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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