Sealey Quality MACHINERY SM94.V4 Instructions Manual

INSTRUCTIONS FOR:

HOLLOW CHISEL MORTISER

Model No: SM94.V4

Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and
properly maintained, give you years of trouble free performance.

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND
CAUTIONS. USE THIS PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY
CAUSE DAMAGE AND/OR PERSONAL INJURY, AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.

1. SAFETY INSTRUCTIONS

1.1. ELECTRICAL SAFETY

 WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following:

You must check all electrical products, before use, to ensure that they are safe. You must inspect power cables, plugs, sockets and any other
connectors for wear or damage. You must ensure that the risk of electric shock is minimised by the installation of appropriate safety devices. A
Residual Current Circuit Breaker (RCCB) should be incorporated in the main distribution board. We also recommend that a Residual Current
Device (RCD) is used. It is particularly important to use an RCD with portable products that are plugged into a supply which is not protected
by an RCCB. If in any doubt consult a qualified electrician. You may obtain a Residual Current Device by contacting your Sealey dealer.
You must also read and understand the following instructions concerning electrical safety.

1.1.1. The Electricity at Work Act 1989 requires that all portable electrical appliances, if used on business premises, are tested by a
qualified electrician, using a Portable Appliance Tester (PAT), at least once a year.

1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of those appliances
and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.

1.1.3. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1. and 1.1.2.
and use a Portable Appliance Tester.

1.1.4. Ensure that cables are always protected against short circuit and overload.

1.1.5. Regularly inspect power supply cables and plugs for wear or damage and check all
connections to ensure that none is loose.

1.1.6. Important: Ensure that the voltage marked on the appliance matches the power supply
to be used and that the plug is fitted with the correct fuse - see fuse rating at right.

1.1.7. DO NOT pull or carry the appliance by the power cable.

1.1.8. DO NOT pull the plug from the socket by the cable.

1.1.9. DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty

Blue
Neutral
Wire

item repaired or replaced by a qualified electrician. When a BS 1363/A UK 3 pin plug is
damaged, cut the cable just above the plug and dispose of the plug safely.
Fit a new plug according to the following instructions (UK only).
a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.

b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check that there are no bare wires, that all wires have been correctly
connected, that the cable outer insulation extends beyond the cable restraint and that the restraint is tight.

Double insulated products, which are always marked with this symbol , are fitted with live (brown) and neutral (blue) wires only.
To rewire, connect the wires as indicated above - DO NOT connect either wire to the earth terminal.

1.1.10. Products which require more than 13 amps are supplied without a plug. In this case you must contact a qualified electrician to ensure
that a suitably rated supply is available. We recommend that you discuss the installation of an industrial round pin plug and
socket with your electrician.

1.1.11. If an extension reel is used it should be fully unwound before connection. A reel with an RCD fitted is preferred since any appliance
plugged into it will be protected. The cable core section is important and should be at least 1.5mm2, but to be absolutely sure that the
capacity of the reel is suitable for this product and for others which may be used in the other output sockets, we recommend the use
of 2.5mm² section cable.

1.2. GENERAL SAFETY

 WARNING!Disconnect the mortiser from the mains power before changing accessories, servicing or performing any maintenance.
 Locate the mortiser in a suitable working area. Fasten the mortiser to a strong flat working surface. Keep area clean and tidy and free

from unrelated materials and ensure there is adequate lighting.

 Maintain the mortiser in good condition (use an authorised service agent).
 Replace or repair damaged parts. Use genuine parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
 Keep the mortiser clean for best and safest performance and check moving parts alignment regularly.
 Keep mortiser tool bits clean and sharp and ensure bit is secured correctly in the mortiser chuck. If worn or damaged replace immediately.
 Remove adjusting keys and wrenches from the mortiser and its vicinity before turning it on.
 Wear approved eye safety protection.
 Handle loose chisels and drill bits with gloves or cloth as they are very sharp, but DO remove gloves and/or cloth before operating

the mortiser. Keep your hands and fingers away from the mortiser tool bit and chisel when operating.

 Remove ill fitting clothing. Remove ties, watches, rings and other loose jewellery, and contain long hair.
 Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
 Secure work piece by resting against the back stop and top holding clamp.
 Ensure there are no foreign objects in the workpiece i.e. nails or screws.
 Use the depth stop for accuracy and to avoid drilling into the work table, and avoid unintentional starting.
 DO NOT start the mortiser with the tool bit resting against the workpiece. Always bring the operating chisel to the workpiece.
 DO NOT attempt to place a workpiece on the mortiser table whilst the cutting tool is working.
 DO NOT use the mortiser for a task it is not designed to perform.
 DO NOT allow untrained persons to operate the mortiser and keep children and unauthorised persons away from the working area.
 DO NOT get the mortiser wet or use in damp or wet locations or areas where there is condensation.
 DO NOT use mortiser where there are flammable liquids, solids or gases such as paint solvents, waste wiping or cleaning rags etc.
 DO NOT operate the mortiser if any parts are damaged or missing as this may cause failure and/or possible personal injury.
 DO NOT leave the mortiser operating unattended.
 DO NOT operate the mortiser when you are tired or under the influence of alcohol, drugs or intoxicating medication.
 When not in use switch off the mortiser and remove plug from the power supply.

Original Language Version

Yellow & Green
Earth Wire

Brown
Live
Wire

Cable
Restraint

FUSE RATING

THIS PRODUCT MUST BE FITTED

WITH A 5 AMP FUSE

SM94.V4 Issue No.1 031209

2. APPLICATION & SPECIFICATION

Bench mounting mortising machine suitable for cutting mortises for joints,
locks and dead-bolts. Twin uprights with hydraulic damper carry head
assembly and have adjustable depth stop for repetitive work. Integral drill
chuck is easily accessible from both sides of the head. Powered by
heavy-duty induction motor with no-volt release switch to prevent
accidental restart after power failure or jam. Supplied with arbor extension
and 13mm drill chuck for occasional drilling operations. Includes table and
work piece clamp assembly. Mortising chisels included.

Motor Power ...........................................370W, 230V.

Chisel Size .......................................... 1/4”, 3/8”, 1/2”

Chuck Size .................................................13mm

Spindle Travel..............................................120mm

Chisel to Table .............................................115mm

Throat Depth ...............................................77mm

Hold Down Capacity..........................................68mm

Table Size ............................................150 x 340mm

Dimensions H (less handle) x W x L ..................640 x 355 x 340mm

Weight .....................................................25kg

3. CONTENTS

CONTENTS (See Fig.1)

1. Tool tray

2. Tool tray fixings (2 x M6 x16mm socket cap bolts & washers)

3. Back Stop

4. Washers x 2 for hold down clamp assembly

5. Hold down clamp adjustment knob

6. Back Stop clamp assembly
6a. Clamp lever fixing
6b. Clamp lever spring
6c. Clamp lever
6d. Clamp lever post

7. Back Stop mounting block fixings (2 x M8 x 20mm socket cap bolts)

8. Back Stop mounting block

9. Arbour extension

10. Drilling chuck

11. Allen Keys 3mm, 5mm, 6mm

12. Work table

13. Table fixing screw (2 x M8 x 25mm Countersunk)

14. Hold down clamp

15. Mortising Chisel + Drill Bit (1/4”) (See Fig.3)

16. Mortising Chisel + Drill Bit (3/8”) (See Fig.3)

17. Mortising Chisel + Drill Bit (1/2”) (See Fig.3)

18. Handle (See Fig.2 & Fig.4)

19. Handle fixing bolt (M6 x 20mm) (See Fig.2)

20. Chuck Key. (See F ig.2)

4. ASSEMBLY

4.1 ASSEMBLY

 WARNING! DO NOT plug the mortiser into the mains

power supply until completely assembled and these
instructions tell you to do so.
DO NOT allow brake fluids, petroleum, penetrating oils etc. to
come into contact with plastic parts of mortiser as damage
may result.

 WARNING! The Mortiser is delivered with the head positioned

low down on the two pillars and is held in this position by a
piece of wood inserted between the top of the head and the
crosspiece on top of the pillars. Care must be taken when
removing this piece of wood as the head is held under spring
pressure and will move rapidly to the top of the pillars when
the wood is removed.

4.1.1 Releasing The Head. Place the mortiser onto a firm, solid
workbench and bring the cast base near to the front edge of
the work surface. Insert the plain end of the handle (18)
through the hole in the shaft on the right side of the head and
fix the handle with the M6 x 20mm socket cap bolt provided
(19). Steady the mortiser by placing your left hand on top of
the unit. Rotate the handle so that it is pointing downwards at
45°. Push the handle further down a small amount to take the
pressure off the wood and get a second person to remove the
piece of wood. Slowly allow the handle to rotate upwards
allowing the head to move to the top of the pillars in a
controlled fashion.

4.2 Back Stop Mounting Block. (See 8 in Figs.1 & 2) Bolt the
Back Stop mounting block in between the two pillars at the
back of the base casting using the two M8 x 20mm socket

Original Language Version

Fig.1

Fig.2

Fig.3

SM94.V4 Issue No.1 031209