jbc jbs-600 User Manual

Made from durable
10mm thick phenolic.

WORKTOP WIDTH

600mm 616mm

Router & worktop not included.

KITCHEN
WORKTOP JIG
600mm

FOR JOINING KITCHEN WORKTOPS
WITH A ROUTER

600mm - 616mm

JOINT

INCLUDES:

3xSetting Bushes

1xInstruction Manual

REQUIRES:

12.7mm (1/2”) Collet Plunge Router

12.7mm (1/2”) x 50mm TCT Router Cutter
Ref. 3/83DX1/2TC

30mm Guide Bush
Ref. GB30

Universal Sub-base for Guide Bush
Ref. UNIBASE*

Two 100mm (4”) Throat Clamps Ref.
FC/200

Panel Butt Connectors
Ref. PC/10/M

JBC/KWJ600

www.jacksonbc.co.uk

*For certain makes & models of router

-1-

INTRODUCTION

Your new Jackson Building Centres worktop jig
will more than satisfy your expectations. It has
been manufactured under stringent Quality
Standards to meet superior performance criteria.

CAUTION: Carefully read through this entire
Instruction Manual before using your new jig.
Take special care to heed the warning symbols.

TECHNICAL DATA

Jig thickness 10mm
Cutter size 12.7mm
Workpiece thickness max. 45mm
Worktop width: min. 600mm

max. 616mm
Guide bush size 30mm
Weight 6.1kg

CONTENTS

TECHNICAL DATA _____________________1
SAFETY ____________________________2-3
ITEMS ENCLOSED ____________________4
DESCRIPTION OF PARTS_______________4
ACCESSORIES

– Recommended Cutters ________________5
– Sub-base Set ________________________5
– Panel Butt Connector Bolts _____________6
– Biscuit Jointer for the Router ____________6
– Flat Biscuit Dowels____________________6
– Clamp ______________________________6

ASSEMBLY

– Location Bush Identification _____________7
– Margin Distance ______________________7
– Setting out the Joints __________________7

OPERATION

– Setting the Length Stop _______________ 8
– Female Joint_________________________8
– Male Joint___________________________9
– Cutting the Bolt Recesses _____________10
– Strengthening the Joint _______________11
– Sealing the Joint ____________________11

SPARE PART ________________________11
MAINTENANCE ______________________11
ENVIRONMENTAL PROTECTION________11
TROUBLESHOOTING _________________12
GUARANTEE ________________________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
98/37/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 kitchen worktop joint in laminate
covered particle board.

-2-

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 before using
our products.

IMPORTANT NOTE:

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
which cannot be completely excluded by
safety mechanisms. Power tools must
therefore always be operated with
caution!

General

1. Disconnect power tool when making
any adjustments. When not in use,
before servicing and when changing
accessories such as cutters,
disconnect power tool and attachment
from power supply. Ensure the
machine is switched off before
plugging tool in or connecting to a
power supply.

2. Always mount the power tool,
accessory or attachment in conformity
with the present instructions. The tool
should not be modified or used for any
application other than that for which it
was designed.

3. Keep children and visitors away. Do
not let children or visitors touch the
tool, accessory or attachment. Keep
children and visitors away from work
area. Make the workshop child proof
with padlock and master switch.

4. Dress properly. Do not wear loose
clothing or jewellry, they can be
caught in moving parts. Rubber
gloves and non-skid footwear is
recommended when working
outdoors. Wear protective hair

covering to contain long hair.

5. Consider working environment. Do
not use the product in the rain or in a
damp environment. Keep work area
well lit. Do not use power tools near
gasoline or flammable liquids. Keep
workshop at a comfortable
temperature so your hands are not
cold. Connect machines that are used
in the open via a residual current
device (RCD) with an actuation
current of 30 mA maximum. Use only
extension cables that are approved for
outdoor use.

6. The accessory or attachment must be
kept level and stable at all times.

7. Keep work area clean. Cluttered
workshops and benches can cause
injuries. Ensure there is sufficient
room to work safely.

8. Use the attachment with the power
tools and accessories specified in this
manual only. Do not force the tool or
attachment to do a job for which it is
not designed.

9. Secure idle tools. When not in use,
tools should be stored in a dry and
high or locked up place, out of reach
of children.

10. For best control and safety use both
hands on the power tool and
attachment. Keep both hands away
from cutting area. Always wait for the
spindle and cutter to stop rotating
before making any adjustments.

11. Always keep guards in place and in
good working order.

12. Remove any nails, staples and other
metal parts from the workpiece.

13. Maintain tools and cutters with care.
Keep cutters sharp and clean for
better and safer performance. Do not
use damaged cutters. Follow
instructions for lubricating and
changing accessories. Keep handles
dry, clean and free from oil and
grease.

14. Maintain accessories. Do not use
damaged accessories. Only use
accessories recommended by the
manufacturer.

15. Check damaged parts. Before
operation inspect the attachment, the
power tool, the cable, extension cable
and the plug carefully for signs of
damage. Check for alignment of
moving parts, binding, breakage,
mounting and any other conditions
that may effect its operation. Have
any damage repaired by an
Authorised Service Agent before using
the tool or accessory. Protect tools
from impact and shock.

16. Do not use tool if switch does not turn

it on or off. Have defective switches
replaced by an Authorised Service
Agent.

17. Don't over reach. Keep proper
footing and balance at all times. Do
not use awkward or uncomfortable
hand positions.

18. Don’t abuse the cable. Never carry
power tool or accessory by cord or
pull it to disconnect from the socket.
Keep cord from heat, oil and sharp
edges. Always trail the power cord
away from the work area.

19. Connect dust extraction equipment.
If devices are provided for the
connection of dust extraction and
collection facilities, ensure these are
connected and properly used.

20. Check all fixing and fastening nuts,
bolts and screws on power tool,
attachment and cutting tools before
use to ensure they are tight and
secure. Periodically check when
machining over long periods.

21. Stay alert. Watch what you are
doing. Use common sense. Do not
operate tools when you are tired,
under the influence of drugs or
alcohol.

22. Personal Protective Equipment
(PPE). All PPE must meet current
UK and EU legislation.

23. Do not leave tools running
unattended. Do not leave tool until it
comes to a complete stop.

24. Always clamp workpiece being
machined securely.

25. Only use cutting tools for
woodworking that meet EN847-1/2
safety standards, and any
subsequent amendments.

26. 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. Disconnect router power tool. When
not in use, before servicing and when
changing accessories such as
cutters, disconnect router and
attachment from power supply.

2. Ensure router cutter has stopped
rotating before changing it. Never
use the spindle lock as a brake.

3. Remove adjusting keys and
spanners. Form the habit of checking
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

-3-

exceeded. Routing sound pressure
may exceed 85dB(A), so ear
protection must be worn.

5. Eye protection. Wear safety goggles,
spectacles or visors to protect the
eyes from ejected waster particles.

6. Respiratory protection. Wear a face
or dust mask, or powered respirator.
Dust masks/filters should be changed
regularly.

7. Do not switch router on with the cutter
touching the workpiece.

8. The direction of routing must always
be opposite to the cutter's direction of
rotation. Do not back-cut or climb-cut.

9. At the end of the cut, release the
router plunge and allow spindle to
stop rotating before putting machine
down.

10. Check before cutting that there are no
obstructions in the path of the router.
When cutting through the full
thickness of the workpiece, ensure
there are no obstacles beneath
workpiece, and that a sacrificial work
surface is used.

Router Cutter Safety

1. Cutting tools are sharp. Care should
be taken when handling them.

2. Always use cutters with a shank
diameter corresponding to the size of
the collet installed in your tool.

3. Always run router cutters at the
spindle speed recommended and
marked accordingly. Ensure cutter
has reached correct speed before
entering workpiece. Recommended
speeds can be found on the
packaging, in cutter instructions, in the
Trend Routing Catalogue or on our
website.

4. Always use router cutters in a router.
Router cutters must not be used in a
drill. Drill and boring bits must not be
used in a router. Router cutters must
only be used for the material cutting
application for which they are
designed. Do not use on metal or
masonry.

5. Never use cutters with a diameter
exceeding the maximum diameter
indicated in the technical data of the
powertool or attachment used.

6. Do not drop cutters or knock them
against hard objects. Do not use
cutters that are damaged.

7. Cutters should be kept clean. Resin
build up should be removed at regular
intervals with Resin Cleaner

®

. The

use of a dry lubricant (Trendicote

®

PTFE) will act as a preventative. Do
not use PTFE spray on plastic parts.

8. When using stacked tooling (multi-

blade, block and groover etc.) on a
spindle arbor, ensure that the cutting
edges are staggered to each other to
reduce the cutting impact.

9. Cutter shanks should be inserted into
the collet to the line indicated on the
shank. This ensures that at least

3

⁄

4

of the shank length is held in the
collet. Do not over-tighten the collet
nut as this will score the shank and
create a weakness and fracture point.

10. Observe the correct assembly
instructions in the router instruction
manual for fitting the collet and nut.
Observe the router power tool manual
instructions on fitting cutters correctly.

11. It is advisable to periodically check
the collet and collet nut. A worn,
distorted or damaged collet can cause
vibration and damage the shank, and
should be replaced. Worn collet nuts
should be replaced.

12. Do not take deep cuts in one pass;
take several shallow or light passes to
reduce the side load applied to the
cutter. Too deep a cut in one pass can
stall the router.

13. Very small diameter cutters must be
handled and used with care.

14. Always return cutter to its packaging
after use.

15. Should you experience excessive
vibration during use stop immediately.
Have the eccentricity of the router,
router cutter and clamping system
checked by a qualified repair agent.

16. All fastening screws and nuts should
be tightened using the appropriate
spanner or key in accordance with the
manufacturers instructions.

Using Routers In A Fixed Position

1. Attention should be made to the
HSE’s Safe Use of Vertical Spindle
Moulding Machines Information Sheet
No.18 and any revisions.

2. After work, release the router plunge
to protect the cutter.

3. Always use a push-stick or push-block
when making any cut less than
300mm in length or when feeding the
last 300mm of the cut.

4. The opening around the cutter should
be reduced to a minimum using
suitably sized insert rings in the table
and closing the back fence cheeks or
fitting a false fence on the back fence.

5. Whenever possible use a work
holding device or jig to secure
component being machined.

6. Ensure attachment is securely fitted to
the workbench, with table surface at

approximately hip height.

7. Ensure a No-Volt Release Switch is
fixed to or adjacent to the attachment,
is easily accessible and that it is used
correctly.

8. In router table (inverted) mode, stand
to the front right of the table. The
cutter will rotate anti-clockwise when
viewed from top so the feed direction
is from the right (against the rotation
of the cutter).

9. In overhead mode, stand to the front
left of the machine table and the feed
direction is from the left.

10. Do not reach underneath table or put
your hands or fingers at any time in
the cutting path while tool is
connected to a power supply.

11. Never thickness timber between the
back of the cutter and the backfence.

Useful Advice When Routing

1. Judge your feed rate by the sound of
the motor. Feed the router at a
constant feed rate. Too slow a feed
rate will result in burning.

2. Take many light passes rather than
one deep cut to reduce the side load
applied to both router and router
cutter.

3. Trial cuts should be made on waste
material before starting any project.

4. When using some attachments
including a router table or dovetail jig,
the use of a fine height adjuster is
highly recommended.

5. When using a template guide bush,
ensure there is sufficient clearance
between cutter tip and inside edge of
bush and that it cannot come into
contact with collet and nut. Ensure
cutter and guide bush are concentric.

Router Cutter Maintenance

1. Composite cutting tools (brazed tip)
must be maintained by a competent
person i.e. a person of training and
experience, who has knowledge of
the design requirements and
understands the levels of safety to be
achieved.

2. The design of composite tools must
not be changed in the process of
maintenance. When re-grinding the
tool, care must be taken not to cause
weakening of the body or the
connection between the cutting edge
and the body.

3. Replacement parts must meet Trend
specification.

4. Tolerances which ensure correct
clamping by the collet shall be
maintained.

Version 6.0 05/2005

-4-

ITEMS ENCLOSED

DESCRIPTION OF PARTS

x1

x1

x3

ai

j

b

e g

g

f

c

ddh

h

&

Jig body

Label

Postform joint slot

Female joint bush location hole

Length setting stop location hole 600mm

a
b
c
d
e

Length setting stop location hole 616mm

Male joint bush location hole

Bolt recess bush location hole

Connecting bolt recess slot

Alloy location bush

f
g
h
i
j

ITEMS REQUIRED

■ 1/2” plunge router.

■ 30mm guide bush.

■ 12.7mm diameter x 50mm cut

router cutter with 1/2” shank.

■ 2 x trestles.

■ 2 x clamps.

■ Hand tools.

■ Panel connector bolts.

■ Wooden biscuits Size No.20.

■ Sealant.