Powermatic 511 User's Manual
Contents
1. 1 22 20402215 RE 216 2750008 1 9 RANNO DISE RSR te 2 LISE 4 2 INA PIN BACKE aires A ne 1 3268220 1 3064730 ersin HANAB ICKE Cosa A rate 1 320008 ss RS cece ete eee Ce CR Re 1 29 3088029 Counterbalance Channel 1 SAR 3848016 Counter Weight ss 1 3070250 PUIS BUSTIN ae paces a 1 sacs 3064741 Pulley Mounting Bracket 1 34 3064742 Pulley Mounting Bracket 1 6715289 BOL eae 8 6861301 Flat Washer 24 6516002 Nylon Loc 3 8 16 30 6716216 SCFEW 3 8 16 X 3 1 2 2 9 6716217 SCFEW nine 3 8 16 X 2 1 2 12 AO 6516028 Wing NO eee 3 8 16 2 A Socket Head Cap Screw 5 16 18 X 1 6 42 0861200 encase IO 15 AS 9 OCR RO2. DO de 306278 Brush Cap 2 DR tues 315286 Stud 350005 Plug Button Otis 23334 Gasket 352115 24 Bearing Plate OS 25245 Oil Seal 352091 Guard Plate 266 59 2 Snap Ring OO ae 952086 Saw Blade Oh Cord Clamp Inner 229952 Screw 2 901964 anne 292059 Motor Housing 6475009 AWARNING Electrical repairs should be attempted only by trained repairmen Contact the nearest SKIL Service Center or other competent repair service 2 62 Oden EXAMPLE THE COMPONENT PARTS small ref no s 38 ARE INCLUDED WHEN ORDERING THE ASSEMBLY PART LARGE REF NO 31 a 0 82 Powermatic Part No 6861260 6861261 6861262 6861258 6861257 6861256 9 CS Short Panel Fence Optional Accessory The Short Panel Fence is designed as an aid in cutting short panels by bringing the panel up to waist height The Fence fits on both the left and right sides of the panel saw which gives support when cutting Figure 23 shows the components of the Short Panel Fence Part No Description Size Qty 2
3. rere ae 1 44 SOCKEL 1 a 6108003 PO 2 Eye 1 4 20 w 2 Ps 6514022 POLOG NUT 2 6514011 AN AO oe 1 Ce 6714269 lex ead anaes 1 4 20 X 3 4 4 0714015 SC ee 1 4 20 X 1 2 2 che 80 3133 1 D 6515001 eee 16 Re 686120 18 DA 6 16030 Cl OW 3 8 16 X 3 4 14 S 6430052 ISO SR 1 Index No Part No Description Size Qty 5918142 SONNO 1 DA 6430050 LOCKING KNOD 1 DO ee 6716210 sus Cad sn eee OIG 10 2 20634 less Motor Bracket Strain Relief Assembly 1 6823020 MACAO ONPE 2 inches Glisse 3998060 ss Tapered te re ts 1 6646048 CouM rbalanee a 1 6 6102053 Nylon Coated Cable 1 64 6710154 Self Tapping 10 24 6 OS 6640017
4. Screw 25 Eee 2 Ball Bearing 2 20 23390 Seal Collar e 329927 Oil Seal 35209 Gear Housing 30 353289 Screw 4 PSS CORRE Expansion Chamber 23336 Cover Plate 23318 Fan CT 329954 Screw 4 329929 Screw 166 Ball Bearing OT A 4521 Loading Spring Washer Se 32993 7 Armature O a h Washer 40 319494 Rubber eae 316596 Terminal 3 A 329940 Brush Holder 2 6861259 329947 Field AO ES tae Terminal 2 AL oa 329956 Terminal 2 48 4459 Loading Spring Washer SR 118488 Ball Bearing See 5 JO Screw Ground to housing 1 Oil Seals and rings must be prelubricated before installation Matched set Ref 13 2 To obtain proper nut tension torque nut to 90 100 in lbs then back off 1 4 turn To replace 315286 stud in stripped housing use 13440 oversized stud 4 convert to 5 8 rd arbor use 6861256 outer washer and 6861257 inner washer 30 Index No Part No Description 320881 and Plug BOO Strain Relief 27039 Set Screw 2 DL ete 320391 Brush and Spring 2
5. te a ee ne 13 UD CS SI LES ere eee 14 Chanana HAC 14 15 16 aie 18 Replacement D a da D D to io onda 20 Parts List 511 Panel 21 511 Panel Saw iii 24 511 Panel Saw Motor with Pushbutton Assembly 2475002 26 511 Panel Saw Dust Collection System iii 27 Electrical Connections ceceeeese cece eeseeeeseeeseeeseeeesseesseeesaeeeseueesaueesaueeseeeesaneesaes 28 S B Factory Service Centers 29 Parts List Skilsaw Model 586 Type 2 511 Panel Saw 30 Short Panel Fence Optional 32 Installation of Short Panel Fence iii 32 OptionalsACCeSSOn eS 8 34 Adjustable Stop Optional Accessory ccccccceeccceececeeeeseeeeseeceeeeeeseeeeseeeseeeseeeeseeeseeeseeeesaeeesaneesaeeeeaes 34 Warnings 10 11 12 13 17 18 19 Read and understand the entire owners manual before attempting assembly or operation Read and understand the warnings posted on the machine and in this manual Failure to comply with all of these warnings may cause serious injury Replace the warning labels if they become obscured or removed This panel saw is designed and intended for use by proper
6. 2 106 sis 30609020 D 1 1092 3069024 BOOM nd dou 1 MO 3069025 BUSA ROGE ion 1 90690260 Side Brush 6 ena etn nn 1 2069027 STFS LS do one 1 113 3069028 Right Side Brush Holder 1 114 6710063 Button Socket Head Cap Screw 10 24 x 1 2 8 115 6510015 Hex Nylon Lock 10 24 8 116 1032 HOSE AM 1 Index No Part No 117 6940064 6 1317 a S JW1015 1203 JW1022 121523 3064748 122 6821498 129 ss 6860801 Description Size Qty 7 Hose Clamp 4 2 1 Y FUNG OY cabs ses Re 1 Hose Clamp Worm 4 1 1 External Tooth 1 23 511 Panel Saw refer to parts list pages 21 23 63 9 24 88 right side A 51 25 511 Panel Saw Motor with Pushbutton Assembly 2475002 refer to parts list page
7. E 18 66 6687015 Tape Scale 2 OP mn 3069021 Carriage Brush Assembly Items 107 thru 113 1 68 3076230 Roller een ce nee amande oc 4 69 6284104 Cable ss iii 4 TO 6330009 Grip FOAM 1 ge 6400012 Insert Threaded 5 16 18 2 A 6164014 1 2475003 1 Ass 681 206 SE conan 4 erent eee 6821497 DSC 1 cee 6823018 ONE ee 5 ft 6710014 Socket Head Cap Screw 10 24 x 3 8 Lg 1 6601823 Nylon XT 1 16 2 E Fead 1 4 20 x 7 8 Lg 1 ce 6930004 Connector DUPIEX nn 1 6861101 RE eee ee 1 3408265 1 el 1 31190802 LABEL a do
8. 800 815 8665 ADDRESS 2729 W McDowell Road 1290 N Grove 780 A South Milliken Avenue 4191 A Power Inn Road 8898 Clairemont Mesa G 2130 De La Cruz Blvd 678 Bryant Street 3728 Phillips Highway 2 16171 N W 57th Avenue 5133 W Cypress Street 5717 Peachtree Indust Blvd 197 Sand Island Access Road 5526 N Milwaukee Avenue 608 W Lake Street 7805 Frontage Road 192 Vanderbilt Avenue 5029 Garrett Avenue 24405 Halsted Rd 2225 University Avenue 1922 Innerbelt Business Ctr Dr 4203 South Blvd 20 Truman Dr South 131 27 31st Avenue 600 W Manlius Street 1245 Tennessee Avenue 5541 Canal Road 623 S E 12th Avenue 333 E Hunting Park Avenue 3221 Liberty Avenue 2457 Walnut Ridge 4930 Dacoma Suite D 1333 A Azalea Garden Road 29 ZIP 85009 92806 91761 95826 92123 95050 80204 32207 33014 33607 30341 96819 60630 60101 66204 02062 20705 48335 95114 63114 28209 08817 11354 13057 45229 44125 97214 19124 15201 75229 77092 602 272 1302 714 630 9461 602 714 909 916 619 292 5202 408 727 8220 303 595 8878 904 396 7028 305 628 3627 813 289 9841 770 451 6365 808 773 630 913 773 774 0892 630 543 4005 913 381 3831 617 255 1836 301 595 4917 810 476 2259 612 645 0656 314 427 2666 704 527 3746 908 572 2265 718 461 0350 315 437 6026 513 641 2501 216 447 0760 503 234 4138 412 261 6468 972 2
9. The adjustable rollers have an eccentric hub Turning the roller when the roller nut is loose changes the position of the roller Turn the roller until it touches the Straightedge making sure the straightedge does not bend NOTE The roller panel may have to be loosened in order to turn the roller See Figure 18 4 When the roller is positioned tighten the roller nut NOTE If a fixed roller has been replaced the above procedure should be repeated 5 Leave the test square clamped to the rollers for the next step Figure 17 LOOSEN NUT OPPOSITE ROLLER LOOSEN ROLLER PANEL IF NECESSARY Figure 18 Step 2 Align Guides AWARNING Disconnect saw from power source before aligning the guides If the saw does not cut at 90 degrees the guides may not be perpendicular to the rollers Adjust as follows 1 Make sure the rollers are aligned 2 Remove the blade guard and mark a blade tooth as a reference NOTE If the saw has a high speed steel blade mark a tooth that points toward the edge of your test square which is still clamped above the rollers 3 Pull the carriage down until the reference tooth of the blade just touches the vertical edge of the test square Figure 19 Continue pulling the carriage down if the blade does not contact the square or the blade binds on the square the guides are not aligned properly 4 Loosen the guide bracket nuts Figure 20 but do not remove the bracket With a dead
10. alignment 3 For best results place material to be cut onto the Panel Saw with the back side facing the operator This will provide the smoothest possible cut on the face side of the panel Panels being cut horizontally ripping must always be fed against the rotation of the saw blade Do not force the saw It will perform better and can be more easily controlled if allowed to work at the rate for which it was designed 6 Ifthe saw is stopped in mid cut allow the blade to stop Then back up the saw if crosscutting or the board if ripping and restart the saw to continue the cut 7 Thin material such as paneling should be properly supported over its length to prevent binding in the blade 8 Panel Saws are designed to cut large panels down to size As the overall panel size becomes smaller and smaller other types of sawing machines can become more convenient and safer to use 511 Panel Saw Features Pulley with enclosed true counterweight L Stainless steel guide tubes Vertical crosscut ruler Dust hose Adjustable stop Horizontal rip ruler Steel panel rollers One piece steel carriage Lower dust outlet FIGURE 2 Introduction This manual is provided by Powermatic covering the safe operation and maintenance procedures for a Model 511 Vertical Panel Saw This manual contains instructions on installation safety precautions general operating procedures maintenance instructions and pa
11. facing out c Align the left side of the bracket with left end of the horizontal cross member Note There should be approximately a 1 2 gap between the bracket and the right end of the horizontal cross member as Figure 25 shown in Figure 25 32 Step 2 With a power drill attach the fence bracket to the vertical cross members with the mounting screws provided The mounting screws provided are self tapping Note The fence bracket is pre drilled for mounting Step 3 Attach the fence mounting bracket to the back side of the panel saw frame as shown in Figure 26 The edge of the mounting bracket should be approximately 5 8 from the edge of the fence bracket Note The center of the mounting hole on the fence bracket should be aligned with the center of the mounting bracket Using a power drill attach one end of the mounting bracket to the horizontal cross member on which the fence bracket is sitting and attach the other end to the next horizontal cross member above it MOUNTING BRACKET APPROX 5 8 L H FENCE BRACKET Figure 26 Step 4 Once the mounting bracket has been secured return to the front of the panel saw and secure the right end of the fence bracket to the mounting bracket with the mounting screws provided Step 5 With a tape measure check the distance from the blade to the right end of the fence bracket The distance should be approximately 4 1 2 Note The scale on
12. our inspection discloses a defect we will either repair or replace the product at our discretion or refund the purchase price if we cannot readily and quickly provide a repair or replacement We will return the repaired product or replacement at WMH Tool Group s expense but if it is determined there is no defect or that the defect resulted from causes not within the scope of WMH Tool Group s warranty then the user must bear the cost of storing and returning the product This warranty gives you specific legal rights you may also have other rights which vary from state to state WMH Tool Group sells through distributors only Members of the WMH Tool Group reserve the right to effect at any time without prior notice alterations to parts fittings and accessory equipment which they may deem necessary for any reason whatsoever Table of Contents AO E AA O ne 2 WV UNINC 4 ee eee eee 7 7 eee 8 OCTO a a a eee Ga Ca eee ee eee eee eee ete on eee es 9 SDE CAOR 9 Ol 8 a i alae ei ole allele 10 UDC AUN oe 10 8 E 10 EXEN TOMT a D 11 OPE aO anae 11 En cn ue 12 CO SCONO 12 Reena en ene
13. square Repeat the above steps for the crosscut ruler on the other side Make a test cut to verify that the ruler is lined up correctly INNER FLANGE OUTER ARBOR FLANGE BOLT Figure 15 LL CEE ELLE 3 LLLE LI LEE RE RULER Figure 16 Alignment If the saw ever needs realignment it should be performed in the following order 1 Align rollers 2 Align guides perpendicular to rollers 3 Align blade parallel to guides To ensure accuracy over the full movement of the saw construct a test square as follows Figure 17 Use a 6 foot metal ruler and two 4 foot metal rulers using the 3 4 and 5 ft measurements ensures squareness Drill holes and attach the rulers with pop rivets or small nuts and bolts The 6 foot ruler is used to check squareness of the rollers The 4 foot ruler is used to check squareness of the guide tubes Step 1 Align Rollers The two outermost rollers are fixed so adjust all other rollers to them Place the 6 foot edge of the square across the rollers to check for alignment The edge of the square should touch all rollers If it does not adjust as follows 1 Clamp the straightedge to the top of the outermost rollers and flat to the frame Position the clamps above the outermost rollers 2 Turn each roller to ensure it does not jam or have excessive clearance from the straightedge If this occurs loosen the roller nut shown in Figure 18 3
14. 47 0447 23502 757 857 4560 315 513 216 503 215 291 9907 412 972 713 757 MANAGER Brian Cherry Frank Bandera Bill Kelley Karen Jo Hall Mike Bergel Darrell Wheeler Don Jordan Dennis Soucek Fabian Arienti Bob Bellott Tim Coe Bob Rios Daniel Gunderson Rick Britton Jack Nielsen Pat Schmidt Ron Bachmann Dennis McCollum Mike Brody Dick Murphy Dan DeJoe Don Robertson Robert Penett Phil Lawther Gregory Weil Joe Carley Joe Oravec Wayne Phillips Jack Hamilton Jeffrey Watts James Flint Chris Chinn Dave Easter Parts List Skilsaw Model 586 Type 2 511 Panel Saw NOTE For all parts and service on the Skil worm drive motor please contact the Skil service center near you from the list on page 29 Index No Part No Description Powermatic Part No lasse 325089 Bearing Cover Washer 2 Lock Pin Bushing SUR DIE IEEE S200 Lock Pin D 44638 Ring Geer PENE 23994 spring Flat Washer O Ring 318324 Self Locking Nut ASS LEE Ball Bearing Su 24 Worm amp Saw Shaft Assy 2 Lock Washer 2 His 3290959 Screw 2 sis 44639 Ring ZO OOF Oil Plug 34180988 Screw 3 2 140 ec Screw 2 2 Screw 4 903859 Hood
15. 721005 Short Panel Shelf Assembly 3064729 Short Fence Brackel RH E 1 3064730 Short Panel Fence Bracket LH 1 3064731 Short Panel Fence Midway 2 3596135 Side Plate Shelf LS 2 3745051 A Sl cag anne a ae ee ee 10 6516002 Hex Lock 3 8 16 10 6687015 2 6716035 Hex Head 3 8 16 x 1 3 4 Lg 10 6746023 Hex Washer Head Screw Self Tapping 1 4 20 x 5 8 Lg 10 6861301 Washer 10 FENCE BRACKET LEFT HAND SHOW L H FENCE BRACKET ALIGN BRACKET FLUSH WITH EDGE OF CROSS BAR Figure 23 SHELF placed here for spacing only Installation of Short Panel Fence Step 1 a On the left side of the panel saw temporarily place the fence shelf on top of the horizontal cross member of the panel saw frame which is approximately 30 from L H the floor See Figure 24 This will space FENCE the left hand fence bracket the correct BRACKET distance off the horizontal cross member b Place the left hand fence bracket bracket with scale reading right to left on top of the fence shelf with the scale side of the bracket
16. Fence is not being used the shelf can be stored behind the fence bracket Optional Accessories Part No Description 2721005 Short Panel Fence Shelf Assembly 6080149 CMT Saw Blade 6080150 Amana Saw Blade 6819003 Adjustable Stop RH 6819004 Adjustable Stop LH Adjustable Stop Optional Accessory The Adjustable Stop has a 66 scale and is available in right hand or left hand versions It mounts to the bottom rail of the panel saw as shown ADJUSTABLE STOP RIGHT HAND SHOWN 34 39 POWERMATIC WMH Tool Group 2420 Vantage Drive Elgin Illinois 60123 Phone 800 274 6848 www wmhtoolgroup com
17. POWERMATIC WMH TOOL GROUP Operating Instructions and Parts Manual Vertical Panel Saw Model 511 WMH TOOL GROUP 2420 Vantage Drive Elgin Illinois 60123 Part No M 0460280 Ph 800 274 6848 Revision D 1 05 www wmhtoolgroup com Copyright WMH Tool Group This manual has been prepared for the owner and operators of a Powermatic Model 511 Panel Saw Its purpose aside from machine operation is to promote safety using accepted operating and maintenance procedures To obtain maximum life and efficiency from your panel saw and to aid in using it safely please read this manual thoroughly and follow the instructions carefully Warranty and Service WMH Tool Group warrants every product it sells If one of our tools needs service or repair one of our Authorized Repair Stations located throughout the United States can provide quick service or information In most cases a WMH Tool Group Repair Station can assist in authorizing repair work obtaining parts or perform routine or major maintenance repair on your Powermatic product For the name of an Authorized Repair Station in your area please call 1 800 274 6848 or visit our web site at www wmhtoolgroup com More Information Remember WMH Tool Group is consistently adding new products to the line For complete up to date product information check with your local WMH Tool Group distributor or visit our web site at www wmhtoolgroup com WMH Tool Group Warranty WMH To
18. ally 2 Loosen carriage locking knob and move carriage to the top of the guides 3 Move the adjustable stop shown in Figure 10 to the measurement on the horizontal scale either left or right side of carriage that matches the desired width of your cut 4 Place the workpiece on top the rollers DO NOT DROP it on the rollers AT LEAST 2 ROLLERS CROSSCUTTING Figure 8 AT LEAST 4 BEYOND CARRIAGE CROSSCUTTING with Short Panel Fence Figure 9 Figure 10 12 5 Slide workpiece into position against the adjustable stop while double checking the cut size via the crosscut rulers Make sure workpiece is adequately supported Use one hand to guide it AWARNING Do not hold workpiece so that your hand is behind the carriage or guides or near the path of the blade 6 Start motor and allow it to reach full speed 7 Pull carriage down slowly and smoothly as the blade moves through the workpiece Keep one hand on the handle at all times and do not force the saw NOTE If the blade binds in the workpiece or the workpiece shifts during the cut stop the motor return the carriage to the top of the guides restart motor and then begin the cut again 8 Support and remove the cut off piece as the saw completes its cut 9 Once the cut is complete turn off the motor and wait for the blade to come to a full stop NOTE A coasting saw blade can mar the edge of a freshly cut workpiece 10 Remove
19. ance with all codes and ordinances If the machine should electrically malfunction or break down grounding provides a path of least resistance to carry electricity away from the operator reducing risk of electric shock The grounding prong on the plug is connected through the green wire inside the cord to the grounding system in the machine Locking Figure 4 THREE PRONG PLUG GROUNDED OUTLET GROUND GROUNDING PRONG Figure 5 The green wire must be the only wire connected to the machine s grounding system and must never be attached to an electrically live terminal A temporary adapter shown in Figure 6 can be used to connect a grounded plug to a two prong outlet The green rigid ear or lug extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box or receptacle Simply remove the center screw from the outlet insert the adapter and re attach the screw through the grounding ear to the outlet If in doubt of proper grounding call a qualified electrician A temporary adapter should only be used until a properly grounded outlet can be installed by a qualified electrician The Canadian Electrical Code prohibits use of temporary adapters Extension Cords Grounded tools require a three wire extension cord As the distance from the supply outlet increases a heavier gauge extension cord must be used Using extension cords with inadequately size
20. blow mallet strike the bracket on the side in the direction you want the guides to go Do not strike the guides 5 Confirm the squareness of guides to rollers as described above When satisfied re tighten guide bracket nuts STEP 3 Align Blade Parallel to Guides The blade must move parallel to the guides or tail burning may occur and the kerf may be wider than the set of the blade Always adjust the rollers and guides before adjusting the blade To check for blade alignment 1 Make sure rollers and guides are aligned first 2 the blade heels or leaves burn marks the cut move the carriage to a crosscut position and make a test cut Examine both sides of the cut to determine which side of the blade is causing the problem Disconnect power from the saw Place your test square on the rollers and lower the carriage so the test square overhangs the blade 5 Place the test square against the blade The entire face of the blade should contact the test square if it does not the blade is in need of alignment Figure 20 SLIDE REFERENCE TOOTH ALONG SQUARE Guide Bracket 6 Loosen but do not remove the two nuts holding the indexing pin assembly See Figure 21 7 burn marks appear on the side of the workpiece rotate saw clockwise until entire face of blade contacts your straightedge If burn marks appear on the right side of workpiece rotate saw counterclockwise until ent
21. d wire causes a serious drop in voltage resulting in loss of power and possible tool damage Figure 7 shows recommended gauges The smaller the gauge number of the wire the greater capacity of the cord for example a 12 gauge cord can carry a higher current than a 14 gauge cord If one extension cord is used for more than one tool add their nameplate amperes and use the sum to determine the required minimum wire size If you are using an extension cord outdoors be sure it is marked with the suffix W A W in Canada to indicate that it is acceptable for outdoor use Be sure your extension cord is properly wired and in good condition Always replace a damaged cord or have it repaired by a qualified person before using it Protect extension cords from sharp objects excessive heat and damp or wet areas Operation Crosscut rulers The panel saw comes with one rip vertical ruler and two crosscut horizontal rulers The rip ruler is preset at the factory The crosscut rulers should be checked and if necessary adjusted before operating the saw Also they should be adjusted after every blade change See Adjusting Crosscut Rulers on page 15 ADAPTER TWO PRONG GROUNDING EAR SECURED GROUNDING EAR WITH SCREW Figure 6 based on limiting the line voltage drop to 5 volt at 150 of the rated amps Figure 7 Operating Tips 1 Use industrial carbide saw blades that are sharp D
22. ire face of blade contacts your straightedge LOOSEN NUTS ON 8 Retighten nuts holding indexing pin OPPOSITE SIDE assembly 9 Make a test cut and further adjustments if necessary Figure 21 Maintenance AWARNING Always unplug panel saw before performing any adjustments maintenance Do not disassemble or do any rewiring to the electrical system contact a qualified electrician Always follow proper lockout tagout procedures during servicing Keep the machine in good working order by adopting a routine maintenance program Daily Use a mild soap and a damp cloth to clean the machine Before using the saw each time clean dust from the motor housing vents Keep the handles clean dry and free from oil or grease Examine the condition of guards switches and power cords Check for misalignment binding of moving parts broken parts loose screws and bolts etc If vibration or unusual noise occurs turn off the saw and correct the problem immediately ACAUTION Do not use cleaning solvents such as gasoline turpentine lacquer thinner paint thinner or ammonia as these are harmful to plastic and some of the insulated parts on the machine Never use flammable or combustible solvents around tools AWARNING Do not immerse the saw in liquid as this may create risk of injury electric shock and damage to the saw 18 Periodically 1 The carriage is designed to move smoothly along the guide t
23. ll times Do not attempt to disassemble or repair counter balance When the machine is not in use keep the saw carriage locking knob securely tightened Familiarize yourself with the following safety notices used in this manual ACAUTION This means that if precautions are not heeded it may result in minor injury and or possible machine damage AWARNING This means that if precautions are not heeded it may result in serious injury or possibly even death SAVE THESE INSTRUCTIONS Warnings Familiarize yourself with the location and content of these decals on your machine AWARNING FOR YOUR OWN SAFETY READ INSTRUCTION MANUAL BEFORE OPERATING SAW ALWAYS WEAR APPROVED EYE PROTECTION WHILE OPERATING THIS SAW USE SAW BLADE GUARD AND SPREADER FOR EVERY OPERATION INCLUDING THROUGH SAWING 8 DO NOT CUT MATERIAL SMALLER THAN MOTOR CARRIAGE 9 DO NOT USE PUSH STICK KEEP HANDS AWAY FROM SAW BLADE 3408248 AND NEVER PLACE HANDS UNDER CARRIAGE DISCONNECT POWER FROM SAW BEFORE REMOVING SAW GUARD OR MAKING ANY ADJUSTMENTS MATERIAL BEING CUT MAY KICK BACK KEEP HANDS BODY AND BYSTANDERS OUT OF PATH OF MATERIAL SEE INSTRUCTIONS ON PREVENTING KICK BACK 3408265 DO NOT REMOVE OR OBSCURE THIS LABEL WHEN RIPPING FEED STOCK IN THIS DIRECTION 3408266 BLADE SIZE FIGURE 1 General Operating Instructions The suggestions listed below are meant to give you a gene
24. ly trained and experienced personnel only If you are not familiar with the proper and safe operation of a panel saw do not use until proper training and knowledge have been obtained Do not use this panel saw for other than its intended use If used for other purposes WMH Tool Group disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use Always wear approved safety glasses face shields while using this panel saw Everyday eyeglasses only have impact resistant lenses they are not safety glasses Before operating this panel saw remove tie rings watches and other jewelry and roll sleeves up past the elbows Remove all loose clothing and confine long hair Non slip footwear or anti skid floor strips are recommended Do not wear gloves Wear ear protectors plugs or muffs during extended periods of operation Some dust created by power sanding sawing grinding drilling and other construction activities contain chemicals known to cause cancer birth defects or other reproductive harm Some examples of these chemicals are e Lead from lead based paint e Crystalline silica from bricks cement and other masonry products e Arsenic and chromium from chemically treated lumber Your risk of exposure varies depending on how often you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipment such as face or d
25. mbly 1 Dino AC Oa a a a cele a la 2 3701160 1 3064716 Glam Bracket Re 1 CR 3019093 Scale Mounino AND En rasta etre nu 2 Phi 3907309 sara 8 10 3745052 POMC BUSHING 2 Des BOP OSS he POLE AEE AE E ee oe col E A 2 39 9079 saselea FOM es GR ce 2 22930 Gude TUDE 58 eee 1 3449005 Motor Carriage Lock Assembly Items 41 98 99 1 3596129 ce Scale Mounting PAS 1 36012153 FUNG 1 3079220 MOIO ee eee ee 1 Noa ae 3575078 assaut Beano Wear Re a RS 3745049 DISC es 1 2042918 Base noue 1 3064746 LOW ACKE 1 2200234 Curd 1 3064745 Upper Mo nting
26. n OR 3408249 MIO OR 1 3408248 Label Blade ROAD 1 BU 3408266 Label Direcional 1 de 6714048 Hex Head Screw 1 4 20 X 1 2 QE 0715085 Hex Head Screw 5 16 18 x 3 4 1 O Pre 6860802 2 4 3856918 sers JA OU E 1 O iaia OLIOT 9D Ground Screw issues 1 OT occai 6286447 LOCK IN re 3 OS 3449006 LOCK Wi InSerS 0400072 esse 1 3449007 67I T2 d esse FICK CAC SOON eee eee 3 8 16 x 2 1 2 Lg 4 102 30 3092 a a 1 1 2 wide 4 3064743 SUD DOME 10 3076235 lt ANS ue On 8 671 6043 Head 3 8 16 x 2 3 4 10 106 2475002 Motor w Pushbutton Assembly Items 50 59 73 75 77 81 87 94 95 97 1 VOT sis 3069022 DIGS BUS en sur cn
27. n block and three cables have been fastened to the counterweight to secure it during shipment This wooden block and cables must be removed before operation of the saw Follow steps 1 through 4 1 Make sure the cable attached to the motor carriage is placed over the pulley on top of the panel saw 2 Loosen the locking knob on the motor Carriage and move the carriage down to the bottom of the panel saw See Figure 3 Tighten the locking knob securely 3 At the back of the panel saw on top of the counterweight housing lift up on the wood block and cut the three cables attached to the block See Figure 4 DO NOT cut the main cable that runs through the pulley 4 Remove the cables and wood block so that the counterweight can slide freely inside the housing Make sure there is enough space on both sides of the panel saw for loading passing and off loading panels Grounding Instructions AWARNING Improper connection of the grounding wire can result in electric shock If you are unsure whether an outlet is properly grounded consult a qualified electrician Do not modify the plug provided with the saw and never remove the grounding prong from the plug If cord or plug is damaged have it repaired before using the machine If plug will not fit the outlet have a proper outlet installed by a qualified electrician The plug must be connected to a properly grounded outlet shown in Figure 5 grounded and installed in accord
28. nob shown in Figure 13 14 Figure 13 Engage spindle lock Figure 14 on the motor to keep spindle from turning Use the wrench provided to loosen and remove the arbor bolt NOTE left hand threads turn clockwise to loosen See Figure 15 Remove outer flange blade and inner flange See Figure 15 Clean spindle flanges bolts and blade to remove dust and debris Re install inner flange and install new blade with arrow pointing as shown in Figure 15 Reinstall outer flange and tighten arbor bolt with wrench Re install blade guard Loosen carriage lock and move carriage to the top of the guides Reconnect power Adjusting Crosscut Rulers The panel saw comes with one rip vertical ruler and two crosscut horizontal rulers The rip ruler is preset at the factory The crosscut rulers should be checked and if necessary adjusted before operating the saw Also they may have to be adjusted after every blade change With the blade installed do the following 1 2 Remove blade guard Loosen carriage locking knob and lower carriage down to the rulers Using a square that measures at least 14 on one side line up one edge of the square with the tips of the saw blade and the other edge with the crosscut ruler See Figure 16 If these are out of square loosen the three bolts that hold the angle bracket to which the scale is attached Slide the angle bracket so that its measure matches the measure on the
29. ol Group makes every effort to assure that its products meet high quality and durability standards and warrants to the original retail consumer purchaser of our products that each product be free from defects in materials and workmanship as follows 1 YEAR LIMITED WARRANTY ON ALL PRODUCTS UNLESS SPECIFIED OTHERWISE This Warranty does not apply to defects due directly or indirectly to misuse abuse negligence or accidents normal wear and tear repair or alterations outside our facilities or to a lack of maintenance WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD SPECIFIED ABOVE BEGINNING FROM THE DATE THE PRODUCT WAS PURCHASED AT RETAIL EXCEPT AS STATED HEREIN ANY IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS ARE EXCLUDED SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU IN NO EVENT SHALL WMH TOOL GROUP 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 To take advantage of this warranty the product or part must be returned for examination postage prepaid to an Authorized Repair Station designated by our office Proof of purchase date and an explanation of the complaint must accompany the merchandise If
30. ral idea of how your new Panel Saw is intended to be operated No amount of instruction can replace good common sense and experience Be sure the operators of your new Panel Saw are given enough time and material to become familiar with the general operating characteristics of this machine and have FULLY READ AND UNDERSTAND all general operating and safety instructions The panel saw is prealigned at the factory No assembly or adjustments are necessary NOTE When your Panel Saw is located in position for operation secure the machine in a manner that will prevent it from being tipped over Operating Tips 1 If you expect smooth clean chip free cuts follow these tips e Use industrial carbide saw blades which are SHARP Dull blades or improperly sharpened blades will cause chipping unclean cuts chatter and will overload the saw motor e NOTE ALWAYS USE A SHARP SAW BLADE IF IN DOUBT REPLACE IT WITH A NEW BLADE e Feeding the material through the machine horizontally or moving the saw carriage through the material vertically MUST BE DONE SLOWLY SMOOTHLY AND WHENEVER POSSIBLE WITHOUT STOPPING Overfeeding will result in poor quality cuts shorten the life of the carbide saw blades and overload the saw motor 2 Caution must be used when setting material onto the material roller carriage Heavy material MUST NOT BE DROPPED ONTO THE ROLLER CARRIAGE Failure to follow this rule will ultimately cause the roller carriage to be pounded out of
31. rs a safe distance from the work area Keep children away Warnings 20 21 22 23 24 25 26 27 28 Make your workshop child proof with padlocks master switches or by removing starter keys Give your work undivided attention Looking around carrying on a conversation and horse play are careless acts that can result in serious injury Maintain a balanced stance at all times so that you do not fall or lean against the blade or other moving parts Do not overreach or use excessive force to perform any machine operation Use the right tool at the correct speed and feed rate Do not force a tool or attachment to do a job for which it was not designed The right tool will do the job better and safer Use recommended accessories improper accessories may be hazardous Maintain tools with care Keep blades sharp and clean for the best and safest performance Follow instructions for lubricating and changing accessories Turn off the machine before cleaning Use a brush or compressed air to remove chips or debris do not use your hands Do not stand on the machine Serious injury could occur if the machine tips over Never leave the machine running unattended Turn the power off and do not leave the machine until it comes to a complete stop Remove loose items and unnecessary work pieces from the area before starting the machine Use common sense keep hands away from and out from under saw carriage at a
32. rts breakdown This machine has been designed and constructed to provide years of trouble free operation if used in accordance with instructions set forth in this manual If there any questions or comments please contact either your local supplier or WMH Tool Group WMH Tool Group can also be reached at our web site www wmhtoolgroup com Specifications tse ee eee ee eee ee ee ee ee een 511 OCR Cine re re en EN nn re PT Ga Se HOTTER 1510007 FRANCO RO OOTY 10 feet ICN II ee tata nee 62 MCD RIO Unlimited Gut 1 1 2 Cut ACCUrACY and Ns ceded 1 64 DAME SES nee re nt ne 8 ROQUIF MISNLS iriso OR a TR RS ins 120V 13 Amps Dimensions kx 120 x 38 x 86 NET etc net tc rae nt ee eee me 435 WAJA IDS ESS a eer 500 The above specifications were current at the time this manual was published but because of our policy of continuous improvement WMH Tool Group reserves the right to change specifications at any time and without prior notice without incurring obligations Installation of Panel Saw Uncrating Remove the panel saw from the shipping container and check for damage Report any damage to the freight company immediately A woode
33. s 6 With the motor at full speed move the workpiece slowly and smoothly through the saw Do not force the workpiece as it may cause binding NOTE If the blade binds in the workpiece or the workpiece shifts during the cut stop the motor back the workpiece out of the saw reposition workpiece restart motor and then begin the cut again AWARNING Do not place hands clothing or body parts under carriage or in cutting path of blade Do not look directly down line of cut as dust and debris are generated during this operation 7 As the workpiece passes through the saw move to the other side and complete the cut by pulling the workpiece past the blade Support the upper piece to prevent it from pinching the blade or the kerf protector or falling away from the machine 8 When cut is finished turn off motor and wait for blade to come to a complete stop Remove workpieces 9 Rotate turntable back to vertical position and return it to the top of the guides Lock the carriage Adjustments The 511 Panel Saw is preset at the factory so no adjustments should be necessary at first However certain alignments should be checked and as the saw gets more use adjustments may be needed Changing the Blade 1 Disconnect saw from power source and observe appropriate lockout procedures to prevent machine from being accidentally powered 2 Tighten carriage lock and remove the blade guard by unscrewing and removing the k
34. s 21 23 59 50 87 122 77 93 26 511 Panel Saw Dust Collection System refer to parts list pages 21 23 117 116 118 TO DUST COLLECTOR 27 Electrical Connections refer to parts list pages 21 23 3 7 q LE o 94 123 93 95 72 a CT 28 ST AZ CA FL GA IL KS MA MD OH OR PA TX VA CITY Phoenix Anaheim Onlano Sacramento San Diego Santa Clara Denver Jacksonville Hialeah Miami Tampa Atlanta Honolulu Chicago Chicago Addison Kansas City Overland Park Boston Norwood Washington DC Beltsville Detroit Farmington Hills St Paul St Louis Overland Charlotte Edison New York City Flushing E Syracuse Cincinnati Cleveland Portland Philadelphia Pittsburgh Dallas Houston Norfolk S B Factory Service Centers for the Skil worm drive motor TELEPHONE 602 272 1121 714 630 3244 909 390 8877 916 451 8473 619 268 8335 408 727 9444 303 893 5123 904 398 0728 305 624 9011 813 289 3770 770 452 8192 808 848 8665 773 774 0600 630 543 8660 913 381 3883 617 255 0272 301 595 1923 810 476 7788 612 645 8744 314 427 0200 704 527 3745 908 572 0875 718 461 0025 315 437 3435 513 242 0244 216 447 0250 503 234 7418 215 291 9900 412 261 6457 972 241 5385 713 681 4893 757 855 2035
35. the fence bracket starts with a measurement of 4 1 2 If necessary loosen the three mounting screws on the fence bracket and adjust it so that the exact distance from the blade to the right end of the fence bracket is 4 1 2 33 Step 6 Place the fence shelf between the bracket and the top of the round bushings with the black molding showing If the shelf is not a snug fit remove the shelf loosen the bushing mounting bolts press up on the bushing retighten the mounting bolts and re install the shelf Step 7 To check the shelves for squareness slide the saw carriage down and place the framing square on top of the left shelf and slide it over to the blade If the shelf is not square to the blade loosen the three mounting screws securing the fence bracket move the bracket until the fence shelf is square to the blade and retighten mounting screws Make a test cut using an 18 tall panel Place the panel on the shelf and cut the end Turn the panel around making sure that the same bottom reference is used and make a second cut Measure at the top and bottom of the panel to make sure the panel is square Make adjustments and test cuts as needed until squareness is achieved DO NOT make any adjustments to the panel saw itself only adjust the fence brackets when checking for squareness Step 8 Install the right side fence bracket to the right side of the panel saw Refer to Steps 1 thru 6 Note When the Short Panel
36. the workpieces return the carriage to the top of the guides and lock the Carriage Ripcutting A ripcut is a horizontal cut made right to left See Figure 11 The workpiece must always be moved in the direction of the arrow on the Carriage AWARNING Ripping must be done in direction of the arrow on saw carriage to prevent risk of injury The minimum length recommended for rip horizontal cuts is 2 1 2 feet so that the workpiece can be supported by at least four rollers This measurement also applies when using the optional Short Panel Fence Pieces shorter than 4 feet can be rotated 90 degrees and be crosscut Here is the basic procedure for ripcutting 1 Make sure there is enough space on both sides of saw to completely load pass and offload the workpiece 2 Pull indexing pin on turntable Figure 12 and rotate turntable counterclockwise The indexing pin will lock into place FOLLOW DIRECTION OF ARROW ON CARRIAGE AAR eT RIPCUTTING Figure 11 Figure 12 3 Select height of saw blade above the rollers Move the carriage until the index tab is aligned with the corresponding dimension on the vertical ruler Lock the carriage securely to the guides with the locking knob 4 Start motor and allow it to reach full speed Place workpiece on the side of machine according to direction of cut shown by the arrow on the carriage DO NOT DROP workpiece on roller
37. ubes If the guide tubes become caked with dust the carriage may not slide evenly or become stuck Occasionally clean the guide tubes with a damp cloth and apply a dry lubricant such as a Spray silicone Rotate the motor to horizontal position and check the motor oil level at the plug Figure 22 shows the location of the oil plug If low fill with SAE 70 or 80 gear oil to proper level The gear oil should be changed at least once a year or more frequenily if the panel saw receives heavy use Every six months 1 Examine the motor brushes and replace as necessary Inspect and clean gears spindles bearings housing etc Inspect switch cord armature etc Test to ensure proper mechanical and electrical performance 19 Figure 22 lt lt q gt 2 Replacement Parts Replacements parts are listed on the following pages To order parts or reach our service department call 1 800 274 6848 between 7 30 a m and 6 00 p m CST Monday through Friday Having the Model Number and Serial Number of your machine available when you call will allow us to serve you quickly and accurately 20 Parts List 511 Panel Saw Index No Part No Description Size Qty 2078021 Assembly Items 15 17 amp 24 1 ee 2218033 Frame Assembly 2423020 Leg Asse
38. ull blades may cause chipping chatter or overloading of the motor you re not sure whether a blade is sharp replace it with a new one 2 Feed material through the saw ripping or lower the carriage crosscutting slowly smoothly and whenever possible without stopping Overfeeding can result in poor quality cuts shorten the life of the blade and overload the motor 3 Do not drop heavy material onto the rollers as this will eventually pound them out of alignment 4 For best results place workpiece onto saw with its backside facing the operator This provides the smoothest cut on the face side of the panel 5 Feed workpiece against the rotation of the saw blade when making horizontal cuts ripping 6 Panel saws are for cutting large panels down to size As the panel gets smaller other types of tools become safer and more convenient to use Crosscutting A crosscut is a vertical cut that is made from the top to the bottom of the workpiece See Figure 8 AWARNING Do not place hands on or under the carriage or in path of saw blade For safety and accuracy the workpiece must be supported on at least two rollers while crosscutting See Figure 8 When the optional Short Panel Fence is used the workpiece must extend at least 4 beyond both sides of the carriage Figure 9 Here is the basic procedure for crosscutting 1 Position the saw motor in the crosscutting position with the blade oriented vertic
39. ust masks that are specifically designed to filter out microscopic particles Do not operate this machine while tired or under the influence of drugs alcohol or any medication Make certain the switch is in the OFF position before connecting the machine to the power supply Make certain the machine is properly grounded through the three wire cord that comes with the unit Make all machine adjustments blade changes or maintenance with the machine unplugged or locked out from the power source Remove adjusting keys and wrenches Form a habit of checking to see that keys and adjusting wrenches are removed from the machine before turning it on Keep safety guards in place at all times when the machine is in use removed for maintenance purposes use extreme caution and replace the guards immediately Check damaged parts Before further use of the machine a guard or other part that is damaged should be carefully checked to determine that it 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 repaired or replaced Machine should be properly tagged until repaired Provide for adequate space surrounding work area and non glare overhead lighting Keep the floor around the machine clean and free of scrap material oil and grease Keep visito
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