Lumberjack DTJ300 Installation manual

+
SAFETY AND OPERATING MANUAL
300MM DOVETAIL JIG
DTJ300-600
ORIGINAL INSTRUCTIONS
DTJ300-600

TABLE OF CONTENTS
Welcome to Lumberjack!
Dear customer, Congratulations on your purchase. Before using the
Product for the first time please be sure to read these instructions for use.
They provide you with all information necessary for using the product safely and to
ensure its long service life.
Closely observe all safety information in these instructions!
General Power Tool Safety Warnings………………………………….…......01
Symbols & Cable Rating Chart ……….…………………………………….………04
Machine Details and Product features……….…………………………….….05
Assembly……………………………………………………………………………………..06
Operation…………………………………………………………………………………….07
Working advice & Maintenance and Service……..…………………………09
Lumberjack Guarantee…………………………………………………………………10
Parts List & Diagram………………………………………………………….…………12
DTJ300-600

DTJ300-600 01
GENERAL POWER TOOL SAFETY WARNINGS
WARNING Read all safety warnings and
all instructions. Failure to follow the warnings
and instructions may result in electric shock, fire
and/or serious injury.
Save all warnings and instructions for
future reference. The term "power tool" in
the warnings refers to your electric (corded)
power tool or battery-operated (cordless) power
tool.
1. Work area safety
a) Keep work area clean and well lit. Cluttered
or dark areas invite accidents.
b) Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools
create sparks which may ignite the dust or
fumes.
c) Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
2. Electrical safety
a) Power tool plugs must match the outlet.
Never modify the plug in any way. Do not use
any adapter plugs with grounded power tools.
Unmodified plugs and matching outlets will
reduce risk of electric shock.
b) Avoid body contact with grounded surfaces,
such as pipes, radiators, ranges and
refrigerators.There is an increased risk of
electric shock if your body is grounded.
c) Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords
increase the risk of electric shock.
e) When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of a
cord suitable for outdoor use reduces the risk of
electric shock.
f) If operating a power tool in a damp location is
unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk
of electric shock.
3. Personal safety
a) Stay alert, watch what you are doing and use
common sense when operating a power tool. Do
not use a power tool while you are tired or under
the influence of drugs, alcohol or medication. A
moment of inattention while operating power
tools may result in serious personal injury.
b) Use personal protective equipment. Always
wear eye protection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions
will reduce personal injuries.
c) Prevent unintentional starting. Ensure the
switch is in the off position before connecting to
power source and/or battery pack, picking up or
carrying the tool. Carrying power tools with your
finger on the switch or energising power tools that
have the switch on invites accidents.
d) Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may
result in personal injury.

DTJ300-600 02
e) Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from moving parts. Loose clothes,
jewellery or long hair can be caught in moving
parts.
g) If devices are provided for the connection of
dust extraction and collection facilities, ensure
these are connected and properly used. Use of
dust collection can reduce dust-related hazards.
4. Power tool use and care
a) Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the
rate for which it was designed.
b) Do not use the power tool if the switch does
not turn it on and off. Any power tool that
cannot be controlled with the switch is
dangerous and must be repaired.
c) Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
d) Store idle power tools out of the reach of
children and do not allow persons unfamiliar
with the power tool or these instructions to
operate the power tool. Power tools are
dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts and
any other condition that may affect the power
tool’s operation. If damaged, have the power tool
repaired before use. Many accidents are caused
by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier
g) Use the power tool, accessories and tool bits
etc. in accordance with these instructions, taking
into account the working conditions and the work
to be performed. Use of the power tool for
operations different from those intended could
result in a hazardous situation.
5. Service
a) Have your power tool serviced by a qualified
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
b) If the replacement of the supply cord is
necessary, this has to be done by the
manufacturer or its agent in order to avoid a
safety hazard.
7. Additional Safety and working
Instructions
7.1. Dust from materials such as lead-containing
coatings, some wood types, minerals and metals
can be harmful to one’s health and cause allergic
reactions, leading to respiratory infections and/or
cancer. Materials containing asbestos may only be
worked by specialists. Observe the relevant
regulations in your country for the materials to be
worked.
GENERAL POWER TOOL SAFETY WARNINGS

DTJ300-600 03
GENERAL POWER TOOL SAFETY WARNINGS
7.2. Prevent dust accumulation at the
workplace. Dust can easily ignite.
8. Additional Safety and Working
Instructions
8.1 Dusts from materials such as
Lead‐containing coatings, some wood
types, minerals and metals can be
harmful to one’s health and cause
allergic reactions, leading to respiratory
infections and/or cancer.
Materials containing asbestos may only be
worked by specialists. Observe the relevant
regulations in your country for the materials to
be worked.
8.2 Prevent dust accumulation at the
workplace. Dusts can easily ignite.
9. Using an Extension Cable.
9.1. If an extension cable is required, use an
approved triple core extension cable suitable
for the power input of the tool.
9.2. Grounded tools always require a three wire
extension cable.
9.3. As the distance from the supply outlet
increases you must use a heavier gauge
extension cable. Using extension cables with
inadequately sized wire causes a serious drop in
voltage, resulting in loss of power and possible
tool damage.
9.4. The smaller the gauge number of the wire
the greater the capacity of the cord.
9.5. When using a cable reel, always unwind the
cable completely.

SYMBOLS AND POWER RATING CHART
Danger! –Read the operating
instructions to reduce the risk of
injury.
Caution! Wear safety goggles.
Caution! Wear ear defenders. The
impact of noise can cause
damage to hearing.
Amperes
7.5M
15M
25M
30M
45M
60M
0 –2.0
6
6
6
6
6
6
2.1 –3.4
6
6
6
6
6
6
3.5 - 5.0
6
6
6
6
10
15
5.1 –7.1
10
10
10
10
15
15
7.1 –12.0
15
15
15
15
20
20
12.1 –20.0
20
20
20
20
25
-
Caution! Risk of Injury! Do
not reach into the running
saw blade.
Caution! Wear a dust mask.
DTJ300-600
06
DTJ300-600 04

DTJ300-600
08
DTJ300-600 05
MACHINE DETAILS AND PRODUCT FEATURES
Machine Details
Specifications:
Min Thickness of Work piece ‐ 8mm
Max Thickness of work piece ‐ 32mm
Max Width of Work Piece:
DTJ300 ‐ 300mm
DTJ600 ‐ 600mm
Max Offset Capacity ‐ 25mm
Package Contents:
Dovetail Jig
½” Template
¼” Dovetail Cutter
Product Features
1. Locking Clamp Handle
2. Eccentric Cam
3. Eccentric Bar
4. Clamp
5. Clamp adjusting Screw
6. Template Securing Screw
7. Backstop Locking Screw
8. Horizontal Stop
9. Vertical Stop
10. Back Stop
11. Template
Intended Use
This jig is intended to cut both male and female
dovetail joints into wood and wood like
materials.

DTJ300-600 06
ASSEMBLY
Avoid unintentional starting of the
machine. During assembly and for all
work on the machine, the power plug
must not be connected to the mains
supply.
Carefully remove all parts included in the
delivery from their packaging.
Remove all packaging material from the
machine and the accessories provided.
Before starting the operation of the machine
for the first time, check if all parts listed in the
box content section have been supplied.
Note: Check the power tool for possible
damage. Before further use the machine,
check that all protective devices are fully
function. Any lightly damaged parts must be
carefully checked to ensure flawless operation
of the tool. All parts must be properly
mounted and all conditions fulfilled that
ensure faultless operation.
Damaged protective devices and parts must be
immediately replaced by an authorised service
centre.
Assembling the Jig
Screw the front and top handles into the
eccentric bars.
–The work pieces will be locked when the top
locking clamp handle is pushed away from you
and when the lower locking clamp handle is
pushed downwards.
Mounting the Jig
There are four holes provided in the base for
mounting the jig.
–Mount the jig to a bench as shown and secure
using suitable screws (not supplied).
–The jig must be mounted flush with the front
edge of the workbench.
–Make sure there is enough space behind the
jig to accommodate the longest length of timber
you are likely to work on.

DTJ300-600 07
OPERATION
Before any work on the machine itself,
remove the mains plug from outlet.
Setting the End Stops
–Use a set square to draw a pencil line
halfway across the first finger of the
template. The line must be square to the
edges of the template.
–Line up the inside edge of the left
horizontal stop with the line you just
drew on the template. Use a set square to
ensure the stop is square to the jig.
–Offset the vertical stop 1/2” to the
right of the horizontal stop. Ensure the
vertical stop is square to the top of the jig.
–Mirror these settings on the right‐hand
side of the jig. Placing Work Pieces
–Align the timber so that the side of the
work piece is mounted in the front
vertical clamp. It should extend above the
front edge of the jig by the thickness of the
piece to be mounted under the top clamp (front
or back of the drawer).

DTJ300-600 08
OPERATION
–The piece of timber in the top clamp is
then butted up to this, so that both
pieces are flush under the template.
–The two pieces sit in the jig as shown
on the right. Make sure that both pieces are
butted up against the horizontal / vertical
stops.
–Use the locking clamp handles to
secure the wood to the jig. You may need
to adjust the top and front clamp bars to suit
the thickness of the timber using the clamp
adjusting screws at either end of each clamp
bar so that the wood is held firmly in place.
When narrow pieces of wood are being used,
place another piece of wood (exactly the same
thickness) underneath the clamp bar at the
opposite end to ensure an even grip on the
wood and to avoid distorting the bars.
Setting the Template Position
–Unlock the two template securing screws
and position the template so that the tips of
the fingers sit 3mm back from the edge of the
vertically mounted timber.
–Lock the template into position using the two
template securing screws.
Setting the Backstop
The distance the backstop needs to be positioned
from the front of the template fingers depends on
the size of router base fitted to your router, the
formula to calculate this is:
–Set a micro-meter or Vernier calliper to the
Calculated depth and adjust the backstop as
Shown (next page).
–Lock into place using the backstop locking
screws. It is not essential that this setting is exact
at this stage as final adjustments can be made
later on.
–Ensure that the template and back stop stay
parallel with the front edge of the jig during this
setting procedure
Setting the Cutter Depth
–Fit the bearing guided router bit securely into
the router collet
–Adjust the cutter depth, until the bottom of the
router bit protrudes 10‐11 mm below the
template fingers.
–You may need to fit a packing piece between the
template and the timber to ensure good contact
between the bearing and the slots in the template.
–The cutting depth is critical to the final fit of the
joint, with as little as 0.5mm change in depth
making all the difference.

DTJ300-600 09
WORKING ADVICE & MAINTENANCE AND SERVICE
General Sawing Instructions
For all cuts, it must first be ensured
that the saw blade at no time can
come in contact with the fence,
screw clamps or other machine
parts. Remove possibly mounted
auxiliary stops or adjust them
accordingly.
Protect the saw blade against impact and
shock. Do not subject the saw blade to
lateral pressure.
Do not saw warped/bent work pieces.
The work piece must always have a
straight edge to face against the fence.
Long work pieces must be under laid or
supported at their free end.
Position of the Operator
–Do not stand in a line with the
saw blade in front of the machine.
Always stand aside of the saw
blade.
This protects your body against possible
kickback.
–Keep hands, fingers and arms away
from the rotating saw blade. Observe the
following instructions:
–Hold the work piece securely with both
hands and press it firmly against the saw
table.
–When sawing narrow work pieces and
bevel angles, always use the supplied hold‐
down stick.
Transport
Before transporting the power tool, the
following steps must be carried out:
–Bring the machine into the transport position.
–Remove all accessories that cannot be
mounted firmly to the power tool.
If possible, place unused saw blades in an
enclosed container for transport.
–Carry the machine by the base or the carry
handle only.
The power tool should always be carried
by two persons in order to avoid back
injuries. When transporting the power
tool, use only the transport devices and
never use the protective devices.
Maintenance and Service
–Before each use inspect the general
condition of the machine. Check for loose
screws, misalignment or binding of moving
parts, cracked or broken parts, and any other
condition that may affect its safe operation.
–Each day remove all sawdust and debris
from the jig with a soft brush, cloth or vacuum.
Do not use solvents or caustic agents to clean
the jig.

DTJ300-600 10
LUMBERJACK GUARANTEE
1. Guarantee
1.1 Lumberjack guarantees that for a
period of 12 months from the date of
purchase the components of
qualifying products (see clauses 1.2.1
to 1.2.8) will be free from defects
caused by faulty construction or
manufacture
1.2 During this period, Lumberjack, will
repair or replace free of charge any
parts which are proved to be faulty
in accordance with paragraph 1.1
providing that:
1.2.1 You follow the claims procedure
set out in clause 2.
1.2.2 Lumberjack and its Authorised
Dealers are given reasonable
opportunity after receiving notice
of the claim to examine the
product.
1.2.3 If asked to do so by lumberjack or
its Authorised Dealer, you return
the product at your own cost to
Lumberjack’s or the supplying
Authorised Dealer’s Premises -
For the examination to take place clearly
stating the Returns Material Authorisation
Number given.
1.2.4 The fault in question is not caused by
industrial use, accidental damage, fair wear
and tear, wilful damage, neglect, incorrect
electrical connection, misuse, alteration or
repair of the product without approval.
1.2.5 The product has been used in a
domestic environment only.
1.2.6 The fault does not relate to
consumable items such as blades, bearings,
drive belts or other wearing parts which
can reasonably be expected to wear at
different rates depending on usage.
1.2.7 The product has not been used for
hire purposes.
1.2.8 The product has been purchased by
you, as the guarantee is not transferable
from a private sale.

DTJ300-600 11
LUMBERJACK GUARANTEE
2. Claims Procedure
2.1 In the first instance please contact the
Authorised Dealer who supplied the product to
you. In our experience many initial problems
with machines that are thought to be fault due
to faulty parts are actually solved by correct
setting up or adjustment of the machine. A good
Authorised Dealer should be able to resolve the
majority of these issues much more quickly than
processing a claim under the guarantee. If a
return is requested by the Authorised Dealer or
Lumberjack, you will be provided with a Returns
Material Authorisation Number which must be
clearly stated on the returned package, and any
accompanying correspondence. Failure to
provide a Returns Material Authorisation
Number may result in item being refused
delivery.
2.2 Any issues with the product resulting in a
potential claim under the guarantee must be
reported to the Authorised Dealer from which it
was purchased within 48 hours of receipt.
2.3 If the authorised Dealer who supplied the
product to you has been unable to satisfy your
query, any claims made under this guarantee
should be made directly to Lumberjack. The
claim itself should be made in a letter setting out
the date and place of purchase, giving a brief
explanation of the problem which has led to the
claim.
2.4 Please note that it is essential that the letter of
claim reaches Lumberjack on the last day of this
guarantee at the latest. Late claims will not be
considered.
3. Limitation of Liability.
3.1 We only supply products for domestic and
private use. You agree not to use the product for
any commercial, business or resale purposes and
we have no liability to you for any loss of profit,
loss of business, business interruption or loss of
business opportunity.
3.2 This guarantee does not confer any rights
other than these expressly set out above and does
not cover any claims for consequential loss or
damage. This guarantee is offered as an extra
benefit and does not affect your statutory rights
as a consumer.
4. Notice
This guarantee applies to all product purchased
from an Authorised Dealer of Lumberjack within
the United Kingdom. Terms of guarantee may vary
in other countries.
DTJ300-600 11

DTJ300-600 12
PARTS LIST & DIAGRAM