deep lock mortiser

MODEL 8900
DEEP LOCK MORTISER
Operator Manual
&
Parts List
REVISION
43
REVISION
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RELEASE 4: JUNE 2008
2
Operational Sequence .
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15
16
GENERAL SAFETY
Read the Operator's Manual and learn to operate the machine safely.
Be alert and observe all safety practices.
This machine can be hazardous in the hands of an unfamiliar, untrained
or complacent operator.
DO NOT RISK INJURY
Observe these safety rules at all times.
1. Disconnect all electrical power and air from the machine when
adjusting, making repairs or cleaning.
2. Do not operate the machine without all guards and covers in place.
3. Maintain the machine for maximum safety and performance.
Make DAILY inspections.
4. Never allow untrained operators to use the machine.
5. Turn all electrical power and air OFF when the machine is not in use or unattended.
6. Only qualified and trained personnel should make repairs.
7. Electrical connections and repairs should be made by a qualified electrician.
8. It is recommended that eye protection be worn while operating the machine.
9. It is recommended that hearing protection be worn while operating the machine.
3
SPECIFICATIONS
Door Width:
No limit
Door Height:
76” to 108”
Door Thickness:
1-3/8” to 2-1/4”
Pocket Length:
1” to 8”
Pocket Depth:
Up to 6”
Pocket Width:
¾” to 1-1/4”
Faceplate Length:
½” to 8-1/2”
Faceplate Width:
1” to 1-1/4”
Faceplate Depth:
Up to 3/8”
Machine Cycle Time:
Approx. 1-1/2 minutes
Approximate Weight:
2000 lbs.
Minimum Floor Space Required:
3’ x 15’ for 8’-0 doors
3’ x 17’ for 9’-0 doors
Air Requirements:
2.0 CFM @ 100 PSI
Vacuum Requirements:
1900 CFM with a 5” duct
Mortiser Bits:
¾” dia. to 1-1/4” dia.
¼-28 NF threads
Faceplate Bits:
½” dia. router bit
¼” or 1/2” shank
5
Electrical Requirements:
With Vacuum208V-3 PHASE 60HZ @ 25 AMPS, AND 208V-1 PHASE 60HZ @ 20 AMPS
OR
230V-3 PHASE 60HZ @ 25 AMPS, AND 230V-1 PHASE 60HZ @ 20 AMPS
OR
460V-3 PHASE 60HZ @ 15 AMPS, AND 230V-1 PHASE 60HZ @ 20 AMPS
Without Vacuum208V-3 PHASE 60HZ @ 10 AMPS, AND 208V-1 PHASE 60HZ @ 20 AMPS
OR
230V-3 PHASE 60HZ @ 10 AMPS, AND 230V-1 PHASE 60HZ @ 20 AMPS
OR
460V-3 PHASE 60HZ @ 10 AMPS, AND 230V-1 PHASE 60HZ @ 20 AMPS
MOTOR SPECIFICATIONS: 3 PHASE
APPLICATION
MORTISER
MOTOR
PART NO.
HP
AMPS
@ 230V
BALDOR
(M3559T)
15-300
3
7.2
MOTOR SPECIFICATIONS: SINGLE PHASE
APPLICATION
MOTOR
PART NO.
HP
VOLT/
AMPS
FACE PLATE ROUTER DEWALT
MOTOR
(DW616)
15-174
1-3/4
115V/
11.0
OSCILLATOR
15-076
.5
GRAINGER
(5K340)
6
115V/
8.6
INSTALLATION
PREFACE
The information in this chapter refers to the installation and setup of the 8900 Deep Lock
Mortiser. After the machine arrives:
1. Uncrate the machine and inspect for shipping damage or shortages.
2. Position the machine in its permanent location .
3. Provide the proper electrical supply (7 wire input)and make connections to
machine and vacuum unit.
4. Provide the proper air supply and make connections.
5. Position and connect the vacuum system.
SHIPPING DAMAGE AND SHORTAGES
After the machine has been uncrated, inspect the entire machine and all other contents of
the crate for shipping damage. In the event there was damage in transit notify the freight
carrier and Norfield Industries immediately.
Inspect the complete shipment against the packing slips to make sure all items listed are
accounted for. If any shortages are noticed, the freight carrier and Norfield Industries
must be notified immediately. While any shortages (other than back orders) or freight
damages are the complete responsibility of the freight carrier, Norfield needs to be
notified so that the replacement of lost or damaged parts can be expedited.
MOVING THE MACHINE
The easiest way to move the machine is by picking it up from below with a fork lift, but
its weight distribution must be watched. Also, be careful not to damage any tubing,
wiring or components mounted to the front or bottom of the frame. The machine weight
approximately 2000 lbs.
POSITIONING THE MACHINE
It is recommended that you allow 4 feet between the rear of the machine, where the
electrical panel is located, and any wall or structure.
Material flow into and out of the machine should also be considered for optimum
performance.
Since the vacuum system can be located and/or connected on either end of the machine,
placement should allow adequate space.
7
INSTALLATION
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SECTION
ELECTRICAL
CONNECTIONS
1-4
ELECTRICAL
CONNECTIONS
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THREE PHASE POWER
L1 - L2 - L3
6,1*/(3+$6(32:(5
L4 - L5 - L6
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8
1900
five
There are two 5" connection points, one located on each end of the frame base.
f
clamp
RING
BLANK
2-1-4 Adjusting the Faceplate Router for Beveled or Square Edge Doors.
The angle the router assembly machines at can be changed to match beveled or square edge doors by
turning the handle located on top of the frame. Turn the handle counter-clockwise for beveled doors
and clockwise square edge doors.
12
See note below:
Note: If the mortiser assembly has stopped in a position that the scale is not visible, a “JOG” function has been
incorporated into the CYCLE START button. By depressing the START button momentarily and quickly
releasing it, the mortiser will move a short distance and rotate the crank arm. A test door should be placed in the
machine when using the Jog function.
13
2-2-5 Adjusting the Door Stops.
To properly locate the lock and faceplate mortises, the 8900 is equipped with two
Door Stop assemblies, one located at each end of the machine. The top of the door is
referenced against the right hand assembly to produce a “left hand” door, and
conversely, the left stop assembly is used for “right hand” doors.
Each stop assembly consists of two manually actuated stop dogs and an adjustable
rod which determines the relationship between the lock mortise and the faceplate
mortise. With the faceplate mortise stop set to zero on the scale, the distance
between the stop dogs should match the center to center distance of the mortiser and
faceplate router and will produce a symmetrical rout. By loosening the rear clamp
handle and offsetting the faceplate router stop assembly, an asymmetrical rout may
be machined if required.
To position the stop assemblies, mark a door at the desired lock height and align the
mark with the centerline of the mortiser assembly. Loosen the clamp handles
securing the stop assembly to the stop bar and slide the entire assembly until the dog
on the right contacts the top of the door. Tighten the clamp handles. Turn the door
around in the machine and repeat for the other stop assembly.
8900 OPERATIONAL SEQUENCE
Section 3
1. Before processing a door, ensure that the Mortiser and Faceplate
Router Assemblies are set to machine the correct width, length, and
depth, and the Faceplate Router is at the proper angle. Always
depress the Emergency Stop Switch before checking or making any
adjustments. Check that the Door Stop Assemblies are set to the
correct lock height.
2. Release the Emergency Stop Switch and turn the Control Power
Switch to the ON position.
3. Load a door into the machine and position it against the appropriate
lock mortiser Door Stop.
4. Clamp the door using the Foot Pedal.
5. Depress the Cycle Start button to start the machining cycle.
6. After the lock mortising operation is complete and the mortiser has
returned to its home position, unclamp the door.
7. Shift the door to the left and position it against the faceplate router
Door Stop.
8. Clamp the door.
9. Grasp the Faceplate Router Knob and depress the button in the center
of the knob to start the motor and plunge the router assembly.
10. Machine the faceplate rout by moving the knob left and right and back
and forth until the mortise is complete. Depress the button to stop the
motor.
11. Unclamp and remove the door.
15
4
4
16
4
4
17
4
18
5
5
5
6
6
6
15-174
DEWALT DW 616 ROUTER MOTOR
1
12-008
GATES 300L100 TIMING BELT
1
blank
GENERAL SAFETY
Read the Operator's Manual and learn to operate the machine safely.
Be alert and observe all safety practices.
This machine can be hazardous in the hands of an unfamiliar, untrained
or complacent operator.
DO NOT RISK INJURY
Observe these safety rules at all times.
1. Disconnect all electrical power and air from the machine when
adjusting, making repairs or cleaning.
2. Do not operate the machine without all guards and covers in place.
3. Maintain the machine for maximum safety and performance.
Make DAILY inspections.
4. Never allow untrained operators to use the machine.
5. Turn all electrical power and air OFF when the machine is not in use or unattended.
6. Only qualified and trained personnel should make repairs.
7. Electrical connections and repairs should be made by a qualified electrician.
8. It is recommended that eye protection be worn while operating the machine.
9. It is recommended that hearing protection be worn while operating the machine.
3
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Toll-Free 800-824-6242
www.norfield.com
PO BOX 459 • Chico, CA 95927 • (530) 891-4214 • FAX: (530) 879-3141