Clarke CONTRACTOR CLJ120 Instruction Manual

LOCK JIG
Model No: CLJ120
Part No: 6462122
OPERATION & MAINTENANCE
INSTRUCTIONS
0405
LOCK JIG

Please note that the details and specifications contained herein, are correct at the time of going
to print. However, CLARKE International reserve the right to change specifications at any time
without prior notice.
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Thank you for purchasing this CLARKE Lock Jig
Before attempting to use the jig, please read this manual thoroughly and follow the
instructions carefully. In doing so you will ensure the safety of yourself and that of others
around you, and you can look forward to the jig giving you long and satisfactory service.
Contents
CLARKE GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt as proof of purchase.
This guarantee is invalid if the product is found to have been abused or tampered
with in any way, or not used for the purpose for which it was intended.
Faulty goods should be returned to their place of purchase, no product can be
returned to us without prior permission.
This guarantee does not effect your statutory rights.
Introduction
The lock jig is a self centering template used for routing out the edges of doors to
accommodate a variety of popular locks and face plates. The nesting plate is
complete with a clamping lever system which automatically positions the lock centrally
in the door and clamps the jig ready to start routing.
Once the nesting plate is in position, a range of inserts can be added depending on
the size of lock to be fitted. The inserts are used in pairs,- one for the lock body, the
other for the lock face plate.
Inserts (3 pairs)
Nesting Plate x1
Washer x 2
Wing Screw x 2 Nylon Spacer x 2
Rubber Grips x 4
Centralising Lever x 2
Other equipment required, (not supplied).
Light duty router capable of plunging the depth of the lock to be fitted, also must
be able to take a 16mm guide bush.
16mm Guide bush.
12.7mm (½”) Router Cutter.

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Safety Precautions
WARNING:
As with all machinery, there are certain hazards involved with their operation and
use. Exercising respect and caution will considerably reduce the risk of personal
injury. However, if normal safety precautions are overlooked or ignored, personal
injury to the operator or damage to property, may result.
1. ALWAYS Learn the equipments applications, limitations and any
specific potential hazards peculiar to it. Read and become familiar
with the entire operating manual.
2. ALWAYS use a face or dust mask if operation is particularly dusty.
3. ALWAYS check for damage. Before using tools and equipment, any
damage should be checked to ensure that it will operate properly,
and perform its intended function. Check for alignment of moving
parts, breakage of parts, mountings, and any other condition that may affect the
equipments operation. Any damage should be properly repaired or the part replaced.
If in doubt, DO NOT use. Consult expert advice.
4. ALWAYS disconnect power tools from the electric supply before servicing and when
making adjustments or changing accessories etc.
5. ALWAYS wear safety goggles, manufactured to the latest European Safety Standards.
Everyday eyeglasses do not have impact resistant lenses, they are not safety glasses.
6. ALWAYS keep work area clean. Cluttered areas and benches
invite accidents.
7. ALWAYS ensure that adequate lighting is available. A
minimum intensity of 300 lux should be provided. Ensure that
lighting is placed so that you will not be working in your own
shadow.
8. ALWAYS keep children away. All visitors should be kept a safe distance from the work
area, especially whilst working with tools particularly power tools.
9. ALWAYS maintain equipment in top condition. Keep tools/machines
clean for the best and safest performance. Follow maintenance
instructions.
10. ALWAYS handle with extreme care do not carry tools/machines by
the electric cable, or yank the cable to disconnect it from the
power supply.
11. ALWAYS ensure the switch is off before plugging in to mains. Avoid
accidental starting.
12. ALWAYS concentrate on the job in hand, no matter how trivial it may seem. Be aware
that accidents are caused by carelessness due to familiarity.
13. ALWAYS keep your proper footing and balance at all times
don’t overreach. For best footing, wear rubber soled
footwear. Keep floor clear of oil, scrap wood etc.
14. ALWAYS seek assistance when lifting heavy objects
(doors and worktops etc).

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Assembly
Jig Assembly
The only assembly required is to attach the centralising levers, this is carried out as follows:
1. With the Clarke logo in the nesting plate facing upwards, insert the lever prongs into
the plate slots (Fig. 1).
2. Fit nylon spacer between the lever and nesting plate (Fig. 2)
3. Fit washer on centralising lever (Fig. 3).
4. Secure with wing screw (Fig. 4).
Repeat steps 1 - 4 for other centralising lever on opposite end.
Fig. 1 Fig. 2
Fig. 3 Fig. 4
Finally turn the jig over and fit rubber grips to lever prongs, a light film of liquid soap or
similar applied to the ends of the prongs will assist with this operation.
Before commencing:
ALWAYS ensure the work area is safe and secure.
ALWAYS ensure the door is secured properly, ideally using wedges or similar on both sides
to prevent door moving whilst using the router etc.
ALWAYS ensure the router path is clear of any obstacles etc.
ALWAYS ensure the router power cable is clear of the jig and is of sufficient length.
ALWAYS read and understand the router instruction manual to ensure safe operation.

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Centre Line
Dotted line showing
lock position
Using the Jig
Depending on the size of lock to be fitted etc, all that is required is to mark on the door
edge the centre line of the lock position. As a general guideline the centre line would
normally be 1 metre from the bottom of the door.
Once the lock position is determined, mark the centre
line across the door edge (Fig. 5). This mark is used to
position the jig in the correct place for routing.
Loosen both wing screws and turn levers fully
anticlockwise.
Place the jig on the edge of the door, slide into position
so that the centre line on the jig lines up with the marked
centre line on the door edge (Fig. 6).
Turn levers fully clockwise and secure in position by
tightening both wing screws (Fig. 6a), DO NOT overtighten.
Check Jig is in the correct position, once satisfied, carefully
secure the jig to the door edge using suitable woodscews
in the securing holes (3mm ø) top and bottom of the jig.
Fig. 5
Fig. 6 Fig. 6a
Before continuing, check that the
centre line on the door is still lined
up with the centre mark on the
nesting plate, if not adjust until it
does.
NOTE: when selecting inserts, take
into account the aperture will cut
approx 1.65mm smaller all round. If
in doubt test on a piece of scrap first.
Securing Holes (3mm ø)
Securing Holes (3mm ø)

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1. Set the router to cut to the thickness of the lock plate + the lock body plate.
2. Position the router onto the jig ensuring the cutter is not touching. Switch the router ON
and plunge to the full preset depth and rout in a clockwise direction until the recess is
completely cut. Switch the router OFF and wait for it to come to a full stop before
lifting it from the jig.
3. Loosen the insert securing screw and remove the insert, DO NOT move the nesting
plate. Square out the recess corners using a sharp chisel.
4. Fit other insert with smaller aperture (lock body) into the nesting plate and secure in
position with locking screw.
5. Set the router to plunge to a maximum depth of 10mm, position the router on the jig as
before. Switch ON and plunge to the full preset depth and rout in a clockwise direction
until the recess is completely cut. Switch the router OFF and wait for it to come to a full
stop before lifting it from the jig.
6. Increase the depth of cut a further 10mm and repeat step 5.
7. Continue to repeat steps 5 & 6 until the required depth is reached, IMPORTANT never
exceed 10mm depth of cut.
8. When the required depth is achieved, switch the router OFF, wait for it to come to a
complete stop, remove the router and store safely.
9. Loosen the insert securing screw and remove the insert, square off the recess corners
using a sharp chisel.
Fig. 7 Fig. 7a
Select the correct pair of
inserts for the lock to be fitted.
Fit the Insert with the largest
aperture (lock plate) into the
nesting plate and secure in
place with locking screw (Fig.
7 & 7a), ensure the insert sits flat
in the nesting plate.