MODEL 350H HINGE ROUTER OPERATOR & PARTS MANUAL
Effective S/N: HDJ-1017 Release: 2
Document Number: 17-351
First Release: September 2008 Second Release: May 2010
This Page is Intentionally Blank
Norfield Industries P.O. Box 459 Chico, Ca. 95927 Technical Support: (530) 891-4214 - Parts: (800) 824-6242 Serial No: _____________________ Date Sold: _____________________
Norfield Industries is the name that represents Quality, Reliability, Support, Innovation and
True Customer Service. We have been dedicated to providing quality products and excellent customer service for more than 40 years. Norfield Industries has earned a reputation in the pre-hanging industry for setting standards for reliable machinery, full technical support, machine parts, full line industrial woodworking tools and supplies and a team of customer care representatives to support you! Our factory-trained technical personnel are ready to assist you on the telephone or in your shop.
TABLE OF CONTENTS
Introduction
5
Safety
6
Specifications
9
Section 1 - Installation
10
Section 2 - Quick Start
12
Section 3 - Settings and Adjustments
13
Section 4 - Special Adjustments
20
Section 5 - Maintenance
24
Section 6 - Parts Schematics
27
INTRODUCTION Your new NORFIELD 350H Jamb Routing machine was designed and manufactured conforming to a set of rigid specifications by trained workers who take pride in the quality of their work. Each Norfield machine must pass a series of tests and inspections before it is released for shipment. In order for this machine to provide you with a long period of continuous and satisfactory service, it is necessary that it be properly installed, operated, and maintained. This manual has been prepared to assist you in carrying out these functions. We urge you to study the contents of this manual and to be guided by the suggestions herein.
SAFETY Safety considerations are an important element of machine installation and operation. Actively maintaining a safety mind-set about yourself and others while working around or on the equipment is of primary importance. Operators and maintenance personnel should refer to the safety information on the following pages to familiarize themselves with warning labels and practices providing for safe operation and servicing of this machine. Danger indicates an imminently hazardous situation, which if not avoided WILL result in death or serious injury. Warning indicates a potentially hazardous situation which, in not avoided, COULD result in death or serious injury. Caution indicates a potentially hazardous situation which, if not avoided MAY result in minor or moderate injury. It may also be used to alert against unsafe practices. Caution, without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided MAY result in property damage but not personal injury. Notice indicates important information that if not followed may CAUSE damage to the equipment. Mandatory Action conveys an action step that should be taken to avoid the hazard.
SAFETY
Do not operate this machine unless all guards are in place and working correctly. If any guards or hazard labels are missing or damaged call Norfield’s Service Department immediately and request a replacement at (800) 824-6242. Read and understand the operator’s manual before using this machine. Failure to follow proper operating instructions could result in death or serious injury.
This machine, when in operation, produces wood chips and dust. The operator and all persons in the work area MUST wear approved eye protection with permanently attached, rigid plastic side shields. These safety glasses must conform to ANSI Z87.1 standards and will have “Z87” printed on the lens. This machine, when in operation, produces a noise level greater than 85dB. The operator and all persons in the work area MUST wear approved hearing protection. OSHA has determined that a noise level in excess of 85dB average in 8 hours can cause permanent hearing damage. We recommend that hearing protection be worn even if the decibel level is below 85dB. Certain types of wood dust can cause allergic reactions. Sawdust has been determined to be a Group A carcinogen by the International Agency for Research on Cancer (IARC). A dust collection system or an approved personal dusk mask MUST be used when operating this equipment.
This machine has moving parts that loose clothing and long hair can become entangled in. Take care not to become caught between the work material and the feed mechanisms or any other moving components.
Before beginning any service repairs, general maintenance, or adjustments you MUST follow proper Lockout Tag-Out procedures. OSHA regulation 1910.147 establishes a minimal lockout tag-out procedure to assist employers in the development of their own procedures.
Only trained personnel that have read and understand the operator’s manual and all the safety precautions may operate this machine.
SAFETY
Inspect the machine at the beginning and end of each shift for damaged or cracked components such as, but not limited to, saw blades, router bits, drill bits, and boring bits.
Never leave this machine unattended while it is in operation. Make sure that all electrical and air is in the off position when the machine is not in use or is unattended and that any cutting blades have come to a complete stop.
Do not attempt to clean material from this machine until all the cutting blades have come to a complete stop. Even when the machine has been turned to the “off� position it may take up to several minutes for the blades to coastdown to a complete stop.
Woodworking machinery is inherently dangerous, common sense and good safety practices are your best defense against injury.
If you have any questions regarding the correct operation of the machine and safety procedures in this manual call the Norfield Industries Service Department at (800)-824-6242
SPECIFICATIONS The Model 350H is a machine designed for mortising for hinges in doors and jambs. The door and jamb are machined simultaneously which insures a matched product with a minimum of material handling and set-up. Both left and right doors and jambs can be machined without any adjustments other than the initial set-up. Different hinge sizes are accommodated by quick, accurate change-overs.
Electrical Requirements AC Line Voltage
Phase
Hertz
Amperage
115
1
60
15
Air Requirements PSI
SCFM
Minimum Supply Pipe I.D.
90
1 7.3 w/ Screwdriver
3/8”
Machine Capabilities Door Width
1’-0” - 3’-6”
Door Height
Up To 8’-0”’
Door Thickness
1-3/8” - 2-1/4”
Jamb Width
2-1/2” - 10-1/2”
Jamb Length
Up To 8’-0”
Jamb Thickness
1/2” - 1-5/8”
Stop Thickness
1/2” Maximum
Butt Spacing
Variable, 6-1/2” from top of door Minimum
Butt Radius
1/4” & 5/8”
Butt Size
3-1/2” x 3-1/2” - 4” x 4” - 4-1/2” x 4-1/2” - 5” x 5” (3” x 3” Optional).
Lock Backsets
N/A
Faceplate Routing
N/A
Floor Space Required (Machine Only) Height
Width
Length
92”
42”
180” 228” if Machine has 2 routers.
SECTION 1 INSTALLATION 1.1 SHIPPING DAMAGE AND SHORTAGES Before and after the crated machine is unloaded from the truck the crate should be inspected for any signs of damage. If suspected damage is found, it must be noted on the bill of lading and signed by the driver and person receiving the shipment. After the machine has been uncrated inspect it and all other contents of the crate for shipping damage. In the event that damage has occurred in transit, notify the freight carrier and Norfield Industries immediately. Inspect the complete shipment against the packing slip to make sure all items listed are accounted for. If any shortages are noticed, the freight carrier and Norfield Industries should be notified immediately.
1.2 POSITIONING THE 350H After uncrating and inspecting the machine for damage and shortages, the machine should be moved from the crate base to its permanent location. Since vibration is not sufficient to cause the machine to creep, there is no need to secure it to the floor.
1.3 AIR SUPPLY AND CONNECTIONS Clean, dry air is necessary for the continued performance and low maintenance of air operated tools and equipment. Foreign materials such as dirt, grit and pipe scale, generally present in air lines, can cause severe abrasive wear in valves and cylinders. Norfield highly recommends that a Filter-Regulator-Lubricator (FRL), in addition to the unit mounted on the machine, be installed in the supply line and the regulator set to 90 PSI. Norfield also recommends the use of an air drying system to help give maximum life to all your air tools. The air connection to the 350H is made at the FRL on the frame cross-member (See Figure 1). If you are using an air operated screwdriver and/or pre-drill, the supply line should be no less than 1/2� ID.
1.4 ELECTRICAL SUPPLY AND CONNECTIONS The 350H requires an electrical input of 115 VAC @ 15 amps. The machine is equipped with a standard 115 volt cord and grounded plug for easy connection. Make sure that the outlet/circuit you are using for the machine can handle the machine as well as any other tools or appliances connected to it. If an extension cord is used, 14-3 is recommended as a minimum. Make sure that the power cord is kept clear of the operator and material movement.
10
Figure 1-1
Valve on FRL
Connect Air to Shut-Off
INSTALLATION
11
SECTION 2 QUICK START The following section is intended to get you up and running in as timely a manner as possible. We are assuming that at this point the machine is uncrated and in position. 1. Read the Safety Section in this manual (pages 6 - 8) 2. Connect air to the Filter-Regulator-Lubricator on the back of the frame. Set the Regulator at 90 PSI (section 1.3) 3. Provide an electrical source for the Butt Router (section 1.4) 4. Check the door width adjustment (section 3.1) 5. Set the Door and Jamb Stops (section 3.2 thru 3.4) 6. Set the Butt Router (section 3.5 thru 3.8) 7. Machine a door and jamb and check your adjustments.
Door Clamp
Jamb Rack Adjustment Router Pivot Lock
Operator Controls Figure 2.1
12
SECTION 3 SETTINGS AND ADJUSTMENTS
T-Track Assembly Jamb Clamp and Reference Assembly
Hardware Tray Main Bar Butt Router Assembly
Door and Jamb Stops
Door Support Assembly
Location of Major Components Figure 2.1
13
SETTINGS AND ADJUSTMENTS
3.1 ADJUSTMENT FOR DOOR WIDTH The 350H is adjustable in 2” increments for doors ranging from 1’-0” to 3’-6” wide. Adjustment is accomplished simply by raising or lowering the Door Support Assembly to the desired location. • • • • •
Remove the Lock Pin from the slotted end of the support tube. Lift the end to the desired location in the Width Index Bracket. Re-insert the pin Raise the other end of the support tube to the desired location. Scales are provided on each bracket to facilitate this adjustment.
Width Index Bracket
Slots for fine-tuning
Lock Pin in slotted end of Door Support Assembly
Figure 3-2
2-1/2”
Figure 3-3 Use the slots in the Width Index brackets to fine tune for door width. The optimum distance from the top of the Main Bar to the edge of the door is 2-1/2” using a door that has been undercut.
14
SETTINGS AND ADJUSTMENTS
3.2 DOOR STOP ADJUSTMENT While the location of the door stop assemblies on the index bar is not critical, it is important that they be located far enough away from the top of the door to prevent any interference between the index blocks used for butt router referencing. Norfield recommends the door stops be located approximately 12” further apart than the length of the door you are setting-up for. Figure 3-4 shows the settings for a 6’-8” door. The top of the door references against the flat head screw in the end of the pivoting stop dog.
Left Hand Door Stop
6” from top and bottom
Right Hand Door Stop
6’-8” door centered on the machine
Figure 3-4
3.3 JAMB STOP ADJUSTMENT (HEADER CLEARANCE) Header clearance is the gap between the top of the door and the head jamb, usually 1/16” to 1/8”. Normally this dimension will not require changing. However, if an adjustment is necessary, leave the door and jamb stop assemblies where they are on the index bar and adjust the jamb stops only. Adjusting the location of the door stop will result in changes to the hinge locations relative to the top of the door. Refer to figure 3-5.
15
SETTINGS AND ADJUSTMENTS
Jamb Stop (Exterior)
1/16” to 1/8” (Header Clearance)
Jamb Stop (Interior)
Jamb Stop Lock Nuts
Door and Jamb Stop Locking Set-Screws
Figure 3-5
Door Stop Flathead Screw
3.4 HINGE SPACING From time to time you may need to change your hinge spacing on an existing index bar or set up a new index bar. To accomplish this, the following procedure is suggested (refer to figure 3-6 on the facing page). (Note: for quick change-over for different door heights and hinge locations, Norfield recommends you have several “extra” index bars). 1. If changing an existing index bar, use a metal scribe and mark the location of the index blocks where they are set for your standard spacing so you can accurately and quickly return them to “standard” 2. Place a “set-up” door on the machine and position it against either door stop. 3. Starting at the top of the door, measure down the edge and make a mark where the top of each hinge is to be located. 4. Loosen the set-screws in the router index blocks.
16
SETTINGS AND ADJUSTMENTS
Alignment Lines on Clamp Bar (Chip Breaker Removed)
Alignment Lines on Door for Hinge
Figure 3-6
5. Lower the router carriage until the locating tabs on the router carriage are over the index block nearest the top of the door and the router carriage is resting on the edge of the door. 6. Move the router carriage until the applicable reference line on the door clamp bar is aligned with the line on the door for the top of the top hinge. Make sure that the top of the door is still referenced to the door stop. (Note - remove white plastic chip breaker). 7. Lift the router up, move the door away from the main bar and tighten the set screws in the index block. 8. Clamp the router carriage back on the door using the index block you just located and check to make sure the lines are still aligned. Repeat the process for the other hinge locations and index block. 9. Turn the door end for end and use it to set up the other hand.
17
SETTINGS AND ADJUSTMENTS
3.5 CHANGING MORTISE SIZE When all three stop tabs are in the path of the stop bolts (as shown in figure 3-7 below) the mortise will be 3-1/2” wide. As stop tabs are rotated out of the path of the stop bolts the mortise width will increase in 1/2” increments i.e. 4”, 4-1/2” and 5”. The distance of cut into the door and jamb is controlled by the stop turret which can be rotated to change from 3-1/2” to 4” butts. The turret stop screws will fine-tune the mortise distance for each setting. Stop Tabs
Stop Bolt Mount Block Stop Bolts
Stop Turret
Stop Screws
Figure 3-7 3.6 CHANGING MORTISE RADIUS Mortise radius is determined by the diameter of the router bit being used. A 1/2” diameter bit will produce a 1/4” radius and a 1-1/4” router bit will produce a 5/8” radius. If the router carriage is going to be changed from one radius to another, the following applies: 1. Change the stop screws in the stop turret - use 10-24 x 3/4” flat head screws for 1/4” radius or 10-24 x 1” flat head screws for 5/8” radius. 2. Also, when changing radius, the stop bolt mount blocks must be moved. The location of the blocks shown in figure 2-7 is for 1/4” radius. When going to 5/8” radius move the stop blocks to the outboard set of holes. 3. Re-adjust width and distance into the door and jamb as required. If frequent changes are made to the hinge radius, it is suggested that a second butt router be purchased and “parked” out of the way on the tram rail when not in use.
18
SETTINGS AND ADJUSTMENTS
3.7 MORTISING FLAT JAMBS When mortising flat jambs (jambs with no stop applied) the stop system shown below in figure 3-7 is used to control the movement of the router into the door and into the jamb. The stop dog is rotated to the “down” position (as shown) and is positioned between the door and jamb when the router is lowered.
Stop Screws Stop Dog
Figure 3-8 By adjusting the stop screws, the distance of mortise into the door and jamb is precisely controlled. This stop system is generally used for 3-1/2” hinges only. If you have need to mortise for 4” or other sized hinges on jambs with no stop applied, it is recommended you purchase an “extra” flat jamb stop assembly and set it for the required mortise dimensions.
3.8 MORTISE DEPTH To change mortise depth open the locking clamp lever and position the “zero” on the adjustment ring exactly above the pointer on the router base. Turn the adjustment ring until the bit is at the desired depth. Note that each mark on the adjustment scale represents a depth change of 1/64” (.015”). Close the clamp lever.
Adjustment Ring
Locking Clamp
Figure 3-9
19
3.9 EXTENDED RANGE ROUTER CARRIAGE (Optional) SPECIFICS: The optional extended range router carriage and related setup is capable of machining all materials as the standard butt router along with the ability to process extra thick exterior jambs and T-shaped mullions with or without weather-stripping applied. When configured for the thicker jambs and mullions the router will accommodate flat or single rabbeted jambs from 1-5/8 to 2-3/4” thick and mullions with 1-1/8” to 2-1/4” center thickness and a 1/2” thick stop on both sides. All other dimensions for jambs and doors are equivalent to the standard capabilities on the Magnum. Change over time from setup for standard jambs to thicker jambs requires less than 5 minutes.
GENERAL USE: The extended range router operates in a similar fashion as the standard butt router with a few variations. The lower indexing pins, 13-597, position the router to perform operations on square edged doors and standard thickness jambs, up to 1-1/2”. To mortise beveled edge doors, raise the rear of the router carriage one position higher and lock it into position with the lower indexing pins. All operations performed in these two configurations are referenced in the standard operating procedures section of the operator’s manual.
PROCEDURE FOR PROCESSING EXTRA THICK JAMBS AND MULLIONS: Configuring the router for thicker jambs as described above requires a few procedures to be followed that vary from the standard router as follows: 1. Raise the rear of the carriage to the top most position and engage the upper indexing pins. 2. To operate the router in this configuration the Door Support must be moved down one door size (i.e. if you are processing a 3’-0” door set the Door Support at 3’-2”) and raise the door approximately 7/8” using a spacer on the rollers (not provided). This is to ensure that the face of the jamb and the edge of the door are flush with one another as the reference point has changed to extend the router’s capabilities. Note: When processing doors and jambs with the router set-up in this configuration, the router will process square edge doors only. The width index adjustment may also cause interference with the main bar on some raised molding doors. In such cases, the door and jamb will need to be processed in separate operations. When machining the jamb, substitute a door without raised molding to provide clamping of the router carriage. When processing T-shaped mullions, the six Jamb Lifter Spacers, 6805-088, that are provided in boxed parts, will need to be installed on the Jamb Lifters, 6805-116, as a rest for the center portion of the mullion. To install these components, orient the Spacers so that the thumb screw is on the right and the center opening is facing down. Insert the Spacers down onto the Jamb Lifters and slide them forward until they are resting firmly against the lip of the Jamb Lifters then tighten the thumb screw to secure.
20
SECTION 4 SPECIAL ADJUSTMENTS 4.1 JAMB RACK ADJUSTMENT Angular Adjustment The jamb supports should be at a 90 degree angle from the face of the door. This can be checked using a framing square. The jamb rack (aluminum extrusion with eight (8) jamb supports) can be rotated to achieve the correct angle. To rotate the jamb rack, loosen the jamb nut on the adjustment link and rotate the link. By shortening the link, the jamb is tilted toward the door (angle decreases). Lengthening the link tilts the jamb away from the door (angle increases). When making this adjustment, be sure to check and adjust both ends of the jamb rack.
Angular Adjustment
Framing Square
Jamb Support
Jamb Nut Adjustment Link
Figure 4-1
21
SPECIAL ADJUSTMENTS
Parallel Adjustment The jamb needs to be parallel with the edge of the door for consistent hinge mortising. This can be checked by raising the jamb to the correct height and checking the relationship between the face of the jamb and the edge of the door at both ends of the machine using a framing square set flat on the jamb and the edge of the door. If adjustment is necessary, loosen the jamb nut on the cylinder rod, remove the clevis pin from the clevis and then rotate the clevis to either extend or retract the length between the cylinder and the link. This in turn will raise or lower the jamb rack and jamb to obtain parallelism. A combination of adjustment on both ends of the cylinder may be necessary. Index Bar
Clevis Pin
Rod End Clevis
Jamb
Jamb Nut
Jamb Lift Cylinder
Link
Figure 4-2 4.2 LEVELING THE ROUTER CARRIAGE In order for the mortises to be the same depth in the door and in the jamb, the router carriage must be level (perpendicular to the face of the door) before and after clamping it in place. Before attempting to level the router carriage, ascertain that the following two conditions exist. •
The hinge edge of a square (non-tapered) door is 2-1/2” above and parallel to the main bar (figure 4-3). If this is not the case, the door support assembly needs to be adjusted (see section 3-1). If the door support is not correctly adjusted the mortises will be deeper in the door at one end, and deeper in the jamb at the other.
•
A 1/32” gap exists between the door clamp bar and the face of the door when the router carriage is resting un-clamped on the door edge and the door is referenced against the main bar. If the gap is less than 1/32”, the clamp bar will strike the edge of the door as the carriage is lowered. If it is greater than 1/32”, the action of the clamp cylinder will pull the
22
SPECIAL ADJUSTMENTS
plate and tram rollers forward causing the pivot point to lower and a deeper mortise in the jamb will result. If the gap is not 1/32”, loosen the four screws that secure the adjusting bolts to the back plate and adjust the carriage by turning the adjusting bolts equally to attain the 1/32” gap. Retighten the screws. If the jamb reference bars do not rest flat on the door edge, the following procedure will correct this (refer to figure 4-4). 1.
Make sure that the door edge is square
2.
Loosen the three tram rollers and raise or lower the back plate until the jamb reference bars are resting flat on the door edge.
3.
Tighten the top center roller.
4.
Position and tighten the two lower rollers, leaving 1/32” clearance between the roller and the tram rail. This will permit the carriage to “rock”, thus conforming to the door edge should the edge be slightly bowed.
5.
Adjust the felt wipers to effectively wipe the top surface of the tram rail.
Tram Rail
Door Clamp Bar Door
Figure 4-3 Back Plate
Adjusting Bolt Tram Roller Felt Wiper
Figure 4-4
23
SPECIAL ADJUSTMENTS
4.3 CHANGING THE BUTT ROUTER FROM 0 TO 3-1/2 DEGREES This feature allows the Magnum to machine the hinge mortises flush with the beveled edge of a double-beveled door. The jamb can be held and machined at the same angle by installing the 6 jamb riser wedges (item # 0001-741) which are included with the standard machine. The wedges slip over the jamb risers and are held in place by a thumb screw on the side. The thin edge of the wedge points toward the door. To change between 0 and 3-1/2 degree mortising, the following procedure is recommended (refer to fig 4-5): 1. Unplug the butt router motor. 2. Install the six jamb riser wedges. 3. Lower the butt router assembly. 4. Release both pivot lock pins by pulling the pin out and rotating it 90 degrees. Push down on the butt router handle to cause the pivot blocks to move up in their slots. While still holding the handle down, rotate the lock pins to allow them to lock the assembly in the “up� position. 5. Reverse the procedure to return the router to the normal position.
Pivot Lock Pin
Figure 4-5
24
SECTION 5 MAINTENANCE 5.1 GENERAL MAINTENANCE Door machines work in an environment of endless sawdust. Sawdust is not only very abrasive when allowed to penetrate motors, bearings, etc., but it also contains pitch. Pitch clings to sliding surfaces and eventually coats the bearings. Mechanisms become “sticky” and if not cleaned soon become inoperable. To combat the effects of sawdust on your machine the following recommendations are made: 1. Using an air hose, blow off the router motor 2-3 times daily. 2. Clean the slide rods on the router carriage daily with a non-oil based solvent (Electrical/ Electronic Grade Contact Cleaner) and wipe the rods dry with a clean, dry cloth. DO NOT LUBRICATE! Any type of lubrication on the slide rods will merely collect more sawdust. 3. Inspect and clean weekly the two cam guides and rollers on the jamb rack. These components are located on the backside of the jamb rack on opposite ends. First blow the cavities clean, then take a brush and clean any pitch left on the rollers and guides. 4. Once a month, clean the rollers on the door support assembly. Pitch build-up on these rollers may cause the door to set crooked and result in un-even mortises.
5.2 ROUTER BITS Router bits need to be sharp to provide a clean, well formed mortise. Check the router bits once daily and replace if the bits look burnt or dull.
When Changing Router Bits ALWAYS Disconnect the Router Electrical Cord 5.3 FILTERS The air filters on your machine are designed to further clean compressed air that is not heavily laden with moisture or impurities. If excessive water or pipe scale is present in the air to the filters, the filters will clog up and pass through the excess water. For this reason, if you do not have an in-plant air cleaning system, we suggest you contact the Norfield Service Department or your local air system supplier for assistance in correcting this problem. Water present in air cylinders and valves will shorten their life by up to 90%. Check the air filters daily. The drain on the pre-filter (particulate) is automatic, but still needs to be checked to make sure it is “dumping” all the water. The particulate air filter will require
25
cleaning at intervals depending on the quantity of impurities in your air supply. The secondary filter (coalescing) is designed to remove very small impurities and oils from the air. This filter must be replaced when the element appears discolored or dirty. NOTE; A DISCOLORED COALESCING FILTER INDICATES A POSSIBLE PROBLEM WITH THE UPSTREAM AIR SUPPLY.
Shutoff Valve Jamb Clamp Regulator Lubricator
Coalescing Filter
Pre-Filter/Regulator
Figure 5-1 5-4 REGULATOR Set the regulator at 90 PSI
5-5 LUBRICATOR Set the lubricator to drop 2-4 drops per minute with one of the air tools running. This is not a critical adjustment, but excess oil in the air serves no useful purpose. Use 10 wt. turbine oil to refill the lubricator as needed. Do not use hydraulic fluid, oil containing additives or any substance not recommended by Norfield as this may cause damage to the machine and air tools.
26
PARTS SCHEMATICS General Assembly
28
Frame Components
29
Filter-Regulator-Lubricator
30
Main Bar
31
Index Bar
32
Jamb Clamp and Reference
33
Butt Router (Front Section)
34
Butt Router (Center Section)
35
Butt Router (Rear Section)
36
Door Support (Standard)
37
Air Tools
38
Door Support (Clamp)
39
3” Butt Router (Front Section)
40
3” Butt Router (Center Section)
41
3” Butt Router (Rear Section)
42
Extended Butt Router (Front Section)
43
Extended Butt Router (Center Section)
44
Extended Butt Router (Rear Section)
45
27
28
29
30
31
32
33
34
35
8
19
2
4
7
21
32
33
13
11
3
34
24
10
30
12
20
23
61
22
6
6809-027 6809-074 6809-075 6809-076 6809-116
33 34 61
DESCRIPTION
Quick Change Flat Jamb Stop
Base Plate
Router Casting
Modified 2" Ferrule BR Vac Casting For DW616
Handle Bracket
SLIDE CASTING Stop Support
Yoke Casting
Main Bearing Block
DEWALT ROUTER MOTOR Spool Carrier
2" VACUUM HOSE X 15'
DEWALT ROUTER CORD
Handle
Butt Router Turret
Nylatron Spool Bushing
Slide Rod Stop Tab
Turret Stop Catch
1/2 Nylatron Spool Bushing
BUTT ROUTER ASSEMBLY (CENTER SECTION)
6807-126
30 32
15-174 6033-001
13 19
24
13-1256
12
6053-100 6055-003
13-1022
11
22 23
13-1021
10
6033-100
0007-101
8
6053-001
0006-004
7
21
0002-006 0005-002
4 6
20
0002-003
3
ITEM PART NO. NUMBER 2 0001-004
1
1
1
1 1
1
1 2
1
1
1 1
1
1
2
1
2
2 6
1
1
QTY.
36
6
5
4
3
2
1
7
22
8
21
9
BUTT ROUTER ASSEMBLY (REAR SECTION)
23
10
20
11
12
13
14
19
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
17
14
17
DESCRIPTION Stop Catch Cover Durakool G10Z-3 Switch Durakool P2008 Clip Outlet Box Mounting Bracket Pivot Bar Pivot Lolck Pin Pivot Bearing Assembly Pivot Block Lock Plate Reid WP 510 Knob Bearing Mount Block Round Spacer Tram R oller Spacer Tram Roller Nachi R6-2RS Bearing Bearing Mounting Block, (Top) Felt Wheel Carriage Bimba 020.5-R Cylinder Pivot Block Adjuster Cylinder Mount
16
PART NUMBER 6809-103 11-034 11-009 11-010 6809-040 6800-044 6809-108 6809-055 6809-106 6809-046 6809-038 13-597 6809-048 9011-038 6809-045 6809-049 12-017 6809-047 0039-002 6809-039 10-582 6809-013 6809-062
15
18
QTY. 1 1 1 1 1 1 1 1 2 2 2 2 1 3 3 3 6 2 2 1 1 4 1
37
38
5
3
PREDRILL ASSEMBLY
8
4
1
7
6
2
PART NUMBER 10-1289 10-1417 10-504 10-703 13-039 13-044 13-047 13-079
DESCRIPTION Hubbell BK-05 Tool Balancer Sioux SSD10S25AC Screwdriver Sioux SDR10S26N3 Drill FLEX HOSE ASSEMBLY #9 Self Centering Bit #490 Bit Holder Apex 440-2 Screwdriver Bit Tool Hangar
SCREWDRIVER ASSEMBLY
ITEM NO. 1 2 3 4 5 6 7 8 2 1 1 2 1 1 1 2
QTY.
39
5
4
6
11
10
9
14
DOOR SUPPORT ASSEMBLY (WITH DOOR CLAMP)
8
7
12
13
18
1
16
3
15
2
17
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NUMBER 6814-028 6814-031 10-1348 6814-106 6814-026 6814-029 6814-027 9804-028 9804-001 9522-138 6814-010 13-1186 0037-009 0058-005 SC-1-0.750 9906-004 9906-005 10-860
DESCRIPTION 1 2 1 1 1 2 1 1 1 1 1 2 5 4 5 1 1 1
QTY.
6815-701
BACKUP BLOCK CLAMP PAD SMC NCQ8B200-150 CYLINDER SLIDE ROD WELDMENT CLAMP PLATE SLIDE SHAFT CLAMP BLOCK Alignment Insert, 1/2-20 Alignment Insert, 1/2-20 1/2-20 X 1-3/8 REDI-THREAD Door Support Jergens 800943 Clevis Roller NYLON FLANGE 3/4" Split Clamp Collar FOOT PLATE Foot Pedal Guard Norgren K71DA00KC0KT1 Valve
40
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
PART NUMBER 6809-010 6809-007 10-262 19-021 0039-005 6809-052 6809-051 6809-005 6809-025 0003-002 6809-008 6809-028 6809-029 10-681 10-620 19-016 19-017 6809-009 6806-028 19-012 10-219 6805-095 6805-096 6806-029 6806-030
21 20
1
18
DESCRIPTION Handle Bracket Butt Router Face Plate PNEUMATIC VALVE 1/8" NPT Label, Warning Guard Removed Chip Shield Clamp Pad Spring Steel Wearstrip Slide Rod Reference Bar Spacer Flat Jamb Locator Clamp Plate Clamp Pivot Plate Pivot Retainer Clippard TV-4MP Air Valve BIMBA F0-171.5 CYLINDER Label, Notice Pull Router Label, Warning Router Starts Butt Router Handle CLAMP BAR SPACER Label, Warning, Ear & Eye Humphrey 31P Valve REFERENCE BAR (3/4 DOOR TO JAMB) OFFSET CLAMP BAR (3/4 DOOR TO JAMB) INDEX CLEVIS CHIP BREAKER (3" HINGE)
17
2
16
4
QTY. 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1
3
5
7
15
9
14
13
12
11
3" BUTT ROUTER ASSEMBLY (FRONT SECTION)
6
8
24
23
25
22
19
6902-707
10
41
6
10
1
3
5
12
19
20
9
8
21
2
15
7
16
11
14
22
17
18
13
4
DESCRIPTION
2" VACUUM HOSE X 15'
Base Plate
Router Casting
Flat Jamb Guide Plate BR Vac Casting For DW616
Modified 2" Ferrule Flat Jamb Dog
Handle Bracket
Stop Support
SLIDE CASTING
Yoke Casting
Main Bearing Block
DEWALT ROUTER MOTOR Spool Carrier
DEWALT ROUTER CORD
Handle
Butt Router Turret
Nylatron Spool Bushing
Slide Rod Stop Tab
Turret Stop Catch
1/2 Nylatron Spool Bushing
3" BUTT ROUTER ASSEMBLY (CENTER SECTION)
13-1256
22
6809-050 6809-074
18 19
6809-076
6809-027 6809-034
16 17
6809-075
6807-126
15
21
6055-003
20
6053-100
15-174 6033-001
9 10
14
13-1022
8
13
13-1021
7
6033-100
0007-101
6
6053-001
0006-004
5
12
0002-006 0005-002
3 4
11
0002-003
2
ITEM PART NO. NUMBER 1 0001-004
1
1
1
1 1
1 1
1
2
1
1
1
1 1
1
2
1
2
2 8
1
1
QTY.
42
6
5
4
3
2
1
7
22
8
21
9
3" BUTT ROUTER ASSEMBLY (REAR SECTION)
23
10
20
11
12
13
14
19
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
17
14
17
DESCRIPTION Stop Catch Cover Durakool G10Z-3 Switch Durakool P2008 Clip Outlet Box Mounting Bracket Pivot Bar Pivot Lolck Pin Pivot Bearing Assembly Pivot Block Lock Plate Reid WP 510 Knob Bearing Mount Block Round Spacer Tram R oller Spacer Tram Roller Nachi R6-2RS Bearing Bearing Mounting Block, (Top) Felt Wheel Carriage Bimba 020.5-R Cylinder Pivot Block Adjuster Cylinder Mount
16
PART NUMBER 6809-103 11-034 11-009 11-010 6809-040 6800-044 6809-108 6809-055 6809-106 6809-046 6809-038 13-597 6809-048 9011-038 6809-045 6809-049 12-017 6809-047 0039-002 6809-039 10-582 6809-013 6809-062
15
18
QTY. 1 1 1 1 1 1 1 1 2 2 2 2 1 3 3 3 6 2 2 1 1 4 1
43
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
PART NUMBER
6809-010 6809-007 10-262 19-021 0039-005 6809-052 6809-051 6809-005 6809-025 6809-012 6809-023 0003-002 6809-024 6809-032 6809-008 6809-028 6809-029 10-681 10-620 19-016 19-017 6809-009 19-012 10-219 6805-090
DESCRIPTION
24 23
1
22
Handle Bracket Butt Router Face Plate PNEUMATIC VALVE 1/8" NPT Label, Warning Guard Removed Chip Shield Clamp Pad Spring Steel Wearstrip Slide Rod Reference Bar Spacer Reference Bar Chip Breaker Flat Jamb Locator Clamp Bar Spacer Offset Clamp Bar Clamp Plate Clamp Pivot Plate Pivot Retainer Clippard TV-4MP Air Valve BIMBA F0-171.5 CYLINDER Label, Notice Pull Router Label, Warning Router Starts Butt Router Handle Label, Warning, Ear & Eye Humphrey 31P Valve INDEX DOG, EXTERIOR BR
21
2
4
2 1 1 1 1 1 1 2 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1
20
QTY.
3
5
6
19
7
8
18
17
16
15
25
14
11
10
EXTERIOR BUTT ROUTER ASSEMBLY (FRONT SECTION)
9
13
12
44
32
21
38
36
33
19
8
7
27
29
37
6
15
30
10
28
20
17
5
18
34
DESCRIPTION
13-1022 13-1021 0007-101 0006-004 0005-002 0002-006 0002-003 0001-004
29 30 32 33 34 36 37 38
1/2 Nylatron Spool Bushing
Slide Rod Turret Stop Catch
Stop Tab
Butt Router Turret Nylatron Spool Bushing
Handle
DEWALT ROUTER CORD
2" Dia Vacuum Hose x 12'
DEWALT ROUTER MOTOR
Spool Carrier
Main Bearing Block
SLIDE CASTING Yoke Casting
Handle Bracket Stop Support
EXTERIOR BUTT ROUTER ASSEMBLY (CENTER SECTION)
15-174
6033-001
21 13-678
6033-100
20
28
6053-100 6053-001
18 19
27
6807-126 6055-003
15 17
Modified 2" Ferrule
BR Vac Casting For DW616
6809-074 6809-027
8
Base Plate Router Casting
Quick Change Flat Jamb Stop
6809-076 6809-075
10
6 7
ITEM PART NO. NUMBER 5 6809-116
1
2 1
6
1 2
2
1
1
1
1
1
1 1
1 2
1
1
1 1
1
QTY.
45
8
12
4
3
5
19
21
10
EXTERIOR BUTT ROUTER ASSEMBLY (REAR SECTION)
18
17
2
20
11
9
23
15
7
22
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1
13
0039-002 10-582 11-009 11-010 11-034 12-017 13-597 6800-044 6805-089 6809-013 6809-021 6809-040 6809-045 6809-047 6809-048 6809-049 6809-055 6809-062 6809-103 6809-106 6809-108 9011-038 6902-706
PART NUMBER
14
DESCRIPTION
6
Felt Wheel Bimba 020.5-R Cylinder Durakool G10Z-3 Switch Durakool P2008 Clip Cover Nachi R6-2RS Bearing Reid WP 510 Knob Mounting Bracket CARRIAGE PLATE, EXTERIOR BR Pivot Block Adjuster BR PIVOT BLOCK Outlet Box Tram R oller Spacer Bearing Mounting Block, (Top) Bearing Mount Block Tram Roller Pivot Lolck Pin Cylinder Mount Stop Catch Pivot Bearing Assembly Pivot Bar Round Spacer LOCK PLATE, EXTERIOR BR
16
6
22
2 1 1 1 1 6 4 1 1 4 2 1 3 2 1 3 1 1 1 2 1 3 2
QTY.
NOTES:
46
NOTES:
47