Powermatic PM2500 Series Service manual

Operating Instructions and Parts Manual
Model PM2500 Series Shaper
Model:
2700
Powermatic
427 New Sanford Road
LaVergne, TN 37086 Part No. M-708323-RU
Ph.: 800-274-6848 Revision A 03/2020
www.powermatic.com Copyright © 2017 Powermatic

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Table of Contents
Table of Contents..........................................................................................................................................2
Warnings.......................................................................................................................................................3
Introduction....................................................................................................................................................6
Specifications................................................................................................................................................6
Optional Accessories ....................................................................................................................................6
Unpacking .....................................................................................................................................................6
Shipping Contents.........................................................................................................................................7
Assembly.......................................................................................................................................................8
Cleaning ....................................................................................................................................................8
Lock Handle Assembly..............................................................................................................................8
Fence Assembly Installation......................................................................................................................8
Cutter Guard..............................................................................................................................................9
Feather Board............................................................................................................................................9
Handwheel Handle....................................................................................................................................9
Electrical Connections...................................................................................................................................9
General Information...................................................................................................................................9
Extension Cords ........................................................................................................................................9
Adjustments ................................................................................................................................................10
Fence Assembly Movement....................................................................................................................10
Ram Dial Calibration................................................................................................................................12
Spindle Gib Adjustment...........................................................................................................................13
Featherboard Hold-downs.......................................................................................................................13
Spindle Assembly Installation..................................................................................................................14
Spindle Assembly Removal.....................................................................................................................14
Shaper Cutter Installation........................................................................................................................15
Changing Spindle Speed.........................................................................................................................16
Belt Replacement....................................................................................................................................16
Precision Miter Gauge.............................................................................................................................17
Drive Belt Tension ...................................................................................................................................16
Operating Controls......................................................................................................................................18
Start/Stop.................................................................................................................................................18
Safety Key...............................................................................................................................................18
Operations...................................................................................................................................................19
Special Cuts................................................................................................................................................28
Troubleshooting ..........................................................................................................................................31
Wiring Diagrams..........................................................................................................................................46
Wiring Diagrams..........................................................................................................................................47
The specifications in this manual are given as general information and are not binding. Powermatic
reserves the right to effect, at any time and without prior notice, changes or alterations to parts, fittings,
and accessory equipment deemed necessary for any reason whatsoever.

3
Warnings
1. Read and understand the entire owner's manual before attempting assembly or operation.
2. Read and understand the warnings posted on the machine and in this manual. Failure to comply with
all of these warnings may cause serious injury.
3. Replace the warning labels if they become obscured or removed.
4. This shaper is designed and intended for use by properly trained and experienced personnel only. If
you are not familiar with the proper and safe operation of a shaper, do not use until proper training
and knowledge have been obtained.
5. Do not use this shaper for other than its intended use. If used for other purposes, Powermatic
disclaims any real or implied warranty and holds itself harmless from any injury that may result from
that use.
6. Always wear approved safety glasses/face shields while using this shaper. Everyday eyeglasses only
have impact resistant lenses; they are not safety glasses.
7. Before operating this shaper, remove tie, rings, watches and other jewelry, and roll sleeves up past
the elbows. Remove all loose clothing and confine long hair. Non-slip footwear or anti-skid floor strips
are recommended. Do not wear gloves.
8. Wear ear protectors (plugs or muffs) during extended periods of operation.
9. Do not operate this machine while tired or under the influence of drugs, alcohol or any medication.
10. Make certain the machine is properly grounded.
11. Make all machine adjustments or maintenance with the machine unplugged from the power source. A
machine under repair should be RED TAGGED to show it must not be used until maintenance is
complete.
12. Remove adjusting keys and wrenches. Form a habit of checking to see that keys and adjusting
wrenches are removed from the machine before turning it on.
13. Keep safety guards in place at all times when the machine is in use. If removed for maintenance
purposes, use extreme caution and replace the guards immediately after maintenance is complete.
14. Check damaged parts. Before further use of the machine, a guard or other part that is damaged
should be carefully checked to determine that it will operate properly and perform its intended
function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting
and any other conditions that may affect its operation. A guard or other part that is damaged should
be properly repaired or replaced.
15. Provide for adequate space surrounding work area and non-glare, overhead lighting.
16. Keep the floor around the machine clean and free of scrap material, oil and grease.
17. Keep visitors a safe distance from the work area. Keep children away.
18. Make your workshop child proof with padlocks, master switches or by removing safety keys.
19. Give your work undivided attention. Looking around, carrying on a conversation and “horse-play” are
careless acts that can result in serious injury.
20. Maintain a balanced stance at all times so that you do not fall or lean against the blade or other
moving parts. Do not overreach or use excessive force to perform any machine operation.
21. Use the right tool at the correct speed and feed rate. Do not force a tool or attachment to do a job for
which it was not designed. The right tool will do the job better and safer.
22. Use recommended accessories; improper accessories may be hazardous.
23. Maintain tools with care. Keep cutter sharp and clean for the best and safest performance. Follow
instructions for lubricating and changing accessories.

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24. Check the cutter for cracks or missing teeth. Do not use a cracked cutter or one with missing teeth or
improper set. Make sure the cutter is securely locked on the arbor.
25. Keep hands clear of the cutter area. Do not reach past the cutter to clear parts or scrap with the
shaper running. Avoid awkward operations and hand positions where a sudden slip could cause your
hand to contact the cutter.
26. Do not attempt to shape boards with loose knots or with nails or other foreign material, on its surface.
Do not attempt to shape twisted, warped, bowed or “in wind” stock unless one edge has been jointed
for guiding purposes prior to shaping.
27. Do not attempt to shape long or wide boards unsupported where spring or weight could cause the
board to shift position.
28. Always use safety devices for all operations where they can be used.
29. Be sure to check the direction of spindle rotation before use.
30. Turn off the machine before cleaning. Use a brush or compressed air to remove chips or debris —do
not use your hands.
31. Do not stand on the machine. Serious injury could occur if the machine tips over.
32. Never leave the machine running unattended. Turn the power off and do not leave the machine until it
comes to a complete stop.
33. Remove loose items and unnecessary work pieces from the area before starting the machine.
Familiarize yourself with the following safety notices used in this manual:
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 titanium dioxide which is known to
the State of California to cause cancer, and 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.

5
3
Short stock –Never shape stock less than 12
inches (304.8mm) in length without special
fixtures. Where practical, shape longer stock and
cut to size.
12 inches (304.8mm) rule –When shaping,
never allow your hands to come closer than 12
inches (304.8mm) to the cutters.
Hand safety –Never pass the hands directly
over, or in front of, the cutters (Figure A). As one
hand approaches the 12 inch (304.8mm) radius
point, remove it (or the push stick) in an arc
motion and reposition hands 12 inches (304.8mm)
beyond the cutters.
Blind cut –When blind cutting, the workpiece is
positioned on top of the template. This keeps the
cutter(s) cutting only the underside of the
workpiece and provides a "distance" guard for the
operator.
Cutter Clearance –With the power disconnected,
always rotate the spindle by hand with any new
set-up to ensure proper clearance with the cutters.
At the same time, check to be sure the cutterhead
is turning in the correct direction.
Stock feed –Feed stock opposite to the direction
of the cutter rotation (Figure B). Never back stock
out of the cutter once the cut has been started.
Instead, pull the stock straight out away from
cutter and begin the cut again.
Guide pin –Whenever possible, use a guide pin
when performing pattern shaping and collar
shaping operations.
Tool maintenance –Clean and sharp tools give
safer and better performance. Dull tools can
cause kickbacks and excessive chatter. Before
making a cut, always check the condition and
adjustment of the tools. Never use a tool that is
not balanced and rated for the selected RPM.
Spindle speed –Do not operate tools at speeds
higher than rated by the manufacturer.
Cutter selection –Use only those cutters
designed to be used on the machine, and mount
only safety type cutters on the spindle.
Stock condition –The danger of kicked-back
stock can occur when the stock has knots, holes,
or foreign objects such as nails. Warped or in-wind
stock should first be jointed on one surface before
attempting to use it on the shaper.
Figure A
Figure B

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Introduction
This manual is provided by Powermatic covering the safe operation and maintenance procedures for a
Powermatic Model PM2500 Series Shaper. This manual contains instructions on installation, safety
precautions, general operating procedures, maintenance instructions and parts breakdown. This machine
has been designed and constructed to provide consistent, long-term operation if used in accordance with
instructions set forth in this manual. 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.
Specifications
Model Number Stock Number
PM2500............................................................................................................................................1792500-RU
PM2500..........................................................................................................................................1792500-3RU
Motor............................................................................................................................................... Stock Number
3HP, 230V, 50Hz, 1 Phase ...............................................................................................................1792500-RU
5HP, 400V, 50Hz, 3 Phase .............................................................................................................1792500-3RU
Table Size (L x W) (mm)........................................................................................................................ 819 x 679
Table T-slot (W x D) (mm)..................................................................................................................19.05 x 9.53
Table Height from Floor (mm)........................................................................................................................863.6
Spindle Size (Standard) (mm).............................................................................................................................30
Router Bit Collet Size (Optional).................................................................................................1/2", 12mm, 8mm
Spindle Capacity Under Nut (mm) ................................................................................................................95mm
Spindle Travel (mm).................................................................................................................................101.6mm
Spindle Speeds (RPM)................................................................................... 4000, 6000, 8000, 10000, reversing
Table Opening Diameter (mm)....................................................................................................................160mm
Insert Opening Diameters ..............................................................................................................2-9/16", 4-5/16"
Fence Size x 2 .........................................................................................................................4-7/8" (H) x 16" (W)
Dust Collection Minimum CFM Required 4" Port..............................................................................................600
Overall Dimensions.....................................................................................32-1/4" (L) x 28-1/4" (W) x 42-3/8" (H)
Weight................................................................................................................. 550 lbs (Shipping), 475 lbs (Net)
Optional Accessories
708372 30mm Spindle
708118 Universal Mobile Base
The specifications given above were current at
time of printing, 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.
Unpacking
1. Remove box and wood crating completely
from around shaper. Check for shipping
damage. Report any damage immediately to
your distributor and shipping agent. Do not
discard any shipping material until the
Shaper is assembled and running properly.
2. Unbolt the shaper from the skid.
3. Carefully slide the shaper from the pallet
onto the floor.
The Shaper should be placed in an area
with a sturdy level floor, good ventilation and
sufficient lighting. Leave enough space
around the machine for mounting extension
wings and rail assemblies, and loading and
off-loading stock and general maintenance
work.

Shipping Contents
Compare the contents of your container with the
parts listings and illustrations on this page to
make sure all parts are intact. Missing parts, if
any, should be reported to your distributor. Read
the instruction manual thoroughly for assembly,
maintenance and safety instructions.
Main Shaper Container
Main Shaper Container
1 Cabinet and Base (A)
1 Fence Assembly (B)
Hardware
Hardware and included tools consist of the follow-
ing items:
1 Wrench (C)
1 Draw Bar (D)
1 30mm Spindle (E)
1 Spindle Nut(F)
1 Hex Wrench (G)
1 Crosspoint / Flathead Screwdriver (H)
1 Handle (J)
1 Miter Assembly (K)
1 Starting Pin (L)
2 Fence Lock (M)
1 Cutter Guard (N)
4 Lock Knob (O)
2 Flat Washer (P)
1 Safety Guard Holder (R)
2 Feather Board (S)
1 1/2" & 8mm & 12mm collets (not shown)
Hardware
8

8
Assembly
Cleaning
Referring to Figure 1:
1. Remove two hex cap screws and flat wash-
ers (A) that secure the fence assembly (B) to
the table and discard.
2. Set the fence assembly (B) aside to permit
cleaning of the table.
3. Peel away the plastic protective wrap (C)
covering the table surface.
Exposed (unpainted) metal surfaces, such as the
table top and extension wings, have been given a
protective coating at the factory.
4. Remove protective coating with a soft cloth
moistened with kerosene.
Do not use acetone, gasoline, or lacquer
thinner for this purpose. Do not use solvents
on plastic parts, and do not use an abrasive
pad because it may scratch the surfaces.
Lock Handle Assembly
1. Locate two fence locks from the hardware
package (Page 9, Item M) and disassemble.
Referring to Figure 1:
2. Place the large washers (E) on the shaft of
each lock handle (D), then insert into the
slotted openings (O) on the fence casting (P).
3. Continue the lock handle re-assembly by
placing one small flat washer (F1), followed by
the spring (G) and second small flat washer
(F2) on each shaft protruding from the bottom
of the casting (P). Place lock nuts (H) on the
threaded ends and tighten all the way (19mm
deep socket required).
When the lock nuts (H) are secured, 1/2"
(12.7mm) of thread should be visible on the
ends of the lock handle shaft (D).
Fence Assembly Installation
1. Place the fence assembly (N) on the table
(Q).
2. Line up the threaded ends of the lock handles
(D) with the threaded mounting holes (R) on
the table (Q) and secure, but allow sufficient
slack to permit the fence to be adjusted
backward and forward.
3. Place the safety guard holder (L) on the cast-
ing (P) and secure with lock knobs (J) and flat
washers (K).
Figure 1

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Cutter Guard
Referring to Figure 2:
Mount the cutter guard (A) to the safety guard
holder (H). Insert two lock knobs (B) through the
cutter guard slots and into the threaded mounting
holes (J) on the safety guard holder (H).
Feather Board
Referring to Figure 2:
Loosen lock handles (C) and slide the rail of the
featherboard so the squared edges of the
carriage bolt (D) engages in the groove (F) along
the top of the fence.
Figure 2
Handwheel Handle
Insert the handle (A, Fig. 3) into the handwheel
(B) and secure with a 14 mm wrench.
Figure 3
Electrical Connections
Electrical connections must
be made by a qualified electrician in
compliance with all relevant codes. This
machine must be properly grounded to help
prevent electrical shock and possible fatal
injury.
General Information
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.
Extension Cords
If an extension cord is necessary, make sure the
cord rating is suitable for the amperage listed on
the machine's motor plate. An undersize cord will
cause a drop in line voltage resulting in loss of
power and overheating.

10
Adjustments
When changing tools, making
adjustments, or doing clean-up and maint-
enance, always turn the machine off and
unplug the machine from its power source.
Fence Assembly Movement
Referring to Figure 4:
The adjustment controls of the fence assembly
are as follows:
A –Fence Assembly Lock Knob –to secure
fence assembly to table
B –Lock Knob –to secure the outfeed fence
C –Outfeed Ram Adjust –fine forward/backward
adjustment for outfeed fence
D –Lock Knob –loosening permits side to side
adjustment of infeed or outfeed fence
E –Lock Knob –loosening permits vertical
adjustment of guard (F)
G –Lock Knob –loosening permits
backward/forward adjustment of guard (F)
Handwheel
The handwheel controls the spindle height.
Spindle height
Referring to Figure 5:
1. Loosen the lock knob (A).
2. Turn the handwheel (B) clockwise to raise
and counterclockwise to lower the spindle
(C).
3. Tighten the lock knob (A).
Figure 4
Figure 5

11
Coplanar Alignment
Follow steps 1–5 to determine if alignment is
necessary. Steps 6–9 will guide you through the
alignment if required.
Verifying that fences are coplanar
1. Remove the guard and spindle attachment.
2. Unlock knobs D1, D2and adjust the fence
assembly (A) so it is positioned approximately
at midpoint; then secure lock knobs D1, D2.
3. Place a straightedge (H) on the table against
the infeed and outfeed fences (F1, F2).
4. Unlock the ram dial lock knob (B).
5. With the ram adjust dial (C) adjust the
position of the outfeed fence (G2) while at the
same time pressing against the straightedge
(H) and attempting to bring both fences (G1,
G2) in-line with the straightedge.
Note: The outfeed fence casting (F2) is
adjust-able while the infeed fence casting (F1)
is stationary and cannot be adjusted.
No adjustment is required if both fences (G1,
G2) are flush with the straightedge as shown in
Figure 6. Proceed to the Ram Dial Calibration
section on page 14.
Adjustment is required if the fences appear
skewed (Figure 7). Continue with the steps
below.
Coplanar Adjustment
6. Remove both fences (J1, J2) and place the
straightedge against the infeed and outfeed
fence castings (Figure 8).
Coplanar Alignment
Read step 7 completely before attempting.
7. Maintain steady pressure of the straightedge
against the fence castings (K, Fig. 8). At the
same time, attempt to bring both fences into
alignment as shown in Figure 9. This is
accomplished by alternately making
incremen-tal adjustments to two setscrews
(M, Fig. 10) on the front face of the casting (L,
Fig. 10) with a 3mm hex wrench, followed by
repositioning the casting with the ram adjust
dial (Q, Fig. 10) as required.
Important: It is recommended that the
adjustment setscrews (M, Fig. 10) be rotated
in 1/16th increments or less at a time.
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10

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Fence perpendicular to table
The outfeed fence must also be perpendicular to
the table. This can be checked as follows:
8. Place a square against the casting (L, Fig.
10) and table.
9. If adjustment is required, adjust setscrews N
(Fig. 10).
Alignment is complete when both fence castings
are coplanar (in-line) as shown in Figure 9 and
the outfeed fence is perpendicular to the table.
10. Replace both fences and secure.
Ram Dial Calibration
The cutter guard should be removed or raised to
provide clearance.
Referring to Figure 11:
1. Loosen the ram dial lock knob (B).
2. Adjust the outfeed ram dial (A) fully
clockwise.
3. With a straightedge (F) pressed against both
infeed and outfeed fences (D, E, G) as
reference, both fences should be in-line as
shown and the scale (C) should indicate zero.
If step 3 can be successfully achieved, no
calibration is required.
If the fences cannot be brought into alignment (L),
adjust as follows:
4. Remove fences (D, E).
5. Using a 10mm wrench, loosen the lock nut
(O, Fig. 10) that secures the zero stop set-
screw (P, Fig, 10) on the casting (L, Fig. 10).
6. Loosen or tighten the setscrew (P, Fig. 10),
as required, to bring fence castings into
alignment as shown in M.
Note: Ram Dial Adjust (A) is fully clockwise
(from step 2).
7. Tighten lock nut (O, Fig. 10).
If the scale (C) does not indicate zero:
8. Loosen two screws (J) that secure the
indicator (H) and adjust until the zero on the
indicator (H) is lined up with the zero on the
scale (K).
9. Tighten screws (J).
Repeat steps 2 and 3 to verify that calibration is
successful.
Figure 11

13
Spindle Gib Adjustment
Referring to Figure 12:
The spindle housing gib on your machine is
factory adjusted and initially should not require
readjust-ment. After a period of use the gib may
wear and become loose, introducing play and
potentially causing the spindle (B) to vibrate. This
requires adjustment.
To adjust:
1. With a 12mm wrench, loosen jam nuts that
secure the gib setscrews in four places (A).
2. With a 4mm hex wrench, tighten each
setscrew 1/8(3.175mm) or less turn starting
with the lowest one, followed by the
uppermost one, then the two middle
setscrews.
If this is not enough to remove the play,
repeat this step until the play is removed.
Note: If the gibs are too tight the front handwheel
that controls the spindle height will be difficult to
turn.
When adjustment is complete:
3. Hold the set-screws in position with the 4mm
hex wrench to maintain the setting while
tightening the jam nuts with the 12mm
wrench.
Featherboard Hold-downs
Referring to Figure 13:
The PM2500 Shaper comes equipped with two
featherboard hold-downs (A, B) mounted on the
infeed and outfeed fences.
1. Loosen lock handles (C) and locking handles
(D).
2. Slide the hold-down guides to the desired
position along the fence and tighten the lock
handles (C).
3. Place the workpiece (E) on the table against
the fence and under the hold-down guide (A).
4. Adjust the featherboard stay to put moderate
pressure on the workpiece, then tighten the
locking handle (D).
Figure 12
Figure 13

14
Spindle Assembly Installation
Referring to Figure 14:
The spindle assembly (B) is mounted to the
arbor (H) and secured with a draw bar (O) and
spindle nut (D). Use the following procedure to
install the spindle assembly. Reverse the order to
remove the spindle.
When changing tools, making
adjustments, or doing clean-up and maint-
enance, always turn the machine off and
unplug the machine from its power source.
1. Raise the arbor (H) all the way using the
handwheel located on the front of the cabinet.
Loosen two lock knobs (E) and slide fence (J)
to rear. Remove cutter guard (K). Loosen two
lock knobs (F) and slide guard cover (G)
back.
Locking the Arbor
2. Locate the spindle lock (L) which is
accessible through the door on the right side
of the cabinet. Pull out and rotate 90ºright or
left, resetting the knob into the indent.
Turn the arbor (H) by hand until it locks, then
verify that it will not rotate.
Installing the Spindle Assembly
3. Thread the spindle nut (D) onto the threaded
end of the spindle (C) in the direction
indicated by arrows (A1, A2). Tighten securely
by hand.
4. Thread the spindle assembly (B) and nut (D)
onto the arbor (H) and hand-tighten only.
5. Insert the draw bar (O) through the opening in
the shaft (N) just below the drive belt (M).
Turn clockwise, fastening and securing it to
the spindle. Tighten the draw bar (O) with
spindle wrench (Inset A).
6. Tighten the nut (D) with the spindle
wrench provided (Inset A).
Shaper Cutter installation is described on the
following page. Note that at this time the arbor
is still locked.
Spindle Assembly Removal
Referring to Figure 14:
The arbor must be locked as described in Spindle
Attachment Installation, step 2.
1. Remove the draw bar (O).
Figure 14

15
2. Loosen the spindle nut (D) then, using the
spindle wrench (Inset A) continue to turn until
the spindle breaks free of the arbor.
Shaper Cutter Installation
Note: Spindle installation is described in the
previous section.
When changing tools, making
adjustments, or doing clean-up and maint-
enance, always turn the machine off and
unplug the machine from its power source.
Locking the Spindle
1. Locate the spindle lock (L, Fig. 14) accessible
through the door on the right side of the
cabinet. Pull out and rotate 90º right or left,
resetting the knob into the indent.
Attempt to turn the spindle assembly
(B, Fig. 14) by hand to verify that it is locked
and will not rotate.
Installing the Shaper Cutter
Referring to Figure 15:
2. Using an 8mm hex wrench (provided),
remove the socket head cap screw (F).
3. Remove the washer (E), keyed collar (C) and
all or as many collars (B) as necessary.
4. Place the shaper cutter (A) (not included)
onto the spindle, oriented in the proper
direction.
5. Place the collars (B) and keyed collar (C)
onto the spindle.
Note: Collars come in several widths and the
stacked selection (B) must be such that the
top of the keyed collar (C) sits slightly above
the top of the spindle (D). This will ensure
sufficient pressure to properly secure the
shaper cutter (A) when installation is
complete.
6. Replace the washer (E) and socket head cap
screw (F). Tighten screw with the 8mm hex
wrench provided.
Unlocking the Spindle
7. Pull out the spindle lock (L, Fig. 14)
accessible through the door on the right side
of the cabinet. Rotate 90º right or left,
resetting the knob into the indent.
Using gloves to prevent injury from the
shaper cutter, turn the spindle assembly by
hand to verify that it turns freely.
Figure 15

16
Changing Spindle Speed
The PM2500 Shaper is equipped with pulleys that
allow you to change the spindle speed. The belt
placed on the upper pulleys as shown in position
B (Fig. 16) provides a 10,000 RPM spindle
speed. Spindle speed for all belt positions are
listed in Table 2 below.
*Belt Position
Spindle Speed
B
10,000 RPM
C
8,000 RPM
D
6,000 RPM
E
4,000 RPM
* Refer to Figure 14
Table 2
To change speed (refer to Figure 16):
1. Disconnect the machine from the power
source.
2. Open the door of the cabinet.
3. Remove the belt tension by moving the belt
tension handle (A) to the unlock position. This
allows the motor (G) to swivel on its mounting
hinge.
4. Move the drive belt (shown in the B position)
to the C, D, or E positions for the spindle
speed desired as determined in Table 2.
5. Lock the belt tension handle (A) which
secures the motor (G) and places tension on
the drive belt (K).
Belt Replacement
Referring to Figure 16:
Replace the drive belt (K) as follows:
1. Disconnect the machine from the power
source.
2. Open the door of the cabinet.
3. Remove the belt tension by moving the belt
tension handle (A) to the unlock position. This
allows the motor (G) to swivel on its mounting
hinge.
4. Work the drive belt down all the way past the
pulleys.
5. Continue sliding the belt down on the left side
until it is free of the bottom pulley (E), then
remove the belt over the top of the motor
pulley (B).
6. Install the new belt by following these steps in
reverse
Figure 16
Drive Belt Tension
Referring to Figure 16:
The drive belt should have sufficient tension to
prevent slippage when the machine is in
operation. If the tension on the belt needs
adjustment:
1. Disconnect the machine from the power
source.
2. Open the door of the cabinet.
3. Locate the belt tension assembly (F) and
loosen the lock nut (H, inset) with a 17mm
wrench.
4. Adjust the hex bushing (J) with a 17mm
wrench (refer to inset for adjustment
direction) for proper tension on the belt (B).
The tension handle (A) must be in the locked
position (right) while performing this step.
Note: Two 17mm wrenches are required for the
next step.
5. Maintain the position of the hex bushing (J)
with one wrench while tightening the lock
nut (H) with the other.

17
Precision Miter Gauge
Setting the miter gauge angle
Referring to Figure 17:
The precision miter gauge has a rack and pinion
adjustment for setting the angle. To operate:
1. Slide the miter gauge into one of the slots on
the table top.
2. Loosen lock handle (A).
To adjust the body (B) of the miter gauge to the
desired angle:
3. Pull the spring-loaded knob (C) out and turn
until the body (B) of the miter gauge is at the
desired angle as indicated on the scale.
4. Tighten the lock handle (A).
Indent settings
There are indents at the 0º, 30ºand 45ºright and
left positions. At these settings, release the
knob (C) to engage the stop rod. Then tighten the
lock handle (A).
Note: Do not rely solely on the indents for an
accurate setting. After the stop rod engages at
the 0º, 30º and 45º positions, make a fine
adjustment with the knob (C) by pulling out and
rotating, if necessary, setting it against the scale
indicator.
Extension plate
The extension plate (D) can be adjusted by
sliding to the right or left or removed entirely.
To adjust –loosen two lock handles (E), position
the extension plate and tighten the lock handles.
To remove –slide the extension plate completely
off and remove the lock handles (E) and
mounting hardware.
Calibrating the miter gauge
1. Place the miter gauge in one of the slots (H)
on the table top.
2. Set the miter gauge to 90º (0º setting on the
scale) by loosening the lock handle (A), then
pulling the spring-loaded knob (C) out and
turning the body (B) until 0º is indicated on
the scale (F).
3. Measure the accuracy of the gauge against
the slot with a combination square.
If adjustment is necessary:
4. Adjust the body (B) until it is perfectly square
(90º) to the miter slot (H).
Figure 17
5. Tighten the lock handle (A).
Verify that the scale indicator (G) reads 0º. If
further adjustment is necessary:
6. Loosen the screw (F) and adjust the
indicator (G) until it reads 0º
7. Tighten the screw (F).

18
Operating Controls
Start/Stop
Power Indicator Light –The start switch has a
power indicator lamp which is on whenever
there is power connected to the shaper, not
just when the shaper is running. Do not assume
that no light means there is no power to the
machine. If the bulb is bad, there will no
indication. Always check before use.
Do not rely that no light
means no power to the machine. Always
check for power first. Failure to comply may
cause serious injury!
Referring to Figure 18:
Start –Press the green start switch (see Note).
When power is connected to the machine, the
green light is always on regardless of whether
the shaper is running or not.
Note: In addition, the switch on the digital
readout must be set to forward (or reverse) and
the cabinet door must be closed.
Stop –Press the red switch to stop.
Reset –In the event that the shaper stops
without pressing the stop button, as the result of
a tripped fuse or circuit breaker, etc.:
1. Press red button to reset
2. Press the green button to restart the
machine.
Figure 18
Safety Key
The start/stop switch on the PM2500 Shaper
comes equipped with a magnetic safety key.
When in place on the switch as shown in
Figure 18 the magnetic safety key trips a relay
which will allow the machine to start and stop
when the respective switches are pressed.
Being magnetic, the lock can be removed to
make the machine inoperable and can be
hidden for safe storage by attaching it
underneath the rail or another magnetic surface.
When using the shaper, place the key on the
switch cover lining up the arrow on the key with
the REMOVE arrow on the cover. Then rotate
the key so the arrow lines up with the LOCK
arrow. This will prevent the safety key from
coming loose from vibration when the machine
is in use.

19
Operations
Overview
Before applying power to the machine, Check the
motor and switch wiring diagrams for proper
voltage connections. Check that all mounting
screws and bolts are tight.
Turn on the motor momentarily to check for proper
rotation. The spindle should rotate counterclock-
wise when looking down on the spindle. Correct as
required.
Run the machine for a short period of time to
ensure that the moving parts are working properly
with no excessive vibration. If a problem develops,
correct it before turning the shaper over for general
use.
Safety Devices
Safety devices such as guards, fixtures, templates
hold-downs, push sticks (Figure 19), feather
boards and power feeders should be used
whenever possible. Figure 19 shows a push stick
which can be easily made from scrap wood.
Note: For the sake of clarity, the shaper guard has
been omitted from most illustrations. All shaper
operations must be done with the proper guard in
place and any other device which insures the
safety of the operator.
Grain Direction Considerations
Plan to shape the workpiece in the same direction
as the grain when possible. Some open grain
woods (such as redwood, fir and oak) will leave a
rough, or slightly splintered edge when cut against
the grain.
Figure 19
Deep cuts require excessive
horsepower and pushing force to control the
cut.
Deep cuts can also cause the wood to splinter or
split and may lead to lost control or personal injury.
Preband shaper the stock whenever possible to
1/16 inch (1.58mm) of finished size. When an edge
finish is unsatisfactory, take two or more cuts with
the final cut no more than 1/16 inch (1.58mm)
deep.
In the case of shaping across the grain, the trailing
board edge will often splinter. To correct this, the
best solution is to make the board 1/4 inch
(6.35mm) oversize in width, shape the board, and
simply trim off the excess.
Cutter Rotation
Counterclockwise Setup –With the cutter installed
as shown in Figure 20, feed the workpiece from
right to left.
Figure 20
Clockwise Setup –With the cutter installed as
shown in Figure 20, feed the workpiece from left to
right.
Figure 21

20
Using the Fence
Using the fence is the safest and most satisfactory
method of shaping, and should always be used
when the work permits. Almost all straight work
can be used with the fence.
For average work, where a portion of the original
edge of the work is not to be touched by the cutter,
both the front and rear fences are set in a straight
line as shown in Figure 22.
When the shaping operation removes the entire
edge of the work, e.g. in jointing or making a full
bead, the shaped edge will not be supported by
the outfeed fence when both fences are in line,
Figure 23. In this case, the stock should be
advanced to the position shown in Figure 21 and
stopped. Turn off the machine and move the
outfeed fence forward to contact the workpiece,
Figure 24. Remove the workpiece, start the motor,
and then continue the operation.
Always remove workpiece
before starting the machine! This will prevent
kickback and potential serious injury.
Figure 22
Figure 23
Figure 24