Turn the top nuts to lower the motor plate,
which will increase the belt tension.
4. Proper tension is achieved when there is
slight deflection in the belt midway between
the pulleys, using moderate finger pressure.
5. Tighten the bottom nuts (Figure 12).
Table Rollers
Your planer is supplied with two table rollers
(Figure 13) which turn as the stock is fed into the
machine, thus reducing friction. It is not possible
to give exact dimensions on the proper height
setting of the table rollers because each type of
wood behaves differently. As a general rule,
however, when planing rough stock the table
rollers should be set at high position.
Recommended Gauges (AWG) of Extension Cords
Amps
Extension Cord Length *
25
feet
50
feet
75
feet
100
feet
150
feet
200
feet
< 5 16 16 16 14 12 12
5 to 8 16 16 14 12 10 NR
8 to 12 14 14 12 10 NR NR
12 to 15 12 12 10 10 NR NR
15 to 20 10 10 10 NR NR NR
21 to 30 10 NR NR NR NR NR
*based on limiting the line voltage drop to 5V at 150% of the
rated amperes.
NR: Not Recommended.
Figure 11
Figure 12
Figure 13
12
When planing smooth stock the rollers should be
set at low position.
NOTE: When raising the roller higher above the
table, the range is from .003" to .006" (Figure
14).
The table rollers are factory set for average
planing and are parallel to the table surface. If
you desire to adjust the table rollers higher or
lower, proceed as follows:
1. Disconnect machine from power source.
2. Lay a straight edge across both rollers.
3. On one side of the table, loosen the set
screws (Figure 15) with a 3mm hex wrench,
and turn the eccentric shafts to raise or
lower the rollers.
4. When proper height is achieved, tighten set
screws.
5. Adjust the rollers from the opposite side of
the table in the same manner.
IMPORTANT: Be sure that the height of front
and rear rollers are the same. The table rollers
must always be set parallel to the table.
Cutterhead
Although your planer was carefully adjusted at
the factory, it should be checked before being
put into operation. Any inaccuracies due to
rough handling in transit can be corrected by
following the directions in this manual.
To check the adjustments you will need a knife-
setting gauge (provided), feeler gauges, and a
dial gauge or home-made gauge block made of
hardwood. This gauge block can be made by
following the dimensions shown in Figure 16.
You will also need to remove the belt guard, so
you can rotate the cutterhead using the pulley.
Knife Adjustments (Model 209 only)
When checking or adjusting cutterhead knives
on the model 209 Planer, proceed as follows:
1. Disconnect machine from power source.
2. Remove the six screws and upper cover
(Figure 17).
3. To check and adjust knives, use the
provided knife setting gauge and check all
four knives. Knives should just contact the
bottom of the center protrusion (D, Figure
18) of the knife gauge. Make sure the feet of
the knife gauge sit solidly upon the
cutterhead, and that its shaft is parallel to
the cutterhead (see Figure 19).
Figure 14
Figure 15
Figure 16
Figure 17
13
4. If an adjustment to one or more of the knives
is necessary, slightly loosen the knife gib (E,
Figure 18) by turning the six screws (F,
Figure 18) into the gib (i.e. clockwise, when
facing the screw heads) with a 12mm hex
wrench. Turn the screws just enough to
relieve stress in the cutterhead without
disturbing the setting of the knives. Do this
for all four knives at the same time.
5. With the knife setting gauge (C, Figure 18)
in place over a knife (G, Figure 18), continue
to loosen the screws (F, Figure 18) until the
springs (H, Figure 18) begin raising the
knife. When knife comes in contact with the
center protrusion of the gauge, snug the gib
by lightly backing out the six screws (F,
Figure 18) against the slot (i.e. counter-
clockwise).
NOTE: At this time, tighten the knife into the
slot just enough to hold knife in position.
6. If additional knives must be reset, repeat
step 5.
7. After all knives are set with screws just
snug, back out and tighten the six screws (F,
Figure 18) against the slot starting with the
end screws first, then the center screws,
until the knife is securely held in the
cutterhead. Tighten the remaining three
knives in the same manner.
After setting or installing
knives, re-check all gib screws. Loose gib
screws can result in knives being thrown out
of the cutterhead, causing severe damage to
the machine and possible serious or fatal
injury to the operator or bystanders.
Replacing and Re-setting Knives
(Model 209 only)
If the knives are removed for sharpening, care
must be exercised in replacing and re-setting
them. Proceed as follows:
1. Disconnect machine from power source.
2. Remove six screws and upper cover (see
Figure 17).
3. To remove knife, loosen the gib (E, Figure
18) by turning the six gib screws clockwise.
Remove gib, knife and springs.
4. Remove the remaining three knives in the
same manner.
5. Thoroughly clean the knife slots, gibs,
springs and gib screws. Check the gib
screws; if the threads appear worn or
stripped or if the heads are becoming
rounded, replace them.
Figure 18 – Model 209 only
Figure 19 – Model 209 only
14
6. Inspect the cutting edge of the knives for
nicks or wire edge. Hone the knives slightly
using a stone or if the knives are to be
sharpened, maintain a cutting angle of 35
degrees.
7. Insert springs, knife and gib into slot of
cutterhead. Back out screws just enough to
hold the knife in the cutterhead.
8. Place knife setting gauge (Figure 19) over
knife.
9. While holding down the knife gauge, loosen
all six screws by turning them into the gib
until the cutting edge of the knife comes in
contact with the protrusion of the gauge.
Snug up the gib by slightly backing out the
six screws against the slot.
NOTE: At this time, only tighten the knife
into the slot just enough to hold the knife in
position.
10. Replace and re-set the other three knives in
the same manner.
11. After all four knives are set with the screws
just snug, back out and tighten the six
screws against the slot starting with the end
screws first and then the center screws until
the knife is securely held in the cutterhead.
Tighten the remaining three knives in the
same manner.
After replacing and checking
knives, check again carefully. Make certain
the direction of knives is correct and all 24
gib screws are tightened securely.
Replacing or Rotating Knife Inserts
(Model 209HH only)
The knife inserts on the model 209HH are four-
sided. When dull, simply remove each insert,
rotate it 90° for a fresh edge, and re-install it.
Use the provided screwdriver with the T25P
socket adaptor to remove the knife insert screw.
See Figure 20. NOTE: A T25 adaptor or driver
can round out the screw head recess. Always
use a T25-Plus driver or adaptor.
It is advisable to rotate all inserts at the same
time to maintain consistent cutting. However, if
one or more knife inserts develops a nick, rotate
only those inserts that are affected.
Each knife insert has an etched reference mark
so you can keep track of the rotations.
IMPORTANT: When removing or rotating
inserts, clean saw dust from the screw, the
insert, and the cutterhead platform.
Figure 19 repeated
Figure 20 – Model 209HH only
Dust accumulation between these elements can
prevent the insert from seating properly, and
may affect the quality of the cut.
To install new knife inserts:
1. Before installing each screw, lightly coat the
screw threads with machine oil and wipe off
any excess.
2. Position knife insert and move it back and
forth to verify there are no burrs or dirt.
3. Hold insert away from the back of the seat
(pull slightly toward yourself if facing the
cutting edge) and allow the screw to pull
insert into position. Note: A slight offset
between screw hole and hole in knife insert
is normal. Do not position insert directly over
screw hole, as it could ride up on the back of
the seat and potentially cause cracking of
the tip.
4. Securely tighten each screw which holds the
knife inserts before operating the planer.
IMPORTANT: Maximum torque for
tightening the screws is 45 to 55 inch
pounds (3.75 to 4.6 foot pounds).
15
Make sure all knife insert
screws are tightened securely. Loose inserts
can be propelled at high speed from a
rotating cutterhead, causing injury.
Work Table Parallel to Cutterhead
The work table is set parallel to the cutterhead at
the factory and no further adjustment should be
necessary. If your machine is planing a taper,
first check to see if the knives are set properly in
the cutterhead. Then check to see if the work
table is set parallel to the cutterhead. Proceed
as follows:
1. Disconnect machine from power source.
2. Place the gauge block (Figure 21) on the
work table directly under the edge of a knife
or knife insert as shown. Make slight contact
with the knife edge by gently raising the
table.
3. Move the gauge block to the opposite end of
the work table. The distance from the work
table to the edge of the knife should be the
same on both ends of the knife.
If the work table is not parallel to the cutterhead,
perform the adjustment procedure as follows:
1. Disconnect machine from power source.
2. Remove bolts holding the planer to the
stand. Tilt planer on its side to expose
underside of base (Figure 22).
3. Remove bolt (A, Figure 22) and loosen bolt
(B-Figure 22) which will allow you to move
the idler sprocket assembly (C, Figure 22)
far enough to release tension on the chain.
4. Remove the chain from the particular
sprocket on the corner of the base that you
need to adjust.
5. Turn the sprocket by hand to bring that
corner into adjustment with the other three
corners. NOTE: Turning sprocket clockwise
will increase the distance between the
working table and the head casting;
counterclockwise will decrease the distance.
This adjustment is very sensitive and it
should not be necessary to turn the sprocket
more than one or two teeth.
6. When adjustments are correct, replace
chain around corner sprocket, slide idler
sprocket (C-Figure 22) back to re-tension
chain, tighten bolt (B, Figure 22) and insert
and tighten bolt (A, Figure 22).
Figure 21
Figure 22
Know the Transmitting Rollers of
Your Planer
(Figure 23)
A. Anti-Kickback Fingers
B. Infeed Roller
C. Chipbreaker
D. Cutterhead
E. Pressure Bar
F. Outfeed Roller
Figure 23
16
Anti-Kickback Fingers
The anti-kickback fingers (A, Figure 23) are an
important safety feature, as they help prevent
kickback of stock. They operate by gravity and
should be inspected frequently to make sure
they are free of gum and pitch, so that they
move independently and operate correctly.
Infeed and Outfeed Roller Spring
Tension
The infeed roller (B, Figure 23) and outfeed
roller (F, Figure 23) are those parts of your
planer that feed the stock while it is being
planed. The infeed roller and the outfeed roller
are under spring tension and this tension must
be sufficient to feed the stock uniformly through
the planer without slipping but should not be so
tight that it causes damage to the board. The
tension should be equal at both ends of each
roller. Note: Contact Powermatic Technical
Service before attempting any adjustments to
spring tension.
Height of Infeed Roller, Chipbreaker,
Pressure Bar and Outfeed Roller
The infeed roller, chipbreaker, pressure bar and
outfeed roller are adjusted at the factory. The
height relationship between these items and the
cutterhead is crucial for accurate and safe
planing. The infeed roller and outfeed roller
should be set 0.032" (0.81mm) below the arc of
the knives. The pressure bar is set 0.006” to
0.008” above the arc of the knives. The
chipbreaker is set even with the knife arc. See
Figure 25.
If any adjustments are necessary for the infeed
roller, chipbreaker, pressure bar or outfeed
roller, they should be done carefully. Use the
following steps as an example of procedure.
NOTE: This procedure uses a home-made
gauge block and feeler gauges, which should be
sufficient for most planer operations. If extra
precise measurements are desired, however,
use a dial indicator device.
Figure 24
Figure 25
17
Outfeed Roller Height
1. Disconnect machine from power source.
2. Make sure the knives are set properly as
previously explained under "Knife
Adjustment."
3. Place the gauge block (J, Figure 26) on the
table directly beneath the cutterhead (D,
Figure 26).
4. Using a 0.032" (0.81mm) feeler gauge (K,
Figure 26) placed on top of the gauge block,
raise the work table until the knife just
touches the feeler gauge when the knife is
at its lowest point. Do not move the work
table any further until the outfeed roller is
adjusted.
5. Remove the feeler gauge and move the
gauge block (J, Figure 27) under one end of
the outfeed roller (F, Figure 27). The bottom
of the outfeed roller should just touch the top
of the gauge block. If an adjustment to the
outfeed roller is necessary, loosen the lock
nut (L, Figure 27) and turn screw (M, Figure
27) until the outfeed roller just touches the
gauge block. Then tighten lock nut (L, Figure
27).
6. Check and adjust the opposite end of the
outfeed roller in the same manner.
Infeed Roller Height
Use the exact same procedure for checking the
infeed roller as you did for the outfeed roller,
using a 0.032" (0.81mm) feeler gauge atop the
gauge block. If adjustment is necessary, use the
lock nut and screw on each end of the infeed
roller.
Chipbreaker Height
The chipbreaker breaks off the larger chips
before the stock reaches the cutterhead. Use
the gauge block to set the chipbreaker even with
the arc of the knives, following the same
procedure as above. If adjustment is needed:
1. Remove top cover.
2. Loosen the lock nuts (A, Figure 28) at both
ends of the chipbreaker, and turn the set
screws to raise or lower the chipbreaker as
needed. The set screws should be turned
the same amount.
3. When the chipbreaker contacts the gauge
block, tighten both lock nuts (A, Figure 28).
Figure 26
Figure 27
Figure 28
18
Pressure Bar Height
The pressure bar prevents the stock from lifting
after it passes under the cutterhead. Check the
height of the pressure bar with your gauge block
and a .008" (0.2mm) feeler gauge. If adjustment
is needed:
1. Remove top cover.
2. Loosen the lock nuts (B, Figure 29) on both
ends of the pressure bar and turn the set
screws as needed.
3. When the pressure bar contacts the top of
the gauge block, tighten the lock nuts (B,
Figure 29).
Chip Deflector
The chip deflector (C, Figure 29) keeps wood
chips from falling into the outfeed roller. The
deflector should be set approximately 1/16" from
the tip of the knives. Make sure the deflector's
front edge is beveled to match the shape of the
cutterhead.
Feed Speed Control
Your machine is equipped with a spiral, serrated
infeed roller and a solid steel outfeed roller.
When the feed rollers are engaged, they turn to
feed the stock. The feed rollers slow
automatically when the machine is under heavy
load for best planing in all conditions. The feed
rollers are driven by chains (A, Figure 30) and
sprockets (B, Figure 30) which take power
directly from the cutterhead through the oil bath
gear box (C, Figure 30).
The gear box has two feed speeds. These are
set by pulling out or pushing in the shift lever (D,
Figure 30) while the machine is running. The
feed speed range is shown in Figure 31.
Do not attempt to change
feed speed while stock is passing through
the machine. Damage to the gearbox may
result.
Changing Accessories for Lowest
Feed Speed
The lowest feed speeds for your planer (16.2
fpm and 20.7 fpm) can be obtained by replacing
the lower (gear shaft) sprocket and its chain
(Figure 31).
A low speed gear kit, consisting of a 50P chain
and 12T sprocket, is provided with your planer.
To change the sprocket and chain on your
machine, proceed as follows:
Figure 29
Figure 30
Figure 31
19
1. Disconnect machine from power source.
2. Remove the three hex cap screws and
washers (E, Figure 30).
3. Remove the three sprockets (B, Figure 30)
from the infeed roller, outfeed roller and the
gear shaft at the same time.
4. When all sprockets have been removed,
replace the gear shaft sprocket (G, Figure
31) and its chain (F, Figure 31) with those of
a different size.
5. Mount all three sprockets and chains to their
shafts, and tighten all hex cap screws and
washers (E, Figure 30).
Return Rollers
The two return rollers on top of the machine
serve as a convenient rest for stock. They save
time and motion for the operator as the stock is
returned to the infeed side.
Depth of Cut
The cutting depth scale is a combination
inch/metric scale (A, Figure 32), with a cutting
range from 0 to 8" (204mm). The distance of
upward or downward movement is controlled by
the handwheel (B, Figure 32). One revolution of
the handwheel is .059" (1.5mm). Before moving
the table up or down, loosen the lock nuts (C,
Figure 32). After obtaining proper table position,
tighten the lock nuts (C, Figure 32).
Maximum depth of cut is 1/8". A limiter (D,
Figure 32) is provided to limit the depth of cut on
full width planing from 3/16" to 1/8".
The depth scale and pointer are adjustable and
should be checked for accuracy. Proceed as
follows:
1. Connect power, and turn on the planer.
2. Take a scrap board and measure its exact
thickness with calipers.
3. Raise or lower the table so the scale reads
the thickness of the board minus 1/16".
Feed the board through the planer.
4. Move the table up another 1/16". Flip the
board over and plane the other side.
5. Measure the board with calipers and
compare with the depth scale on the planer.
If the scale needs adjustment, loosen the
screws and shift the scale up or down as
needed. Tighten screws when finished.
Figure 32
20
Maintenance
Disconnect machine from
power source before performing any
maintenance.
Periodic or regular inspections are required to
ensure that the machine is in proper adjustment,
that all screws are tight, that belts are in good
condition, that dust has not accumulated in the
electrical enclosures, and that there are no worn
or loose electrical connections.
Buildup of sawdust and other debris can cause
your machine to plane inaccurately. Periodic
cleaning is not only recommended but
mandatory for accurate planing.
Close-fitting parts, such as the cutterhead slot
and gibs, should be cleaned with a cloth or
brush and non-flammable solvent, and freed
from clinging foreign matter.
Remove resin and other accumulations from
feed rollers and table with a soft rag and non-
flammable solvent.
Periodically check all the chains for proper
tension and adjust accordingly if required.
TIP: If a foreign object nicks the knives, instead
of throwing them away or trying to grind out the
deep nick, simply stagger the knives in the head,
moving one knife no more than 1/4" to the right
and another knife no more than 1/4" to the left.
The nick should no longer be noticeable.
The table should be kept clean and free of rust.
Some users prefer a paste wax coating. Another
option is talcum powder applied with a
blackboard eraser rubbed in vigorously once a
week; this will fill casting pores and form a
moisture barrier. This method provides a table
top that is slick and allows rust rings to be easily
wiped from the surface. Important also is the fact
that talcum powder will not stain wood or mar
finishes as wax pickup does.
Lubrication
The bearings on the cutterhead are factory
lubricated and sealed for life – no lubrication is
required.
GEARBOX LUBRICANT
The lubricant in the gear box must be replaced
every 2,500 hours. Multi-purpose gear box
lubricant will be suitable.
To replace the lubricant:
1. Remove the drain plug (A, Figure 33) with a
14mm wrench, and remove filler plug (B-
Figure 33). Drain dirty oil thoroughly.
2. Tighten the drain plug (A, Figure 33).
3. Fill with clean lubricant through hole (B,
Figure 33).
4. Reinstall and tighten filler plug (B, Figure
33).
Figure 33
21
The item numbers on this chart are referenced to the surrounding illustrations.
No. Position Interval Suitable Types of Lubricant Figure No.
1 Drive Chain Frequently Grease 33
2 Gear Box When operated more than 2,500
hours
Standard gear oil, 70-90 weight
Capacity: 0.46L (0.122 gal.)
33
3 Return Rollers Frequently SAE-30 35
4 Worm Gear Frequently Grease 36
5 Lead Screw Frequently Grease 36
6 Column Frequently Clean and SAE-30 36
7 Table Chain Frequently Grease 37
8 Feed Rollers Frequently SAE-30 38
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
22
Troubleshooting: Operating Problems
Trouble Probable Cause Remedy
Snipe.
(NOTE: Snipe cannot
be eliminated, but
can be so minimized
as to be negligible.)
Table rollers not set properly. Adjust rollers to proper height.
Inadequate support of long boards.
Support long boards with extension
rollers.
Uneven feed roller pressure front to
back.
Adjust feed roller pressure.
Dull knives or knife inserts.
209: Sharpen or replace knives.
209HH: Rotate or replace inserts.
Lumber not butted properly.
Butt end to end each piece of stock
as they pass through.
Fuzzy grain.
Planing wood with high moisture
content.
Remove moisture by drying, or use
different stock.
Dull knives or knife inserts.
209: Sharpen or replace knives.
209HH: Rotate or replace inserts.
Torn grain.
Too heavy a cut. Adjust proper depth of cut.
Knives (or inserts) cutting against the
grain.
Cut along the grain where possible.
Dull knives or knife inserts.
209: Sharpen or replace knives.
209HH: Rotate or replace inserts.
Rough/raised grain.
Dull knives or knife inserts.
209: Sharpen or replace knives.
209HH: Rotate or replace inserts.
Too heavy a cut. Adjust proper depth of cut.
Planing wood with high moisture
content.
Remove moisture by drying, or use
different stock.
Rounded, glossy
surface.
Dull knives or knife inserts.
209: Sharpen or replace knives.
209HH: Rotate or replace inserts.
Feed rate too slow. Increase feed rate.
Cutting depth too shallow. Increase cutting depth.
Poor feeding of
lumber.
Inadequate feed roller pressure.
Adjust feed roller tension. If proper
tension cannot be achieved, replace
feed rollers.
Planer table rough or dirty.
Clean pitch and residue from table,
and apply paste wax.
Belt slipping on pulleys. Tighten belt.
Surface of feed rollers too smooth.
Lightly roughen the feed roller surface
with sandpaper.
23
Troubleshooting: Mechanical and Electrical Problems
Trouble Probable Cause Remedy
Uneven depth of cut
side to side.
Knife projection from cutterhead is
incorrect (209 only)
Adjust knife projection.
Table not parallel to cutterhead. Adjust table/cutterhead parallelism.
Board thickness does
not match depth of
cut scale.
Depth of cut scale is incorrect. Adjust depth of cut scale.
Chain is jumping.
Inadequate tension. Adjust chain tension.
Sprockets misaligned. Align sprockets.
Sprockets are worn. Replace sprockets.
Machine will not
start/restart or
repeatedly trips
circuit breaker or
blows fuses.
No incoming power. Verify power connections to planer.
Overload automatic reset has not
reset.
When planer overloads on the circuit
breaker built into the motor starter, it
takes time for the machine to cool
down before restart. Allow unit to
adequately cool before attempting
restart. If problem persists, check
amp setting on the motor starter
inside the electrical box.
Planer frequently trips.
One cause of overloading trips which
is not electrical in nature is too heavy
a cut. The solution is to take a lighter
cut.
If too deep a cut is not the problem,
then 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.
Check amp setting on motor starter.
Building circuit breaker trips or fuse
blows.
Verify that planer is on a circuit of
correct size. If circuit size is correct,
there is probably a loose electrical
lead. Check amp settting on motor
starter.
Loose electrical connections.
Go through all the electrical
connections on the planer including
motor connections, verifying the
tightness of each. Look for any signs
of electrical arcing which is a sure
indicator of loose connections or
circuit overload.
24
Trouble Probable Cause Remedy
Machine will not
start/restart or
repeatedly trips
circuit breaker or
blows fuses.
(cont.)
Motor starter failure.
Examine motor starter for burned or
failed components. If damage is
found, replace motor starter. If motor
starter looks okay but is still suspect,
you have two options: have a
qualified electrician test the motor
starter for function, or purchase a new
starter and establish if that was the
problem on changeout.
If you have access to a voltmeter, you
can separate a starter failure from a
motor failure by first, verifying
incoming voltage at 230+/-10 and
second, checking the voltage
between starter and motor at 230+/-
10.
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.
Motor failure.
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 to a
quality electric motor repair shop and
have it tested.
Miswiring of the unit.
Check to confirm all electrical
connections are correct and properly
tight. Make any needed corrections.
On/off switch failure.
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.
Optional Accessories
6292621 Knives, Single-Sided (set of 4) for model 209 only
1791212 Knife Inserts (set of 10) for model 209HH only
708520 DRO Scale Retrofit Kit
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.
25
Cutterhead Assembly
26
Parts List: Cutterhead Assembly
Index No. Part No. Description Size Qty
1 ................ 6012204 .................... Nut ........................................................................... 5/16-18NC .................... 2
2 ................ 6292622 .................... Knife Locking Bar * .................................................. ...................................... 4
3 ................ VB-M59 ..................... Belt (model 209) ...................................................... ...................................... 3
.................. 209HH-1003 .............. Belt (model 209HH) ................................................. ...................................... 3
4 ................ 6292696 .................... Bolt .......................................................................... ...................................... 2
5 ................ 6292639 .................... Hex Head Bolt ......................................................... M8 x 1.25P x 20L .......... 2
6 ................ 6292631 .................... Washer .................................................................... 8 x 30 x 3 ...................... 1
7 ................ 6292660 .................... Hex Head Bolt With Washer .................................... M6 x 1.25P x 12L ........ 16
8 ................ 6292621 .................... Knife (set of 4) * ....................................................... ...................................... 1
9 ................ 6292698 .................... Hex Nut .................................................................... 5/16”-18NC ................... 2
10 .............. 6292630 .................... Machined Pulley ...................................................... ...................................... 1
11 .............. 6292633 .................... Motor Pulley ............................................................. ...................................... 1
12 .............. 6292672 .................... Collector Tube ......................................................... ...................................... 1
13 .............. 6292654 .................... Hex Head Bolt ......................................................... M6 x 1.0P x 12L .......... 10
14 .............. 6292653 .................... Washer .................................................................... 1/4 ............................... 12
15 .............. TS-1482011 .............. Hex Cap Screw ........................................................ M6 x 1.0P x 10L ............ 6
16 .............. 6292670 .................... Upper Cover ............................................................ ...................................... 1
17 .............. 6292814 .................... Flat Washer ............................................................. 8.5 x 23 x2T .................. 4
18 .............. 6292675 .................... Hex Cap Screw ........................................................ M6 x 1.0P x 16L ............ 9
19 .............. 6292682 .................... Handwheel ............................................................... ...................................... 1
20 .............. 6292684 .................... Handle ..................................................................... ...................................... 1
21 .............. 6292620 .................... Spring * .................................................................... ...................................... 8
22 .............. 6292663 .................... Chip Deflector .......................................................... ...................................... 1
23 .............. 6292652 .................... Plate Spring ............................................................. ...................................... 3
24 .............. 6292640 .................... Set Screw ................................................................ M6 x 1.0P x 16 .............. 9
25 .............. 6292662 .................... Plate Spring ............................................................. 0.6 ................................. 1
26 .............. 6292637 .................... Screw ....................................................................... M22 x 1.5P x 20 ............ 4
27 .............. 6292720 .................... Collar ....................................................................... ...................................... 1
28 .............. 6292716 .................... Bracket .................................................................... ...................................... 1
29 .............. 6292717 .................... Shaft ........................................................................ ...................................... 1
30A ............ 209HH-IPA ................ Idle Pulley Assembly – model 209HH (index no. 14,30,31,91,112) ............... 1
30 .............. 6292715 .................... Idle Pulley ................................................................ ...................................... 2
31 .............. 6292714 .................... Shaft ........................................................................ ...................................... 2
32 .............. 6292693 .................... Safety Hatch ............................................................ ...................................... 1
33 .............. 6292690 .................... Spring Pin ................................................................ 6 Dia x20 ....................... 2
34 .............. 6292689 .................... Cover ....................................................................... ...................................... 1
35 .............. 6292694 .................... Socket Head Cap Screw ......................................... M8 x 1.25P x 40L .......... 1
36 .............. 6292719 .................... Spring ...................................................................... ...................................... 1
37 .............. 6292718 .................... Hanger ..................................................................... ...................................... 1
38 .............. 6292817 .................... Round Head Screw ................................................. M6 x 1.0P x 12L ............ 1
39 .............. 6292818 .................... Hex Head Bolt ......................................................... M8 x 1.25P x 18L .......... 4
41 .............. 6292693 .................... Safety Hatch ............................................................ ...................................... 1
43 .............. 6292618 .................... Set Screw ................................................................ M10 x 1.5P x 12L .......... 8
44 .............. TS-1524031 .............. Set Screw ................................................................ M8 x 1.25P x 12L .......... 5
45 .............. 6292617 .................... Casting Head ........................................................... ...................................... 1
46 .............. 6292659 .................... Shaft ........................................................................ ...................................... 2
47 .............. 6292705 .................... Rivet ........................................................................ ...................................... 4
48 .............. 6292641 .................... Hex Nut .................................................................... M6 x 1.0P ...................... 8
49 .............. 6292661 .................... Set Screw ................................................................ M6 x 1.0 x 20L .............. 2
50 .............. 6292669 .................... Flat Head Machine Screw........................................ M6 x 0.8P x 8L .............. 2
51 .............. 6292668 .................... Cut Limiter Plate ...................................................... ...................................... 1
52 .............. 6292687 .................... Cut Limiter Pointer ................................................... ...................................... 1
53 .............. 6292685 .................... Scale ........................................................................ ...................................... 1
54 .............. BB-6206ZZ ................ Bearing .................................................................... 6206ZZ-2NSE ............... 1
55 .............. 6292629 .................... Key .......................................................................... 8 x 8 x 36 ...................... 1
56 .............. 6292619 .................... Cutterhead * ............................................................ ...................................... 1
58 .............. 6292636 .................... Spring ...................................................................... ...................................... 4
59 .............. 6292635 .................... Bushing .................................................................... ...................................... 4
* Index Nos. 2, 8, 21 and 56 are used only on the Model 209 Planer.
27
Index No. Part No. Description Size Qty
60 .............. 6292638 .................... Plate ........................................................................ ...................................... 4
61 .............. 6292658 .................... Lock Washer ............................................................ ...................................... 2
62 .............. 6292657 .................... Pressure Plate ......................................................... ...................................... 1
63 .............. 6292646 .................... Outfeed Roller ......................................................... ...................................... 1
64 .............. 6292642 .................... Key .......................................................................... 5 x 5 x 23 ...................... 2
65 .............. 6292647 .................... Sprocket .................................................................. ...................................... 1
66 .............. 6292644 .................... Washer .................................................................... 6.2 x 20 x 3T ................. 2
67 .............. 6292645 .................... Hex Head Bolt ......................................................... M6 x 1.0P x 16L ............ 2
68 .............. 6292656 .................... Bracket .................................................................... ...................................... 1
69 .............. 6292655 .................... Shaft ........................................................................ ...................................... 1
70 .............. 6292650 .................... Chip Breaker ............................................................ ...................................... 1
71 .............. 6292643 .................... Sprocket .................................................................. 31T ................................ 1
72 .............. 6292649 .................... Retaining Ring ......................................................... STW-12 ......................... 2
73 .............. 6292667 .................... Retaining Ring ......................................................... ...................................... 2
74 .............. 6292665 .................... Collar ....................................................................... .................................... 56
75 .............. 6292664 .................... Anti-kickback Finger ................................................ .................................... 55
76 .............. 6292648 .................... Locking Bolt ............................................................. ...................................... 1
77 .............. 6292666 .................... Shaft ........................................................................ ...................................... 1
78 .............. 6292651 .................... Nut ........................................................................... M12 x 1.75P .................. 2
79 .............. 6292634 .................... Infeed Roller ............................................................ ...................................... 1
80 .............. 6292706 .................... Chain ...................................................................... 06B ............................... 1
81 .............. 6292673 .................... Roller Stand ............................................................. ...................................... 3
82 .............. 6292674 .................... Roller ....................................................................... ...................................... 2
83 .............. 6292678 .................... Worm Gear Box ....................................................... ...................................... 1
84 .............. 6292677 .................... Hex Socket Cap Screw ............................................ M6 x 1.0P x 50L ............ 3
85 .............. 6292676 .................... Worm ....................................................................... ...................................... 1
86 .............. 6292681 .................... Key .......................................................................... 4 x 4 x 10 ...................... 1
87 .............. 6292679 .................... Bearing .................................................................... 6201Z ............................ 1
88 .............. 6292680 .................... Retaining Ring ......................................................... RTW-32 ........................ 1
89 .............. 6292713 .................... Collar ....................................................................... ...................................... 1
90 .............. 6292683 .................... Washer .................................................................... 1/2 ................................ 1
91 .............. 6292813 .................... Hex Socket Cap Screw ............................................ M6 x 1.0P x 10L ............ 1
92 .............. 6292821 .................... Hex Socket Cap Screw ............................................ M5 x 0.8P x 10L ............ 3
93 .............. 6292815 .................... Hex Head Bolt ......................................................... M6 x 1.
0P x 16L ............ 5
94 .............. 209-1094 ................... Sponge .................................................................... ...................................... 2
95 .............. 209-1095 ................... Pulley Guard ............................................................ ...................................... 1
96 .............. 209-1096 ................... Pulley Cover ............................................................ ...................................... 1
97 .............. 209-1097A ................. Strain Relief, Momentary Switch Cord ..................... ...................................... 1
98 .............. TS-1540031 .............. Hex Nut .................................................................... M5 ................................. 2
99 .............. TS-1550031 .............. Flat Washer ............................................................. M5 ................................. 4
100 ............ 209-1100A ................. Switch Box ............................................................... ...................................... 1
101 ............ 209-1101 ................... Switch, Off ............................................................... ...................................... 1
102 ............ 209-1102 ................... Switch, On ............................................................... ...................................... 1
103 ............ 209-1103 ................... Switch Plate ............................................................. ...................................... 1
104 ............ TS-1481041 .............. Hex Cap Screw ........................................................ M5 x 0.8P x 16L ............ 2
105 ............ 209-1105 ................... Cord ......................................................................... 1Ph, 300V ..................... 1
.................. 209-1105A ................. Cord ......................................................................... 3Ph, 600V ..................... 1
106 ............ 6012192 .................... Warning Label ......................................................... ...................................... 1
107 ............ 6292820 .................... Label ........................................................................ ...................................... 1
108 ............ 6292819 .................... Label, Lubrication .................................................... ...................................... 1
109 ............ 1791275A .................. Helical Cutterhead ** (serial no. 1702209HH4949 and higher) ...................... 1
110 ............ 1791212A .................. Knife Insert (set of 10) ** ......................................... 15x15x2.5mm ... total 100
111 ............ 15HH-2102A ............. Knife Insert Screw ** ................................................ T25P, #10-32 x1/2 .... 100
112 ............ 209HH-1112 .............. Bracket .................................................................... ...................................... 1
113 ............ TS-2361081 .............. Lock Washer ............................................................ M8 ................................. 1
114 ............ TS-1490051 .............. Hex Cap Screw ........................................................ M8 x 1.25P x 30 ............ 1
115 ............ 6292816 .................... Feed Rate Label (not shown) .................................. ...................................... 1
** Index Nos. 109, 110 and 111 are used only on the Model 209HH helical cutterhead.
28
Base Assembly
29
Parts List: Base Assembly
Index No. Part No. Description Size Qty
1 ................ 6292649 .................... Ring, Retaining ........................................................ STW-12 ......................... 1
2 ................ 6292742 .................... Gear ......................................................................... 24T ................................ 1
3 ................ 6292740 .................... Retaining Ring ......................................................... RTW-38 ........................ 1
4 ................ 6292739 .................... Bushing .................................................................... ...................................... 1
5 ................ 6292738 .................... Nut ........................................................................... ...................................... 4
6 ................ 6292741 .................... Key .......................................................................... 4 x 4 x 10 ...................... 1
7 ................ 6292737 .................... Lead Screw .............................................................. ...................................... 1
8 ................ 6292758 .................... Expansion Bend ...................................................... ...................................... 8
9 ................ 209-309 ..................... Machined Screw ...................................................... M5 x 2.12P x 10L ........ 30
10 .............. 6292756 .................... Pipe Band ................................................................ .................................... 16
11 .............. 6292735 .................... Column .................................................................... ...................................... 1
12 .............. 6292755 .................... Retaining Ring, ETW-19 .......................................... ...................................... 4
13 .............. 6292754 .................... Crane Post ............................................................... ...................................... 4
14 .............. 6285855 .................... Bearing .................................................................... 6202ZZ ......................... 4
15 .............. 6292744 .................... Retaining Ring, RTW-35 .......................................... ...................................... 4
16 .............. 6292746 .................... Sprocket .................................................................. 10T ................................ 4
17 .............. 209-317 ..................... Flat Washer ............................................................. 10 x 19 x 1.5T ............... 4
18 .............. 6292627 .................... Hex Nut .................................................................... M10 x 1.25P .................. 4
19 .............. 6292747 .................... Flat Washer ............................................................. 8.2 x 22 x 3T ................. 2
20 .............. 6292748 .................... Hex Head Bolt ......................................................... M8 x 1.25P x 25L .......... 2
21 .............. 6292618 .................... Set Screw ................................................................ M10 x 1.5P x 12 ............ 8
22 .............. 6292753 .................... Chain ....................................................................... #40 x 166P .................... 1
23 .............. 6292749 .................... Bracket .................................................................... ...................................... 1
24 .............. 6292750 .................... Shaft ........................................................................ ...................................... 1
25 .............. 6292751 .................... Sprocket .................................................................. 10T ................................ 1
26 .............. 6292752 .................... Retaining Ring ......................................................... STW-15 ......................... 1
27 .............. 6292736 .................... Lead Screw .............................................................. ...................................... 1
28 .............. 6292734 .................... Column .................................................................... ...................................... 3
29 .............. 6292733 .................... Base ........................................................................ ...................................... 1
30 .............. 209-330 ..................... Gasket ..................................................................... ...................................... 1
31 .............. 209-331 ..................... Screw ....................................................................... M5 x 0.8P x 18L ............ 2
30
Gearbox Assembly
31
Parts List: Gearbox Assembly
Index No. Part No. Description Size Qty
1 ................ 6292788 .................... Socket Head Cap Screw ......................................... M6 x 1.0P x 25L ............ 5
2 ................ 6292785 .................... Pin ........................................................................... 8 x20 ............................. 2
3 ................ 6292787 .................... Cover ....................................................................... ...................................... 1
4 ................ 6292765 .................... Bearing .................................................................... 6201 .............................. 4
5 ................ 6292768 .................... Key .......................................................................... 5 x 5 x12 ....................... 1
6 ................ 6292767 .................... Shaft ........................................................................ 18T ................................ 1
7 ................ 6292766 .................... Gear ......................................................................... 47T ................................ 1
8 ................ 6292762 .................... Gear ......................................................................... 16T ................................ 1
9 ................ BB-6204ZZ ................ Bearing .................................................................... 6204ZZ ......................... 2
10 .............. TS-1503041 .............. Socket Head Cap Screw ......................................... M6 x 1.0P x 16L ............ 1
11 .............. 6292764 .................... Flat Washer ............................................................. ...................................... 1
12 .............. 6292790 .................... Hex Socket Cap Screw ............................................ M8 x 1.25P x 50L .......... 4
13 .............. TS-1482031 .............. Hex Head Bolt ......................................................... M6 x 1.0P x 16L ............ 1
14 .............. 6292779 .................... Sprocket .................................................................. 12T ................................ 1
.................. 6292791 .................... Sprocket .................................................................. 18T ................................ 1
15 .............. 6292780 .................... Chain ....................................................................... 06B x 50P ..................... 1
.................. 209HH-415 ................ Chain ....................................................................... 06B x 53P ..................... 1
.................. 6292822 .................... Low Speed Gear Kit (includes #14-6292779 and #15-6292780)
16 .............. 6292784 .................... Knob ........................................................................ ...................................... 1
17 .............. 6292654 .................... Hex Head Bolt ......................................................... M6 x 1.0P x 12L ............ 1
18 .............. 6292769 .................... Gear ......................................................................... 71T ................................ 1
19 .............. 6292770 .................... Key .......................................................................... 5 x 5 x 10 ...................... 1
20 .............. 6292774 .................... Key .......................................................................... 6 x 6 x 40 ...................... 1
21 .............. 6292771 .................... Shaft ........................................................................ 18T ................................ 1
22 .............. 6292763 .................... Hex Socket Cap Screw ............................................ M6 x 1.0P x 20L ............ 1
23 .............. 6292778 .................... Oil Seal .................................................................... SC24 x 47 x 6 ............... 1
24 .............. 6292775 .................... Ball ...........................................................................
6 ................................ 1
25 .............. 6292776 .................... Spring ...................................................................... ...................................... 1
26 .............. 6292777 .................... Shaft ........................................................................ ...................................... 1
27 .............. 6292772 .................... Gear Assembly ........................................................ ...................................... 1
28 .............. 6292786 .................... Piece Packing .......................................................... ...................................... 1
29 .............. 6292789 .................... Oil Plug .................................................................... PT1/4”-19 ...................... 2
30 .............. 6292759 .................... Gear Box ................................................................. ...................................... 1
31 .............. 6292760 .................... Oil Seal .................................................................... ...................................... 1
32 .............. 6292783 .................... Oil Ring .................................................................... ...................................... 1
33 .............. 6292782 .................... Handle ..................................................................... ...................................... 1
34 .............. 6292781 .................... Clutch ...................................................................... ...................................... 1
32
Stand Assembly
Parts List: Stand Assembly
Index No. Part No. Description Size Qty
1 ................ 209-5001 ................... Strain Relief, Motor & Junction Box ......................... ...................................... 3
2 ................ 6292804 .................... Key .......................................................................... ...................................... 1
3 ................ 6292802 .................... Hex Nut .................................................................... M8 x 1.25P .................... 4
4 ................ TS-1550061 .............. Flat Washer ............................................................. M8 ................................. 4
5 ................ 6292651 .................... Hex Nut .................................................................... M12 x 1.75P .................. 8
6 ................ 6292683 .................... Washer .................................................................... 1/2 ............................... 12
7 ................ 6292799 .................... Adjusting Bolt ........................................................... ...................................... 2
8 ................ 6292798 .................... Collar ....................................................................... ...................................... 1
9 ................ 6292711 .................... Set Screw ................................................................ M8 x 1.25P x 8L ............ 5
10 .............. 6292797 .................... Motor Mount (model 209 only) ................................. ...................................... 1
.................. 209HH-5010 .............. Motor Mount (model 209HH only)............................ ...................................... 1
11 .............. TS-1550061 .............. Washer .................................................................... 8.5 x 23 x 2T ................. 4
12 .............. TS-1490071 .............. Hex Head Bolt ......................................................... M8 x 1.25P x 40L .......... 4
13 .............. 6292796 .................... Bar ........................................................................... ...................................... 2
14 .............. 6292794 .................... Cover ....................................................................... ...................................... 1
15 .............. 6292795 .................... Machine Screw ........................................................ M6 x 1.0P x 20 .............. 4
33
Index No. Part No. Description Size Qty
16 .............. 209-5016B ................. Magnetic Switch (model 209 only) ........................... 5HP 1PH 230V ............. 1
.................. 209-5016BC .............. Contactor (not shown) ............................................. ...................................... 1
.................. 209-5016BO .............. Overload (model 209 only, not shown) .................... ...................................... 1
.................. 209-5016C ................ Magnetic Switch (model 209HH only) ..................... 5HP 1PH 230V ............. 1
.................. 209-5016BC .............. Contactor (not shown) ............................................. ...................................... 1
.................. 209-5016CO .............. Overload (model 209HH only, not shown) ............... ...................................... 1
.................. 209-5016F ................. Magnetic Switch ...................................................... 5HP 3PH 230V ............. 1
.................. 209-5016DC .............. Contactor (not shown) ............................................. ...................................... 1
.................. 209-5016DO .............. Overload (not shown) .............................................. ...................................... 1
.................. 209-5016G ................ Magnetic Switch ...................................................... 5HP 3PH 460V ............. 1
.................. 209-5016EC .............. Contactor (not shown) ............................................. ...................................... 1
.................. 209-5016EO .............. Overload (not shown) .............................................. ...................................... 1
17 .............. 6296136 .................... Pan Head Machine Screw ....................................... #10-24NC x 1/2L ........... 2
18 .............. 209-5018 ................... Lock Knob ................................................................ 5/16-18NC x 3/4 ............ 2
19 .............. 209-5019A ................. Stand (model 209 only) ........................................... ...................................... 1
.................. 209HH-5019A ........... Stand (model 209HH only) ...................................... ...................................... 1
20 .............. TS-1490031 .............. Hex Cap Screw ........................................................ M8 x 1.25P x 20 ............ 4
21 .............. 209-5021 ................... Wheel ...................................................................... ...................................... 4
22 .............. TS-1541031 .............. Nylon Hex Nut ......................................................... M8 ................................. 4
23 .............. 209-5023 ................... Motor (209) .............................................................. 5HP, 1Ph, 230V ............ 1
.................. 209-5023F ................. Motor Fan (not shown)............................................. ...................................... 1
.................. 209-5023FC .............. Motor Fan Cover (not shown) .................................. ...................................... 1
.................. 209-5023CS .............. Centrifugal Switch (not shown) ................................ ...................................... 1
.................. 209-5023SC .............. Start Capacitor (not shown) ..................................... ...................................... 1
.................. 209-5023RC .............. Running Capacitor (not shown) ............................... ...................................... 1
.................. 209-5023B ................. Motor (209) .............................................................. 5HP, 3Ph, 230/460V ..... 1
.................. 209-5023F ................. Motor Fan (not shown)............................................. ...................................... 1
.................. 209-5023FC .............. Motor Fan Cover (not shown) .................................. ...................................... 1
.................. 209HH-5023 .............. Motor (209HH) ......................................................... 5HP, 1Ph, 230V ............ 1
.................. 209HH-5023F ............ Motor Fan (not shown)............................................. ...................................... 1
.................. 209HH-5023FC ......... Motor Fan Cover (not shown) .................................. ...................................... 1
.................. 209HH-5023CS ......... Centrifugal Switch (not shown) ................................ ...................................... 1
.................. 209HH-5023SC ......... Start Capacitor (not shown) ..................................... 800MFD 250VAC .......... 1
.................. 209HH-5023RC
......... Running Capacitor (not shown) ............................... 50F 350VAC ............... 1
.................. 209HH-5023C ........... Motor (209HH) ......................................................... 5HP, 3Ph, 230/460V ..... 1
.................. 209-5023F ................. Motor Fan (not shown)............................................. ...................................... 1
.................. 209-5023FC .............. Motor Fan Cover (not shown) .................................. ...................................... 1
24 .............. 209-524 ..................... Switch Plate ............................................................. ...................................... 1
25 .............. 209-525 ..................... Strain Relief, Stand .................................................. ...................................... 1
26 .............. 209-526A ................... Power Cord .............................................................. 1Ph, 300V ..................... 1
.................. 209-526B ................... Power Cord .............................................................. 3Ph, 600V ..................... 1
27 .............. 209-527A ................... Cord, Motor to Switch .............................................. 1Ph, 300V ..................... 1
.................. 209-527B ................... Cord, Motor to Switch .............................................. 3Ph, 600V ..................... 1
28 .............. 6292805 .................... Hex Head Bolt ......................................................... M12 x 1.75P x 60L ........ 4
29 .............. 6292757 .................... Machined Screw ...................................................... M5 x 0.8P x 8L .............. 4
31 .............. TS-0810012 .............. Slotted Round Head Machine Screw ....................... #10-24 x 1/4 .................. 1
32 .............. 209-5032 ................... Grounding Cord ....................................................... ...................................... 1
33 .............. 209-5033 ................... Cord Connection ...................................................... ...................................... 1
34 .............. 209-5034 ................... Screw ....................................................................... M5 x 0.8P x 6 ................ 4
35 .............. 209-5035 ................... Star Washer ............................................................. M5 ................................. 2
36 .............. 209-5036 ................... Strain Relief ............................................................. ...................................... 1
37 .............. 209-5037A ................. Junction Box ............................................................ ...................................... 1
38 .............. 209-5038 ................... Junction Box Cover ................................................. ...................................... 1
39 .............. PM2000-105 .............. Powermatic Name Plate .......................................... ...................................... 1
40 .............. PM2700-440 .............. Wide Stripe .............................................................. ....................... sold per ft.
41 .............. PM2700-441 .............. Narrow Stripe ........................................................... ....................... sold per ft.
42 .............. TS-0813022 .............. Pan Head Screw ...................................................... 1/4-20 x 3/8 ................... 2
43 .............. 209-5043 ................... Strain Relief, Power & Motor Cord........................... ...................................... 2
44 .............. 209-5044 ................... Strain Relief, Magnetic Switch ................................. ...................................... 1
34
Parts List: Table Assembly
Index No. Part No. Description Size Qty
1 ................ 6292724 .................... Eccentric Shaft ........................................................ ...................................... 4
2 ................ 6292679 .................... Bearing .................................................................... 6201Z ............................ 4
3 ................ 6292722 .................... Roll .......................................................................... ...................................... 2
4 ................ 6292728 .................... Knob ........................................................................ ...................................... 2
5 ................ 6292727 .................... Locksmith ................................................................ ...................................... 2
6 ................ TS-1523041 .............. Set Screw ................................................................ M6 x 12L ....................... 4
7 ................ 6292724 .................... Eccentric Shaft ........................................................ ...................................... 4
8 ................ 6292729 .................... Socket Head Cap Screw ......................................... M8 x 1.25P x 20L .......... 8
9 ................ 6292726 .................... Locking Bolt ............................................................. ...................................... 2
10 .............. 6292725 .................... Locking Bar .............................................................. ...................................... 2
11 .............. 209-2011 ................... Table ........................................................................ ...................................... 1
12 .............. 209-2012 ................... Extension ................................................................. ...................................... 2
13 .............. TS-1490041 .............. Hex Cap Screw ........................................................ M8 x 25L ....................... 6
14 .............. TS-1504041 .............. Socket Head Cap Screw ......................................... M8 x 20L ....................... 6
35
Electrical Connections – Single Phase, 230 Volt only
36
Electrical Connections – 3 Phase, 230 Volt only
4T2
ManAuto
97
A2
95
R
96
O
R
14NO
6T3
17
98
2T1
3L2
13NO
5L3
1L1
A1
37
Electrical Connections – 3 Phase, 460 Volt only
4T2
ManAuto
97
A2
95
R
96
O
R
14NO
6T3
17
98
2T1
3L2
13NO
5L3
1L1
A1
38
Preventive Maintenance
Checklist for Model 209 and 209HH Planers
[ ] Work area around machine marked off clearly.
[ ] Non-skid floor strips in area where operator normally stands.
[ ] Inspect entire machine for loose bolts, nuts, screws. Tighten and replace as necessary.
[ ] Clean table and cutterhead area, removing sawdust and chips with a soft bristle brush. Remove
gum and pitch with oven cleaner.
[ ] Lubricate appropriate places with a good grade non-hardening grease.
[ ] Clean table surface. If rusted, use paste mixture of household ammonia, a good commercial
detergent and 000 steel wool. Wash surface down with hot, soapy water, rinse and dry
thoroughly. Coat surface with talcum powder, rubbing briskly into surface with a clean blackboard
eraser.
[ ] Check blade condition; should be sharp and free of nicks or grooves.
[ ] Check belt condition. Replace as needed. Dress with belt dressing. Check belt tension.
[ ] Check motor for loose wiring and sawdust congestion, pulleys tight and in line.
[ ] Check bearings. Replace any bad or suspect bearings immediately.
[ ] Check leveling of extension tables with main table.
39
40
427 New Sanford Rd.
LaVergne, TN 37086
Phone: 800-274-6848
www.powermatic.com
