MANU-LOCK v9

MANU-LOCK v9
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:12 Page 19
LOCK/JIG
Aluminium Adjustable
Lever Type (Batch. 10/2012 EB)
Please read these instructions before use.
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 1
LOCK/JIG
Dear Customer
TECHNICAL DATA
Thank you for purchasing this Trend product, we
hope you enjoy many years of creative and
productive use.
Cutter size
Min. workpiece
12mm
34mm
Please remember to return your guarantee card
within 28 days of purchase.
Max. workpiece
58mm
Template size
59.8mm x 239mm
Largest face plate inner
aperture size
32mm x 177mm
Guide bush size
30mm
Weight
4.5kg
CONTENTS
TECHNICAL DATA _____________________1
SAFETY PRECAUTIONS ______________2-3
ITEMS ENCLOSED ____________________4
DESCRIPTION OF PARTS _______________5
ACCESSORIES _______________________6
- Assembly ___________________________7
- Setting the Spacers ___________________7
- Choice of Set-ups - Option 1 ____________8
- Option 2 ____________________________9
- Option 3 ____________________________9
- Fitting the Guide Bush ________________10
- Steel Templates _____________________11
- Template Selection Chart ______________11
- Special Note for Template 11 ___________11
OPERATION
- Marking Out ________________________12
- Centring the Jig______________________13
- Quick Centring for 44mm doors _________13
- Routing the Mortise___________________14
- Routing the Face-plate ________________14
- Finishing ___________________________15
- Deeper Mortise ______________________15
- Cutting Key & Spindle Hole ____________15
MAINTENANCE ______________________15
ENVIRONMENTAL PROTECTION ________15
GUARANTEE ________________________15
SPARE PARTS
- Spare Parts List _____________________16
- Spare Parts Diagram__________________IB
The following symbols are used throughout this
manual:
Denotes risk of personal injury, loss of
life or damage to the tool in case of nonobservance of the instructions in this
manual.
Refer to the instruction manual of
your power tool.
This unit must not be put into service until it has
been established that the power tool to be
connected to this unit is in compliance with
2006/42/EC (identified by the CE marking on the
power tool).
INTENDED USE
This jig is intended for use with a plunge router
with suitable guide bush and router cutter fitted
to rout a mortise and face plate for locks in
wooden doors.
☎
-1-
If you require further safety advice,
technical information or spare parts,
please call Trend Technical Support
or visit www.trend-uk.com
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 2
LOCK/JIG
SAFETY
WARNING:
Observe the safety regulations in the
instruction manual of the power tool to be
used. Please read the following
instructions carefully. Failure to do so
could lead to serious injury. When using
electric tools, basic safety precautions,
including the following should always be
followed to reduce the risk of fire, electric
shock and personal injury. Also observe
any applicable additional safety rules.
Read the following safety instructions
before attempting to operate this product.
PLEASE KEEP THESE
INSTRUCTIONS IN A SAFE PLACE.
The attention of UK users is drawn to The
Provision and Use of Work Equipment
Regulations 1998, and any subsequent
amendments.
Users should also read the HSE/HSC
Safe Use of Woodworking Machinery
Approved Code of Practice and Guidance
Document and any amendments.
Users must be competent with
woodworking equipment before using our
products.
IMPORTANT NOTE:
outdoors. Wear protective hair
covering to contain long hair.
awkward or uncomfortable hand
positions.
17. Donʼt abuse the cable. Never carry
5. Consider working environment. Do
power tool or accessory by cord or
not use the product in the rain or in a
pull it to disconnect from the socket.
damp environment. Keep work area
Keep cord from heat, oil and sharp
well lit. Do not use power tools near
edges. Always trail the power cord
gasoline or flammable liquids. Keep
away from the work area.
workshop at a comfortable
temperature so your hands are not
18.
Connect dust extraction equipment.
cold. Connect machines that are used
If devices are provided for the
in the open via a residual current
connection of dust extraction and
device (RCD) with an actuation
collection facilities, ensure these are
current of 30 mA maximum. Use only
connected and properly used.
extension cables that are approved for
outdoor use.
19. Check all fixing and fastening nuts,
bolts and screws on power tool,
6. The accessory or attachment must be
attachment and cutting tools before
kept level and stable at all times.
use to ensure they are tight and
secure. Periodically check when
7. Keep work area clean. Cluttered
machining over long periods.
workshops and benches can cause
injuries. Ensure there is sufficient
20.
Stay alert. Watch what you are doing.
room to work safely.
Use common sense. Do not operate
tools when you are tired, under the
8. Secure idle tools. When not in use,
influence of drugs or alcohol.
tools should be stored in a dry and
high or locked up place, out of reach
21.
Personal Protective Equipment (PPE)
of children.
for eye, ear and respiratory protection
must be worn. All PPE must meet
9. For best control and safety use both
current UK and EU legislation.
hands on the power tool and
attachment. Keep both hands away
22.
Do not leave tools running
from cutting area. Always wait for the
unattended. Do not leave tool until it
spindle and cutter to stop rotating
comes to a complete stop.
before making any adjustments.
23. Always clamp workpiece being
10. Always keep guards in place and in
machined securely.
good working order.
Residual Risk. Although the safety
instructions and operating manuals for
our tools contain extensive instructions on
safe working with power tools, every
power tool involves a certain residual risk 11. Remove any nails, staples and other
which cannot be completely excluded by
metal parts from the workpiece.
safety mechanisms. Power tools must
therefore always be operated with
12. Maintain tools and cutters with care.
caution!
Keep cutters sharp and clean for
better and safer performance. Do not
General
use damaged cutters. Follow
1. Disconnect power tool and attachment
instructions for lubricating and
from power supply when not in use,
changing accessories. Keep handles
before servicing, when making
dry, clean and free from oil and
adjustments and when changing
grease.
accessories such as cutters. Ensure
13. Maintain accessories. Do not use
switch is in “off” position. Always
damaged accessories. Only use
ensure cutter has stopped rotating.
accessories recommended by the
2. Always mount the power tool,
manufacturer.
accessory or attachment in conformity
14. Check damaged parts. Before
with the instructions. Only use
operation inspect the attachment, the
attachment and accessories specified
power tool, the cable, extension cable
in the power tool manual. The tool or
and the plug carefully for signs of
attachment should not be modified or
damage. Check for alignment of
used for any application other than
moving parts, binding, breakage,
that for which it was designed. Do not
mounting and any other conditions
force tool.
that may effect its operation. Have any
3. Keep children and visitors away. Do
damage repaired by an Authorised
not let children or visitors touch the
Service Agent before using the tool or
tool, accessory or attachment. Keep
accessory. Protect tools from impact
children and visitors away from work
and shock.
area. Make the workshop child proof
15. Do not use tool if switch does not turn
with padlock and master switch.
it on or off. Have defective switches
4. Dress properly. Do not wear loose
replaced by an Authorised Service
clothing or jewellery, they can be
Agent
caught in moving parts. Rubber
16. Don't over reach. Keep proper footing
gloves and non-skid footwear is
and balance at all times. Do not use
recommended when working
-2-
24. Only use cutting tools for
woodworking that meet EN847-1/2
safety standards, and any
subsequent amendments.
25. Vibration levels. Hand held power
tools produce different vibration
levels. You should always refer to the
specifications and relevant Health &
Safety Guide.
Routing Safety
1. Read and understand instructions
supplied with power tool, attachment
and cutter.
2. Keep hands, hair and clothing clear of
the cutter.
3. Remove adjusting keys and
spanners. Check to see that keys
and adjusting spanners are removed
from the router tool, cutter and
attachment before turning router on.
Make sure cutter can rotate freely.
4. Noise. Take appropriate measures
for the protection of hearing if the
sound pressure of 85dB(A) is
exceeded. Routing sound pressure
may exceed 85dB(A), so ear
protection must be worn.
5. Eye protection. Always wear eye
protection in the form of safety
goggles, spectacles or visors to
protect the eyes.
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 3
LOCK/JIG
6. Respiratory protection. Wear a face
or dust mask, or powered respirator.
Dust masks/filters should be changed
regularly.
indicated on the shank. This ensures
that at least 3⁄4 of the shank length is
held in the collet. Ensure clamping
surfaces are cleaned to remove dirt,
grease, oil and water.
component being machined. Ensure
any attachment is securely fitted to the
workbench, with table surface at
approximately hip height.
7. Do not switch router on with the cutter
6. Use a No-Volt Release Switch. Ensure
touching the workpiece. At the end of 10. Observe the correct assembly and
it is fixed securely, easily accessible
fitting instructions in the router
the cut, release the router plunge and
and used correctly.
instruction manual for fitting the collet,
allow spindle to stop rotating. Never
7.
In router table (inverted) mode, stand
nut and cutter.
use the spindle lock as a brake
to the front right of the table. The
8. The direction of routing must always 11.Tool and tool bodies shall be clamped
cutter will rotate anti-clockwise when
in such a way that they will not
be opposite to the cutter's direction of
viewed from top so the feed direction
become loose during operation. Care
rotation. Do not back-cut or climb-cut.
is from the right (against the rotation of
shall be taken when mounting cutting
the cutter). In overhead mode, stand
9. Check before cutting that there are no
tools to ensure that the clamping is by
to the front left of the machine table
obstructions in the path of the router.
the shank of the cutting tool and that
and the feed direction is from the left.
Ensure there are no obstacles
the cutting edges are not in contact
beneath workpiece when cutting full
8.
Do not reach underneath table or put
with each other or with the clamping
thickness, and that a sacrificial work
your hands or fingers at any time in
elements.
surface is used.
the cutting path while tool is connected
12. It is advisable to periodically check
to a power supply.
Router Cutter Safety
the collet and collet nut. A damaged,
9.
Never thickness timber between the
1. Cutting tools are sharp. Care should
worn or distorted collet and nut can
back of the cutter and the backfence.
be taken when handling them. Do not
cause vibration and shank damage.
drop cutters or knock them against
Do not over-tighten the collet nut
Useful Advice When Routing
hard objects. Handle very small
1. Judge your feed rate by the sound of
13. Do not take deep cuts in one pass;
diameter cutters with extra care.
the motor. Feed the router at a
take several shallow or light passes to
Always return cutter to its packaging
constant feed rate. Too slow a feed
reduce the side load applied to the
after use.
rate will result in burning.
cutter and router. Too deep a cut in
2. Always use cutters with a shank
one pass can stall the router.
2.
Trial cuts should be made on waste
diameter corresponding to the size of
material before starting any project.
15. In case of excessive vibrations whilst
the collet installed in your tool.
using the router stop immediately and 3. When using some attachments e.g. a
3. The maximum speed (n.max) marked
have the eccentricity of the router,
router table or dovetail jig, a fine
on the tool, or in instructions or on
router cutter and clamping system
height adjuster is recommended.
packaging shall not be exceeded.
checked by competent personnel
Where stated the speed range shall
4. When using a template guide bush,
be adhered to. Recommended speeds 15. All fastening screws and nuts should
ensure there is sufficient clearance
be tightened using the appropriate
are shown in the Trend Routing
between cutter tip and inside edge of
spanner or key and to the torque
Catalogue and/or website.
bush and that it cannot come into
value provided by the manufacturer.
contact with collet and nut. Ensure
4. Always use router cutters in a router.
cutter and guide bush are concentric.
Drill and boring bits must not be used 16. Extension of the spanner or tightening
using hammer blows shall not be
in a router. Router cutters must only
Router Cutter Repair/Maintenance
permitted.
be used for the material cutting
1. Repair of tools is only allowed in
application for which they are
17.Clamping screws shall be tightened
accordance with the manufacturers
designed. Do not use on metal or
according to instructions provided by
instructions.
masonry.
the manufacture. Where instructions
3. The design of composite (tipped) tools
are
not
provided,
clamping
screws
5. Never use cutters with a diameter
shall not be changed in process of
shall be tightened in sequence from
exceeding the maximum diameter
repair. Composite tools shall be
the centre outwards.
indicated in the technical data of the
repaired by a competent person i.e. a
powertool or attachment used.
Using Routers In A Fixed Position
person of training and experience, who
has knowledge of the design
6. Before each use check that the cutting 1. Attention should be made to the
requirements and understands the
tool is sharp and free from damage.
HSEʼs Safe Use of Vertical Spindle
levels of safety to be achieved.
Do not use the cutting tool if it is dull,
Moulding Machines Information Sheet
broken or cracked or if in any other
No.18 and any revisions.
4. Repair shall therefore include, e.g. the
damage is noticeable or suspected.
use of spare parts which are in
2. After work, release the router plunge
accordance with the specification of
7. Cutters should be kept clean. Resin
to protect the cutter.
the original parts provided by the
build up should be removed at regular
manufacturer.
3. Always use a push-stick or push-block
intervals with Resin Cleaner®. The
when making any cut less than
use of a PTFE dry lubricant will
5. Tolerances which ensure correct
300mm in length or when feeding the
reduce resin build up. Do not use
clamping shall be maintained.
last 300mm of the cut.
PTFE spray on plastic parts.
6. Care shall be taken that regrinding of
4. The opening around the cutter should
8. When using stacked tooling (multithe cutting edge will not cause
be reduced to a minimum using
blade, block and groover etc.) on a
weakening of the body and the
suitably sized insert rings in the table
spindle arbor, ensure that the cutting
connection of the cutting edge to the
and closing the back fence cheeks or
edges are staggered to each other to
body.
fitting a false fence on the back fence.
reduce the cutting impact.
Version 7.1 06/2006
9. Cutter shanks should be inserted into 5. Whenever possible use a work
holding device or jig to secure
the collet all the way to the line
-3-
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 4
LOCK/JIG
ITEMS ENCLOSED
x1
x1
x6
x1
x2
x2
x2
x3
x3
LOCK
JIG
x1
Mortise x4
x1
Face-plate x12
ITEMS REQUIRED
GUARANTEE
■ 1/2” collet plunge router (or 1/4” collet plunge
router for face plate only).
■ 30mm guide bush (or 16mm plus collar).
■ 12mm diameter router cutter with suitable
shank size.
■ Door clamping device.
■ Hand tools.
■ No. 2 Phillips Screwdriver.
-4-
LOCK
JIG
x1
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 5
LOCK/JIG
DESCRIPTION OF PARTS
Use the drawing below as
a guide to assemble
the jig.
I
H
G
A
Jig body
K
B
Adjustable lever
fixing stud
J
E
D
C Clamp bar (datum)
D Adjustable lever
washer
E
Adjustable lever
M8
F
Spacer finger
fixing stud
C
G Spacer finger
F
H Spring washer
I
Mini knob M5
J
Guide bush collar
16mm to 30mm
K
Collar park
L
Mortise template
N
B
M Face plate
template
A
N Clamping knob
with pad
L
O Jig template
aperture recess
M
P
Central aperture
O
Ensure jig is clean and free of oil
before use.
TOP VIEW
P
-5-
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 6
LOCK/JIG
ACCESSORIES
Please use only Trend original accessories.
30mm Guide Bush
Ref. GB30
trend
R
Should the correct guide bush not be available
to suit your routerʼs base, you will need to use
the Trend UNIBASE in conjunction with a 30mm
guide bush, Ref. GB30 or 16mm guide bush
Ref. GB160.
Universal Sub-base
Ref. UNIBASE
The Unibase contain screws, a line up bush and pin.
The line up pin and bush ensure exact alignment of
sub-base with the router spindle, when fitted with the
relevant collet.
Fits following router models
Atlas Copco OFSE2000 Bosch GOF 1300ACE, 1600A,
1700ACE Casals FT2000VCE CMT CMT1850, 2000,
DeWalt DW624, 625EK, 629 Draper R1900V Elu MOF 131,
177(E) Felisatti TP246(E), R346EC Festo OF2000E Freud
FT2000E Hitachi M12V, M12SA, TR12 Metabo OF1612,
OFE1812 Ryobi RE600N, R600N, RE601, R500, R502 Skil
1875U1 Wadkin R500
Door Stand
Ref. D/STAND/A
Holds door on itʼs edge whilst routing hinge recess
and mortise for locks. Maximum weight 50kg and for
doors 32mm to 55mm thick. Allows door to be tilted
back to assist fitting to door frame.
Door Clamp
Ref. D/CLAMP/A
Holds door whilst drilling and fitting locks. Ratchet
clamp design for doors up to 55mm thick.
Corner Chisel
Ref. C/CHISEL
Squares up rounded corners in one operation. High
speed steel. Use with a hammer.
24” Carry Case
Ref. CASE/DH
Accepts Door Stand, Lock Jig, Door Clamp and
accessories.
-6-
UNIBASE
mm
30
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 7
LOCK/JIG
ASSEMBLY
Setting the Spacer Fingers
■ Remove the transit washer and nut from the
middle adjusting lever fixing stud (2) on the jig
body (1). Fit the three washers (4), and fit the
three adjustable levers (5). To tighten the
adjustable levers, lift the lever up and rotate
the knurled part whilst keeping the lever body
stationary. When hand-tight, release the
ratchet and tighten using the lever.
■ Spacers may need to to be used to ensure
the spigot of the guide bush will not contact
the door edge when routing.
■ Three spacers per end of the jig are provided
and can be parked against the jig body when
not required.
■ Clamp the jig to the door and place the router
fitted with guide bush into the aperture. If the
guide bush does not contact the door edge,
then no spacers need to be used.
■ Remove the protective film from the spacer
fingers (7) then place three spacer fingers
onto the spacer finger fixing stud (6). See
Setting the Spacers (right) for adjustment. Fit
the spring washer (8) and the mini knob (9)
onto the spacer finger fixing stud (6) and
tighten. Repeat procedure for other
assembly.
■ If the guide bush contacts the door edge
calculate how many spacers are required.
Each spacer is 2mm thick.
■ To reposition the spacers, undo each of the
two M5 knobs, remove knob and washer and
lift off the spacers. Reposition the required
number of spacers by 90° so they line up
across the jig and replace all unused spacers.
Ensure an equal number of spacers are used
at each end. Refit the washers and the M5
knobs and tighten.
No spacer
fingers used.
On timber that is over 56mm thick it
may be necessary to remove the M5
knobs and use two accessory M5 hex
nuts ref WP-NUT/05 (1 off) to secure.
One spacer
finger used.
In some circumstances when a guide
bush with a long spigot is used it may
contact the clamping bar, if this occurs
a shallower spigot guide bush will be
required.
Special Note:
The Lock Jig can be used to cut the face-plate
recess in the edge of doors whilst it is hung.
Face-plate only
The mortise should NOT be routed
when the door is hung.
Always ensure that the door is firmly
secured if routing the face-plate on a
hung door, so there is no possibility of
the door swinging open or shut.
-7-
Face-plate and mortise
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 8
LOCK/JIG
Choice of Set-ups
Option 1
One Spacer required
with T9/T10/T11 router.
4
+
+
Heavy duty router with 1⁄2”
collet e.g. T10/T11 Router
Suitable Plunge Router:
Your router should have following
plunge length:
- For 2” deep locks at least 54mm.
- For 21⁄2" deep locks at least
66mm.
- Auger bit and drill required for 3”
deep locks for all routers.
12mm
Router Cutter
Ref. TR37X1/2TC
overall length 115mm
OR USE
Router Cutter
Ref. TR37MX1/2TC
30mm Guide
Bush Ref. GB30
See page 8 if a
suitable guide bush
is not available
for your router.
overall length 100mm
with the following
routers:
RYOBI R600, R600(N)
RE601
Makita 3612(C)
Skil 1875U1
Fit sufficient length of the shank into
the collet. Ideally at maximum
plunge, only as much of the cutter
should protrude below the base as is
required to reach the depth of the
mortise.
Due to the extra long length of this
cutter, extra care should be taken to
avoid damage. The cutter should be
used to plunge rout a series of
overlapping holes. See page 13.
Do not attempt to increase the depth
of cut by having less than the
optimum length of the cutter’s shank
inserted in the collet of your router.
The guide bush Ref GB30/A cannot
be used with the jig for internal
doors.
-8-
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 9
LOCK/JIG
Option
2
+
+
12mm
Medium duty router with
1⁄4” collet e.g. T5 Router
Router Cutter
Ref. TR12X1/4TC
30mm Guide Bush
Ref. GB30
overall length 70mm
OR USE
Router Cutter
Ref. 3/8LX1/4TC
overall length 66mm
Option
Deepening of
mortise with auger
bit and drill will be
required.
3
Using the Lock Jig with the Trend Hinge Jig
■ If the Lock Jig is to be used in conjunction with the Trend Hinge
Jig, use the Guide Bush Collar to bush out the 16mm guide bush
(supplied with the Hinge Jig) to 30mm diameter. This makes it
unnecessary to change guide bushes between operations.
Guide Bush Collar
Ref. GB/COLL/1630
Supplied with Lock Jig
+
+
16mm Guide
Bush Ref.
GB160
Supplied with
Hinge Jig
12mm
Medium duty router with
1⁄4” collet e.g. T5 Router
Router Cutter
Ref. TR12X1/4TC
or 3/8LX1/4TC
-9-
Deepening of
mortise with auger
bit and drill will be
required.
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 10
LOCK/JIG
Fitting the Guide Bush
Guide bush
collar
Ref. GB30
Ref. GB30
Fitting Guide Bush to T10/T11 Router
■ If using the Trend T10/T11 Router, fit a 30mm
guide bush Ref.GB30. Make sure the bush is
correctly centred.
If there is any doubt about the
concentricity of cutter relevant to the
guide bush, then a sub-base should
be used in order to ensure an
accurate fit of face-plate.
Ref. GB160
Fitting Guide Bush to T5 Router
■ If using the Trend T5 Router, purchase and fit
a GB30.
■ If using the Hinge Jig, fit the GB160 supplied
with the Hinge Jig. By using the Guide Bush
Collar supplied with the Lock Jig, the same
router set-up can be used by simply fitting the
collar in between the hinge and lock
operations.
■ The guide bush collar can be stored on the
spigot fixed to the outside of the clamp bar
when not in use.
Ensure guide bush collar is fitted fully
onto the guide bush with chamfer
facing the jig.
Make sure guide bush
collar is fitted with
chamfered edge facing
the jig when parked.
This will make it easier
to remove.
Frequently check that the guide bush
collar is seated properly on the the
guide bush. Check that the collar has
not worked loose otherwise this will
affect the cut.
-10-
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 11
LOCK/JIG
Steel Templates
■ Mortise templates (letters A,B,C etc.) have
smaller apertures for the lock body and faceplate templates have a larger aperture
(numbered 1, 2, 3 etc.).
Please note templates have square
corners so care must be taken when
handling.
Template Selection Chart
A
Face-plate Dimensions:
7
Approx.
Imperial
7⁄8" x 61⁄8"
7⁄8" x 6"
1" x 43⁄4"
1" x 5"
1" x 51⁄4"
1" x 53⁄4"
1" x 6"
1" x 61⁄8"
1" x 61⁄2"
1" x 7"
1" x 21⁄4"
1" x 21⁄4"
1” x 63⁄8"
■ They are attached to the jig by means of the
two strong magnets incorporated in the jig
body. Ensure that the seating for template is
free of wood dust.
■ The templates are reversible and have no
defined top or bottom (except template 11,
see below right).
■ A laminated loose sheet ʻLook-up Chartʼ is
supplied with this manual showing popular
makes of lock and their correct template
selection.
Metric
22.2 x 156mm
22.5 x 152.5mm
25.4 x 121mm
25.4 x 127.5mm
25.4 x 133.5mm
25.4 x 145mm
25.4 x 153mm
25.4 x 156mm
25.4 x 165.5mm
25.4 x 177mm
25 x 57.5mm
26 x 56.5mm
25.6 x 162mm
Select
Template
1
2
3
4
5
6
7
8
9
10
11 UPPER
11 LOWER
12
Mortise Dimensions:
■ By referring to the loose sheet ʻLook-up
Chartʼ, choose the correct templates. If your
lock is not listed use the chart above right to
calculate which two plates are required for the
mortise and face-plate eg. B7.
Approx.
Imperial
5⁄8" x 27⁄8"
5⁄8" x 41⁄4"
3⁄4" x 31⁄8"
3⁄4" x 41⁄4"
■ For the latest information on templates
available, see our website www.trend-uk.com/downloads
or call Trend Technical Support.
Metric
16 x 72mm *+
16 x 107mm *
19 x 79mm*
19 x 109mm*
Select
Template
A
B
C
D
* These are maximum mortise lengths, unless radius ends are
squared with a chisel. However, smaller mortise locks can be
accommodated depending on the position of their fixing screws.
+ Note actual size of mortise is 16mm x 79mm (5⁄8” x 37⁄64”).
Special Note for Template 11
■ Template 11 is used for 1" mortise latches.
Two aperture sizes are offered in the one
template, to cater for the two popular sizes of
mortise latch face-plates available.
Template upper aperture
Centre line notches
for Template 11
CL
■ The upper aperture will suit a latch plate
25mm x 57.5mm. The lower aperture will suit
a latch plate 25.6mm x 56.5mm.
■ Two additional centre line notches on the jig
body are used in conjunction with this
template.
■ Ensure you accurately measure the face-plate
before selecting the appropriate aperture.
11
■ The mortise for the latch body should be cut
with a suitable auger bit and drill.
-11-
Template lower aperture
Template number
should be at the bottom
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 12
LOCK/JIG
OPERATION
Marking Out
■ Choose the position of the lock carefully.
Position the lock with the centre of the spindle
aperture at approximately 1m above the floor.
Whilst the lock is on the edge of the door,
mark the top and bottom of the lock case on
the door edge. Do not choose a position
where the cross member joins the stile as it
will weaken the door.
■ Then using a marking gauge set to half the
thickness of the door, join the marks to show
where the centre line of the mortise lock will
be. Ensure the centre line is long enough to
sight them on the centre line notches on the
jig body.
CL
■ Mark a horizontal line across the edge at the
centre of your lock position. You now have
two centre lines to line up with the notches on
the jig body.
Please note, the centre of the mortise
may not be on the centre line of the
spindle hole.
■ Mark out the spindle and keyhole position on
the face of the door as normal using a paper
template or the lock body as shown with a
bradawl (ensuring the front of the lock is flush
with the door edge).
Ensure working position is
comfortable, especially when setting
up and when routing a door edge.
Ensure door is clamped and held
securely when using the jig.
-12-
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:11 Page 13
LOCK/JIG
Centring the Jig
When using the lock jig, the clamp bar is used as the
datum edge. Before the jig can be used the clamp bar
datum has to be set by the user. The jig template
aperture recess has v notches that are punched into the
jig body. Due to the manufacturing tolerances there may
be some deviation between the v notches, subsequently
the notches should only be act as an initial guide to
position the jig on the door. Furthermore when the spacer
fingers are used this raises the jig higher making it more
difficult to align to the pencil marks to the v notches.
Adjustable
levers
Lobe
knobs
Jig template
aperture recess
Clamp bar
(datum)
■ After the lock position has been marked on the
door, loosen the two lobe clamping knobs and
the three adjustable levers (which are a ratchet
type and require lifting to change their position)
so that the jig can fit to the door.
■ Initially set up jig using the v notches to get an
approximate centre of the door.
■ To set the jig accurately, either measure with a
rule or tape to position jig template aperture
recess centrally, or place the largest template
into the jig and look down vertically to gauge
position. Adjust the two clamping knobs
accordingly to move the jig forward or
backwards to centre. Once the jig is centred and
parallel, slide the clamping knob against the
door edge and tighten the adjustable levers.
■ Check clamping bar is fully against the door
edge and adjust adjustable levers if necessary.
The datum has now been set.
■ The jig can now be clamped into position by
tightening the two lobe knobs. Only gentle
pressure is required.
The jig template aperture recess
notches in the jig central aperture
are to be used as an initial visual
guide only, always check the jig and
template is centred to the door using
a rule or tape measure before
routing.
Make sure the correct templates are
used eg A, B, C etc for the mortise,
and 1,2,3 etc for the face-plate.
Do not over-tighten lobe knobs as
damage to the door or jig may occur.
The adjustable levers may require the
machine screw to be tightened with a
No. 2 Phillips screwdriver before use.
■ Once set, the only marking requirement for
further doors of same thickness is a single offset
measurement from the rail or bottom of the door
to the top of the jig.
Special Note:
If fitting the lock to a non-solid core door, ensure
the lock block is located first.
-13-
Trial cuts should be made on waste
material to check correct templates
have been selected and that face
plate/mortise is central.
Trial cuts should be made on waste
material to check correct templates
have been selected and that jig is
set up accurately.
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:12 Page 14
LOCK/JIG
See special
note on page 5.
Plunge rout a
series of holes
Rout clockwise
for clean up
Routing the Mortise
■ Fit the relevant mortise template to the jig
body eg A, B, C etc. Ensure that seating for
template is free of wood dust. Template may
need to be tilted (long edge first) into the jig
template aperture recess to fit.
■ Plunge rout the mortise by drilling a series of
overlapping holes no more than 20mm deep.
■ Make sure plunge locking lever of router is
locked and then clean up by making a shallow
pass no more than 20mm around the
template in a clock-wise direction.
■ Remove loose waste with a screwdriver and
vacuum extractor and repeat plunge and rout
operations until full depth is achieved.
■ Depending on router set-up, deepening of
mortise with auger bit and drill may be
required.
Rout in shallow passes. Do not
attempt to increase the depth of cut
by having less than the optimum
length of the cutter’s shank inserted
in the collet of your router. Trial
cuts should be made on waste
material to check the fit before
routing the door.
See special
note on page 5.
Routing the Face-plate
■ Fit the relevant face-plate template eg 1, 2, 3
etc. Ensure seating is clear of any wood dust
or swarf. Template may need to be tilted (long
edge first) into the jig template aperture
recess to fit.
■ Zero the depth of the cutter, by lowering it
until it touches the door edge.
■ Insert the lock fixing plate together with the
face-plate between the revolving depth guide
and the fine adjuster screw. Lower the fine
adjuster (1) and lock it off (2) see picture.
■ Release the plunge locking lever.
■ To rout the face-plate, plunge cutter to full
depth of face-plate in the middle of the
template and lock off plunge.
■ Rout in a clockwise direction to the set depth.
Release the plunge locking lever.
After use of the jig, keep jig assembled and store
carefully.
-14-
To set cutter plunge depth measure
the depth of the lock body from the
face to the back and add 3mm to
allow for clearance.
4
1
2
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:12 Page 15
LOCK/JIG
Finishing
TIP
■ The corners of the face-plate recess will need
squaring off with a sharp chisel. Alternatively
the Trend Corner Chisel Ref. C/CHISEL, can
be used to square off the rounded corners
with one tap of a hammer.
Before testing fit of the lock, engage the
lock bolt in the locked position to enable
the lock to be removed easily.
MAINTENANCE
The jig has been designed to operate over a long
period of time with a minimum of maintenance.
Continual satisfactory operation depends upon
proper tool care and regular cleaning.
Deeper Mortise
■ Should you need to cut the mortise deeper
than the maximum depth possible with the
router cutter or router, use a relevant sized
auger bit in an electric drill to complete the
operation.
Cleaning
■ Regularly clean the jig with a soft cloth.
Lubrication
■ Your jig requires no additional lubrication.
Storage
■ This jig should be stored in its packaging after
use.
■ An accessory case is also available
Ref. CASE/DH.
ENVIRONMENTAL PROTECTION
■ Use a drill fitted with a suitable size drill bit to
bore a hole for the spindle and the keyhole.
Recycle raw materials instead of disposing as
waste.
Packaging should be sorted for environmentalfriendly recycling.
The product and its accessories at the end of their
life should be sorted for environmental friendly
recycling.
■ Insert the lock body, test spindle and key
actions then screw lock into place.
GUARANTEE
Cutting Key and Spindle Holes
■ To mark the frame to receive the striking
plate, heavily mark the end of the lock bolt
with a pencil. Close the door, open the lock
bolt as far as it will go and gently move the
door backwards and forwards.
The jig carries a manufacturers guarantee in
accordance with the conditions on the enclosed
guarantee card.
■ The pencil marks on the frame will indicate
the position of the recess for the lock striking.
-15-
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:12 Page 16
LOCK/JIG
Please use only Trend original spare parts.
LOCK JIG - SPARE PARTS LIST
No.
Qty.
1
2
3
4
5
6
6A
7
8
8A
9
10
11
12
1
1
6
2
3
2
2
3
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
13
14
15
16
17
18
v3.0 10/2002
Desc.
Ref.
Lock Jig Body
Clamp Bar
Spacer Finger
Mini Knob 15mm Female M5 x 15mm
Adjustable Lever Female M8
Lobe Knob Male M10 x 40mm Tapped <07/02
Lobe Knob Male M10 x 40mm Ball End >07/02
Washer 8.5mm x 25mm x 1.5mm <07/02
Plastic Cap 35mm Dia Black <07/02
Plastic Cap Ball End >07/02
Lobe Knob Foot <07/02
Machine Screw Csk M4 x 10mm Pozi <07/02
Spring Washer M5
Mortise Template A (34 x 97mm)
Mortise Template B (34 x 132mm)
Mortise Template C (37 x 104mm)
Mortise Template D (37 x 134mm)
Face Plate Template 1 (40.4 x 174mm)
Face Plate Template 2 (40.7 x 170.5mm)
Face Plate Template 3 (43.6 x 139mm)
Face Plate Template 4 (43.6 x 145mm)
Face Plate Template 5 (43.6 x 151.5mm)
Face Plate Template 6 (43.6 x 163mm)
Face Plate Template 7 (43.6 x 171mm)
Face Plate Template 8 (43.6 x 174mm)
Face Plate Template 9 (43.6 x 183.5mm)
Face Plate Template 10 (43.6 x 195mm)
Face Plate Template 11 Latch
Face Plate Template 12 (44.2 x 180mm)
Template Set (16pcs)
Magnet 15mm x 3mm (4 Pack)
Guide Bush Collar 16mm to 30mm
Look-up Chart
Manual
WP-LOCK/01
WP-LOCK/02
WP-LOCK/03
WP-LOCK/04
WP-LOCK/05
WP-LOCK/06
WP-LOCK/06A
WP-WASH/17
WP-LOCK/08
WP-LOCK/08A
WP-LOCK/09
WP-SCW/69
WP-WASH/29
WP-LOCK/T/A
WP-LOCK/T/B
WP-LOCK/T/C
WP-LOCK/T/D
WP-LOCK/T/1
WP-LOCK/T/2
WP-LOCK/T/3
WP-LOCK/T/4
WP-LOCK/T/5
WP-LOCK/T/6
WP-LOCK/T/7
WP-LOCK/T/8
WP-LOCK/T/9
WP-LOCK/T/10
WP-LOCK/T/11
WP-LOCK/T/12
WP-LOCK/T/SET
MAG/PACK/1
GB/COLL/1630
LEAF/LC/LOCK
MANU/LOCK
-16-
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:12 Page 17
LOCK/JIG
LOCK JIG - SPARE PARTS DIAGRAM
v3.0 10/2002
4
11
3
5
16
7
2
15
1
6A
6
18
9
10
8
12
LOCK
JIG
8A
<07/02
17
13
14
-IB-
MANU/LOCK v9 (Batch 10/2012 EB)
MANU-LOCK v9_MANU-LOCK v9 07/11/2012 10:12 Page 18
RECYCLABLE
Trend Machinery & Cutting Tools Ltd.
Odhams Trading Estate St Albans Road
Watford WD24 7TR England
Tel: 0044(0)1923 249911
[email protected]
www.trend-uk.com
© Copyright Trend 2012. No part of this publication may be reproduced, stored or transmitted in any form without prior permission.
Our policy of continuous improvement means that specifications may change without notice. Trend Machinery and Cutting Tools
cannot be held liable for any material rendered unusable or any form of consequential loss. E&OE
® All trademarks acknowledged.
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