Hoffmann PU2-TL User manual

© Hoffmann Machine Company, Inc.
OPERATING MANUAL
for
Hoffmann Dovetail Routing Machine
Model PU2-TL
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 PU2-TL Dovetail Routing Machine
- 1 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
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 PU2-TL Dovetail Routing Machine
- 2 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
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 PU2-TL Dovetail Routing Machine
- 3 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
3. Operator Training
The Hoffmann Dovetail Routing Machine model PU2-TL 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 PU2-TL 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 PU2-TL 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 clamp and secures the workpiece. With the
workpiece clamped securely, the router motor is turned on and raised up automatically and the
spinning router bit moves 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 motor returns
to it’s resting position and is shut off. A pneumatic valve is triggered when the motor has reached
it’s home position, this valve releases the material clamp and the workpiece is 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 PU2-TL Dovetail Routing Machine
- 4 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
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, 8.5 Amps. - single phase
Router motors one Hoffmann brand motor, 1,000 Watt
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: 297 lbs.
Dovetail Key sizes W-1, W-2, W-3, W-4

Hoffmann PU2-TL Dovetail Routing Machine
- 5 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
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 PU2-TL Dovetail Routing Machine
- 6 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
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.
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 router has 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 clamp and the steel
fence plate are properly tightened, and do not change the settings until booth parts are routed.
Routing height adjustment rod with yellow scale and locking lever

Hoffmann PU2-TL Dovetail Routing Machine
- 7 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
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.
Processing 45 degree miter joint with material against center fence plate and rear fence
set at 90 degree to table surface

Hoffmann PU2-TL Dovetail Routing Machine
- 8 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
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.
Square Stop with locking lever and tape scale recessed in machine table

Hoffmann PU2-TL Dovetail Routing Machine
- 9 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
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.
9.5 Adjusting tilt angle for motor carriage
The motor carriage on PU2-TL models can be tilted forward and backward +/- 45 degrees.
The carriage angle is adjusted with the right hand wheel on front of the machine; the angle is
displayed on an angle scale on the right hand side of the machine.
Right hand wheel = adjust table top in and out Left hand wheel = adjust motor carriage angle

Hoffmann PU2-TL Dovetail Routing Machine
- 10 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
Angle scale on right hand side of machine
After adjusting the carriage angle to the desired setting, use the left hand wheel to move the table
top close (within 1/8”of the back fence).
Tilting the carriage forward requires the table to be moved out toward the operator.
Tilting the carriage backward requires the table to be moved back away from the operator.
After adjusting carriage angle and table position, be sure to check and adjust if necessary the
position of the pneumatic hold-down clamp. Clamp must be set to securely hold workpiece in
place.
Clamp height should be set to no more than 1/8”above material.

Hoffmann PU2-TL Dovetail Routing Machine
- 11 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
Motor carriage tilted back and motor raised for clarity
Note: Table top must be closer to rear fence before operating machine.

Hoffmann PU2-TL Dovetail Routing Machine
- 12 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
Motor carriage tilted forward and motor raised for clarity

Hoffmann PU2-TL Dovetail Routing Machine
- 13 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
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 the first both keyway location and the routing height is set. When the first keyway has been
routed in every piece, the fence plate is moved for the second. For a production environment, it is advisable to build a
fixture to support the moulding in the correct position.
NOTE: Pictures show procedure on standard PU-2 model –same set-up is used on PU2-TL model!
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 PU2-TL Dovetail Routing Machine
- 14 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
10. Accessories for PU2-TL machines (standard PU-2 machine shown)
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 not available for PU2-TL
Laser guide for working to pencil lines Fence extension rail with flip-stop

Hoffmann PU2-TL Dovetail Routing Machine
- 15 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
order number: W 3900006 order number: W 3900001 / W 3900003
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 have been disconnected.
2. Raise the motor carriage manually and slide a wooden spacer block (approx. 2” thick)
between the two guide rods (1).
3. Loosen the allen head screw (2) in the motor bracket and carefully slide the motor out.
4. Use the included metric wrenches (18mm, 22mm) to open the ¼” collet and remove the old
router bit.
5. 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”
6. Slide the motor back into the carriage and use the included aluminum set-up jig to set the
proper distance.
Use the smallest step for W-1, the middle step for W-2 and the deepest step for W-3.
A separate jig is available for W-4 size router bits.
7. Remove the spacer block and lower the carriage to its home position.
8. Make a test cut to verify proper settings.

Hoffmann PU2-TL Dovetail Routing Machine
- 16 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
Step 3: Loosen allen head screw in motor bracket and remove motor
Step 4-5: Motor removed to change router bit

Hoffmann PU2-TL Dovetail Routing Machine
- 17 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
Step 6: Motor is moved into motor bracket until tip of router bit touches set-up jig.

Hoffmann PU2-TL Dovetail Routing Machine
- 18 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
12. 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 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”.
9. Verify that electrical power and compressed air have been disconnected.
10. Raise the motor carriage manually and slide a wooden spacer block (approx. 2” thick)
between the two guide rods.
11. Loosen the hex head screw in the motor collet.
12. Carefully move the motor further toward the operator to increase the routing depth, or move
the motor 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.
13. Tighten the hex cap screw, remove the spacer and lower the carriage.
14. Re-connect the electrical power and compressed air supplies and make a test cut. If the new
setting is unsatisfactory, the above steps are repeated.
To re-set the machine to the factory setting, use the included aluminum set-up jig.
Wrong Setting Correct Setting
13. Applications for the Hoffmann Dovetail Joining System

Hoffmann PU2-TL Dovetail Routing Machine
- 19 -
Hoffmann Machine Company, Inc. 1386 Drexel Road Valdese, NC 28690
Phone: (828) 430 - 4510 Fax: (828) 430 - 4620 e-mail: [e-mail]
www.Hoffmann-USA.com
15. 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!