Hoffmann PP2 User manual

© Hoffmann Machine Company, Inc.
OPERATING MANUAL
for
Hoffmann Dovetail Routing Machine
Model PP2
Hoffmann Machine Company, Inc.
1386 Drexel Road Valdese, NC 28690 USA
Phone: (828) 430 - 4510 Fax: [phone]
e-mail: [e-mail]
www.Hoffmann-USA.com
Toll-free Technical Support: (866) 248 –0100

Hoffmann PP2 Dovetail Routing Machine
- 1 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
1. Safety and Warning Labels
A number of important warning labels have been attached to this Dovetail Routing Machine for
your information and protection.
For your own safety, please take a moment to locate and read all warning labels before operating
this machine.
If a label has been removed, defaced or is illegible, please contact Hoffmann Machine Company,
Inc. to request a free replacement.
NEVER REMOVE ANY SAFETY OR WARNING LABEL!

Hoffmann PP2 Dovetail Routing Machine
- 2 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
2. Safety Rules
Read and understand these safety rules before operating this machine!
1. Always disconnect the machine from the electrical power supply and from compressed air
supply before attempting any adjustment, repair or maintenance procedure (change of router
bit, depth-of-cut adjustment, removal of wood dust, etc.).
2. Do not allow power cord or air hose to lay on the floor, in the way of passing personnel or the
machine operator. They will cause a trip hazard.
3. Always wear eye and ear protection as well as a respirator suitable for wood dust.
4. Remove or confine loose hair, clothing and jewelry to avoid entanglement.
5. Avoid a dangerous environment. Do not expose electrical equipment to rain. Do not use in
presence of flammable liquids or gases.
6. Keep the area around the machine clean and free from scrap, sawdust, wood chips, oil and
grease to avoid the danger of slipping.
7. Always use a suitable dust collection system. Duct must be properly connected to the dust
extraction port at the back of the machine.
8. Use only sharp and flawless original Hoffmann router bits.
9. Check the machine upon receipt as well as before every use for improper functioning and
worn or damaged parts. Make sure the appropriate router bit is securely installed.
10. Broken or defective parts must not be used until replaced or repaired by a qualified
technician.
11. When interrupting work or upon leaving the area, machine must be switched off.
12.Only trained and qualified personnel must be allowed to use machine.
13.Only original Hoffmann replacement parts must be used to rebuild machine.

Hoffmann PP2 Dovetail Routing Machine
- 3 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
3. Operator Training
The Hoffmann Dovetail Routing Machine model PP-2 is to be operated, maintained and repaired
only by properly trained and qualified personnel. It is imperative that the operator has carefully
read and understood these operating instructions, and that he or she is aware of all potential risks
resulting from operating this machine.
If the operator does not posses sufficient English language skills to completely understand all
sections of this manual, especially the sections on Warning Labels and Safety Rules, it is the
responsibility of the purchaser to retain a qualified translator to translate this entire manual.
All applicable safety procedures and rules, including but not limited to all OSHA Rules and
Regulations, are to be adhered to.
Any unauthorized modification or alteration to this machine by the operator or owner, including
the use of router bits other than Original Hoffmann Dovetail Router Bits, will immediately void the
machine warranty. The manufacturer cannot be held liable if the machine is used for any
operations other than outlined in this manual or if the machine is modified or altered.
Please refer to the complete Hoffmann Machine Company, Inc. warranty in the back of this
operating manual.
4. General Machine Description
The Hoffmann Dovetail Routing Machine model PP-2 is designed solely to process material for
the Hoffmann Dovetail Joining System.
This machine is to be used only to process material for Hoffmann Dovetail Keys, size W-1, W-2,
W-3 and W-4.
USE OF THIS MACHINE FOR ANY OTHER OPERATION IS DANGEROUS AND WILL VOID THE WARRANTY.
The manufacturer cannot be held liable if the machine is used for any operations other than
outlined in this manual.
The Hoffmann Dovetail Routing Machine model PP-2 is designed to rout dovetail shaped
keyways in hard and softwoods as well as wood related sheet goods, such as particleboard,
MDF, plywood, MDO, etc.
The material is placed on the machine table, the proper location is established with either a steel
fence plate for miter joints, or with square stops for butt joints.
Depressing the foot pedal activates the hold-down clamps and secures the workpiece. With the
workpiece clamped securely, the router motors are turned on and raised up automatically and the
spinning router bits move up into the material. A height adjustment rod is used to set the routing
height. When the pre-set height is reached, a pneumatic valve is triggered and the motors return
to their resting position and are shut off. A pneumatic valve is triggered when the motors have
reached their home position, this valve releases the material clamps and the workpieces are
removed from the machine table by the operator.
WARNING:
The machine is equipped with an automatic ON/OFF feature, depressing the foot pedal starts the
router motors immediately and releasing the pedal returns the motors to their home position.

Hoffmann PP2 Dovetail Routing Machine
- 4 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
5. Potential Risks and Dangers
Even when the machine is used as designed, and when the aforementioned safety rules are
adhered to, the potential risk of injury must always be considered.
It is especially important to be aware of the following:
The risk of pinching between stationary and moveable parts of the machine.
The risk of pinching on the clamping devices of the machine.
The risk of injury from sharp edges when handling, adjusting or changing the tooling.
The risk of injury due to the inhalation of wood dust when operating the machine.
The potential risk of injury on the electrical parts of the machine.
The potential risk of injury on the pneumatic elements of the machine.
6. Toolkit
The machine is shipped with a Hoffmann toolkit, consisting of:
•Hex key 2.5mm
•Hex key 3.0mm
•Hex key 4.0mm
•Hex key 5.0mm
•Hex key 6.0mm
•Wrench 14mm
•Wrench 17mm
•Wrench 18mm
•Wrench 22mm
•One Safety Equipment Starter Kit (safety glasses, ear plugs, dust mask)
This starter kit is included as a courtesy to allow the machinery owner to start using this
machine upon receipt. It is the machine owner’s responsibility to supply additional safety
equipment as needed, and the machine operator’s responsibility to use all safety equipment as
instructed.
7. Technical Data
Electrical Supply 120 Volt, 60 Hz, 17 Amps. - single phase
Router motors two Hoffmann brand motors, 1,000 Watt each
Rotation CCW (counter clockwise)
Revolutions per minute 33,000 rpm (idle)
Collet size ¼” = 6.35mm (8mm collet required for W-4 router bits)
Compressed air supply 90 psi = 6.0 bar
Dust collection: One 4” diameter duct, approx. 500 cfm required
Max. routing height 4”
Max. material thickness: 5 ¾”
Operating noise 75.3 dB (A)
Weight: 348 lbs.
Dovetail Key sizes W-1, W-2, W-3, W-4

Hoffmann PP2 Dovetail Routing Machine
- 5 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
8. Machine Installation
8.1 Unpacking – Inspection
Upon receipt, check the machine and shipping container for any damage. Report any
transportation damage to the delivering carrier and indicate it on the bill of lading. Request an
immediate inspection for assessment of damage. Claim should then be entered with the carrier.
The carrier is solely responsible for any loss or damage during transit.
8.2 Placement
After unpacking, select a suitable location with enough room around the machine for safe and
unobstructed workflow, cleaning and maintenance.
The floor should be sound and reasonably level. When properly installed, the machine should not
rock or wobble.
8.3 Cleaning
Clean the machine and remove the applied rust preventive coating with a cotton rag and thin oil
(WD-40 or similar). Be careful when using liquids containing silicones – the finishing process of
your material could later be impaired.
Never use thinner or solvents to clean machine, damage could result.
8.4 Electric Connection
Only a licensed electrician shall connect the electrical supply line to the machine. The electrical
connection to 120 volts, single phase power must be made in accordance with all applicable
codes and laws. If a disconnect switch is required, one must be installed by the owner. If a plug-
receptacle connection is allowed, the power cord must be routed out of the path of normal
operator movement and should be protected from damage.
8.5 Compressed Air
Route a compressed airline to the machine. Caution: If a rubber hose is used make sure that is
does not lay on the floor in the path of normal operator movement. It is recommended that the
compressed airline drop from overhead. The airline connection should be made with a quick
disconnect fitting to allow for positive lock-out from the air source when performing adjustments,
cleaning, maintenance or repair work. The connection is made to the incoming side of the air
filter, regulator and lubricator assembly, which is mounted on the outside of the machine base.
CAUTION: WHEN AIR PRESSURE IS INTRODUCED TO THE MACHINE, THE HOLD DOWN
CLAMP AND THE MOTOR CARRIAGE WILL IMMEDIATELY MOVE TO THEIR HOME
POSITIONS. THEREFORE, USE EXTREME CAUTION AND STAND CLEAR OF THE
MACHINE WHENEVER COMPRESSED AIR IS INITIALLY CONNECTED.

Hoffmann PP2 Dovetail Routing Machine
- 6 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
9. Machine Operation
9.1 Standard 45-degree miters with one key per joint
The machine is equipped with a routing height adjustment rod (2). The scale (3) on the vertical bar
indicates the height the router bit will travel into the material. To adjust the height, simply loosen the locking
lever (1) and move the bar to the desired height.
Always use the longest key possible to achieve a tight joint on the face side of the workpiece.
(PU2 model shown - routing height adjustment is
identical for PU2 and PP2 machines.)
With the routing height and the keyway position set, place the material on the table and lower the
pneumatic hold-down clamps to within 1/8” above the workpiece. Secure the setting by tightening the
orange handles.
Start the routing operation by depressing the pneumatic foot pedal. Do not release the switch until the
routing sequence is completed and the routers have returned to their home position. Once the clamps have
released the workpieces, they can be removed from the table.
Before routing the material make sure the orange handles securing the hold-down clamps and the steel
fence plate are properly tightened, and do not change the settings until booth parts are routed.
9.2 Standard 45-degree miters with multiple keys per joint
Adjust the machine and process the material for one dovetail key as described above.
After all material has been machined for the first key location, re-set the steel fence plate (1) on the
machine table (and re-set the routing height if necessary) and proceed as before.

Hoffmann PP2 Dovetail Routing Machine
- 7 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
9.3 Miter joints with angles other than 45 degrees
Replace the standard 45-degree steel fence plate (shipped with machine) with either a fixed fence plate for
hexagon or octagon frames, or the adjustable Hoffmann Synchro fence and proceed as outlined in section
9.2.
The square stop (1) can also be used to machine miter joints with any given angle.
The square stop (1) is set to the desired position and locked in place. All material is machined on its right
end miters with this setting.
The square stop is then moved to the other side of the table, and the same position is set with the aid of the
tape scale (2).
With both settings being equal, a perfectly aligned corner is achieved.
9.4 Butt-joints with square cut ends (e.g. face-frame construction, round parts)
Remove the steel fence plate from the machine table and use the supplied square aluminum stop
(1) instead. Recessed in the machine table is a tape scale (2), with is used to adjust these stops.

Hoffmann PP2 Dovetail Routing Machine
- 8 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
9.5 Compound Miter Joints
Moulding joined with a compound miter is machined almost like a standard, flat moulding. To achieve a tight and
correctly aligned joint, the mitered face must be placed tight against the machine back fence and the moulding edge
must rest against the black steel fence plate.
The machine is adjusted for both keyway locations and the routing heights are set for each head. For a production
environment, it is advisable to build a fixture to support the moulding in the correct position.
(Pictures depict PU-2 single-head machine, same set-up is used for PP2 models)
dovetail keyway locations place miter face tight against back fence
moulding edge rests against fence plate Keys are inserted with a round steel punch
The completed joint with no visible fastener.
Note: Depending on moulding width, use two or
more Keys for tight joints.
Use of good quality glue is important.
For best results, use a shop-made jig to
hold moulding steady while routing (jig
can be mounted to recessed aluminum
fence rail).
Place first Key close to inside corner and
second Key close to outside corner - choose
thick moulding sections and use longest Key
possible.

Hoffmann PP2 Dovetail Routing Machine
- 9 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
10. Accessories for PU2 and PP2 production models
Synchro fence, adjustable from 18-64º Table flip-stop with spring loaded tab
order number: W 3105000 order number: W 3900002
Inside corner fences for 45º miters Mullion jig for coped mullion joints
order number: W 3208000 order number: W 3108000
Laser guide for working to pencil lines Fence extension rail with flip-stop
order number: W 3900006 order number: W 3900001 / W 3900003

Hoffmann PP2 Dovetail Routing Machine
- 10 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
11. Change of router bit
ALWAYS DISCONNECT THE ELECTRICAL POWER SUPPLY AND COMPRESSED AIR LINE BEFORE
ATTEMPTING ANY SERVICE,MAINTENANCE OR REPAIR WORK!
Follow proper “Lock-Out / Tag-Out” procedures as specified by the Occupational Safety and
Health Administration “OSHA”.
1. Verify that electrical power and compressed air supply has been disconnected.
2. Loosen the lock-nut and raise the motor carriage manually by turning the threaded stem on the back of
the motor carriage. Raise the carriage until the router bit is approx. 1/4” above the machine table.
3. Remove the old chip breakers from the table recess and discard.
4. Loosen the hex head screw in the black motor bracket and carefully slide the motor out.
5. Use the included metric wrenches (18mm & 22mm) to open the ¼” or 8mm collet and remove the old
router bit.
6. Install new bit and tighten collet securely.
Distance between tip of router bit and top of collet should be:
For W-1 router bit: 15.5 mm = 0.610”
For W-2 router bit: 17.0 mm = 0.669”
For W-3 router bit: 19.0 mm = 0.749”
7. Slide the motor back into the bracket and use the square stop to set the proper distance. The stop has
three steps in one side (W1, W2, W3) and one large step machined in the opposite for W4 router bits.
Slide the square stop out of the fence rail and remove the locking lever, washer and square nut. Place
the stop upside down on the table to use.
Use the smallest step for W-1, the middle step for W-2 and the deepest step for W-3.
8. Lower the carriage to its home position.
9. Make a test cut and verify proper settings by inserting a Hoffmann key.
10. Raise the carriage again until the bit is approx. 2” above the table, then install a new chip breaker
insert. Place a piece of scrap wood over the insert and slowly lower the running router bit down through
the wood. The scrap wood eliminates tearout on the surface of the chip breaker.
Hold the scrap wood securely in place and be aware of the turning bit at all times. Lower the router
carriage by turning the threaded stem slowly. When the motor has shut off, secure the threaded stem
with the locknut.
Machined steps for W1-W2-W3 bits Machined step for W4 bit
Square or “butt-joint” stop

Hoffmann PP2 Dovetail Routing Machine
- 11 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
11.1 Change of router bit on PP2 production models
ALWAYS DISCONNECT THE ELECTRICAL POWER SUPPLY AND COMPRESSED AIR LINE BEFORE
ATTEMPTING ANY SERVICE,MAINTENANCE OR REPAIR WORK!
Lift motor carriage with threaded stem Router bit raised approx. 1/4” above table
Loosen screw in motor bracket to remove motor For best results, discard old chip breaker
Use square stop to adjust new router bit projection Scrap wood placed on machine table for initial
cut through new chip breaker
Lower the router bit SLOWLY with threaded stem!

Hoffmann PP2 Dovetail Routing Machine
- 12 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
11.2 Fine Adjustment
The operator can adjust the tightness of an assembled joint as well as the clamping force exerted
by the key.
ALWAYS DISCONNECT THE ELECTRICAL POWER AND COMPRESSED AIR SUPPLY BEFORE ATTEMPTING
ANY SERVICE,MAINTENANCE OR REPAIR WORK!
Follow proper “Lock-Out / Tag-Out” procedures as specified by the Occupational Safety and
Health Administration “OSHA”.
11. Verify that electrical power and compressed air supply have been disconnected.
12. Raise the motor carriage as described before.
13. Remove the chip breaker.
14. Open the collet with two open-end wrenches.
15. Carefully move the router bit further toward the operator to increase the routing depth, or
move the router bit away from the operator to decrease the routing depth.
Only a small movement (0.1 – 0.5mm = 0.004 – 0.020”) is necessary to make a noticeable
difference.
16. Tighten the bit in the collet and lower the carriage.
17. Re-connect the electrical power and compressed air supply and make a test cut.
18. When the new setting is to your satisfaction, re-install the chip breakers and follow the
procedures on the previous page for the initial cut through the chip breaker.
To re-set the machine to the factory setting, use the included aluminum set-up jig.
Wrong Setting Correct Setting
12. Applications for the Hoffmann Dovetail Joining System

Hoffmann PP2 Dovetail Routing Machine
- 13 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
13. Installation of fence extensions
If accessory fence extensions have been ordered with the machine please follow these assembly
instructions:
1. Push the left and right hand side fence with the steel connector plate (2) and bolt (1) into the
machine fence profile.
2. Tighten the screw (3) on the connector plate.
3. Attach the self-adhesive tape scale to the fence extension.
Proper line-up with the table scale is important!
14. Maintenance
ALWAYS DISCONNECT THE ELECTRICAL POWER AND COMPRESSED AIR SUPPLY BEFORE ATTEMPTING
ANY SERVICE,MAINTENANCE OR REPAIR WORK!
Follow proper “Lock-Out / Tag-Out” procedures as specified by the Occupational Safety and
Health Administration “OSHA”.
•All moving parts should be cleaned weekly and lubricated as necessary.
•The cooling vents in the motor housing must be kept free from dust and debris.
•Promptly replace damaged or worn router bits. Use only Original Hoffmann Dovetail Router
Bits for best performance.
•All fasteners, nuts and bolts should be checked periodically and re-tightened as necessary.
•Periodically check the machine for damage or unusual wear. Never operate the machine if
damaged.
•Do not modify the machine. Any modification will void the warranty and may cause a
hazardous condition.
•Remove condensation from the air filter assembly by opening drain on bottom of plastic
reservoir, as needed.
•Re-fill oil reservoir with good quality air tool oil, as needed.
Set-screw should be adjusted to dispense one drop of oil approx. every 30-40 machining
cycles.

Hoffmann PP2 Dovetail Routing Machine
- 14 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
15. Parts List
1. Cast aluminum table base
2. Steel cabinet
3. 45 degree fence plate
4. Bolt
5. Washer
6. Square nut
7. Stop-ring
8. Bolt
9. Fence rail
10. Grommet
11. Screw
12. Aluminum disc
13. Guide block
14. Screw
15. Knob
16. Height adjustment rod
17. Self adhesive scale
18. Knob
19. Aluminum bracket, left side
20. Aluminum bracket, right side
21. Screw
22. Square steel tube
23. Foam pad
24. Screw
25. Stem for hold-down cylinder
26. Locking lever
27. Mounting plate
28. Short-stroke cylinder
29. Screw
30. Dust collection fitting
31. Mounting bracket for hold-down stem
32. Guide rod
33. Linear bearing
34. Screw
35. Washer
36. Bearing seal
37. Motor carriage base plate
38. Screw
39. Screw
40. Router motor
41. Screw

Hoffmann PP2 Dovetail Routing Machine
- 15 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
42. Screw
43. Locking lever
44. Screw
45. Hold-down plate
46. Chip breaker
47. Screw
48. Screw
49. Guide block, front
50. Guide block, rear
51. Knob
52. Square nut
53. Screw
54. Mounting angle bracket
55. Motor collet
56. Screw
57. Screw
58. Pneumatic cylinder (main cylinder)
59. Locking lever
60. Tape scale
61. Square stop
62. Locking lever
63. Router bit
64. Adjustable foot
65. Nut
66. Foot pedal
67. Dust collection hose
68. Hose clamp
69. N/A
70. Washer
71. Emergency-Stop Switch
72. Screw
73. Air regulator-filter-lubricator unit
74. Screw
75. Washer
87. Limit Switch
95. Grommet
96. Mounting bracket
101. Pneumatic limit switch
Please see page 1 of this manual for location and type of Warning and Safety Labels on this machine!

Hoffmann PP2 Dovetail Routing Machine
- 16 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
16.1 PP2 side view

Hoffmann PP2 Dovetail Routing Machine
- 17 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
16.2 PP2 front view

Hoffmann PP2 Dovetail Routing Machine
- 18 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
16.3 PP2 top view

Hoffmann PP2 Dovetail Routing Machine
- 19 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [email protected]
www.Hoffmann-USA.com
17. Electrical Schematic
This schematic depicts the typical wiring diagram for a PU2 single-head routing machine.
On PP2 double-head models, the second motor is wired into the same contactor.