Powermatic 209-1 Service manual

Operating Instructions and Parts Manual
20-inch Planer
Models 209 and 209HH
Powermatic
427 New Sanford Road Part No. M-0460283
LaVergne, TN 37086 Revision H 06/2017
Ph.: 800-274-6848 ECR 161019105259
www.powermatic.com Copyright © 2017 Powermatic

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.

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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..............................................................................................................................38

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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.

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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.
Health hazards. 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 to avoid inhaling dust generated from wood
products.
Wood products emit chemicals known to the State of California to cause birth defects or other
reproductive harm. (California Health and Safety Code Section 25249.6)
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.

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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 (10,12,19mm) – provided
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 12mm 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.