Major Manufacturing HIT-66-200 User manual

INSTRUCTIONS
FOR
HIT-66-200
LOCK MORTISER
1825 VIA BURTON
ANAHEIM CA 92806
714-772-5202 / FAX [phone]
EMAIL: [email protected]
WEB: WWW.MAJORMFG.COM
WHEN USING POWER TOOLS
ALWAYS WEAR
EYE AND EAR PROTECTION!!
Copyright 2012—Major Manufacturing Inc

THINK
SAFETY!!
WHEN USING POWER TOOLS
ALWAYS WEAR
EYE PROTECTION!!
Before attempting any installation know
how to safely use the power tools involved.
Be sure all bits and cutters are sharp and
in good condition and all power tools and
extension cords are in good working order
and properly grounded. AND MOST
IMPORTANTLY, BE SURE TO WEAR,
EYE AND EAR PROTECTION.
PAGE 2
Copyright 2012—Major Manufacturing Inc

Attach the mortiser attachment to the HIT
-66 clamp set using the supplied
1/4-20 x 1-1/2” socket screws. The mor-
tiser is held to the HIT-66 clamp system
with two screws on top and two on the
bottom. Leave all screws loose at this
time.
Once all screws have been installed they
can be tightened.
Slide the mortise bit into the unit and
slide the stop collar on the end of the
shaft.
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Copyright 2012—Major Manufacturing Inc
NOTE: The HIT-66 clamps
shown are not part of the
HIT-66-200 mortiser set and
must be purchased as a
separate item.

With both clamps opened
equally, install both inside and
outside templates to the HIT-66
clamp as shown. Do not tighten
the 10-32 screws at this time.
When all screws have been
loosely installed, then it is ok to
tighten.
There are two clamps on the
rod guides, one top and one
bottom. When aligned to the top
and bottom scribe lines on the
guide plate, they will limit the
travel. They are set up for a
standard 6-1/2” mortise. The
bottom of the top clamp should
be on the top line, and the top of
the bottom clamp should be on
the bottom line. Tighten the
screws when adjusted. To
change the size of the mortise,
use the scribe lines as a guide
and adjust accordingly. To
change the size of the mortise
by 1/8” move each clamp 1/16”
in the desired direction.
The next part to attach to the
template is the alignment guide.
When installed, it will align the
mortise pocket to the drill guide.
Notice the scribe mark in the
picture at the left. The guide can
be attached to either template, it
is attached with two 10-32 x 3/4”
flat head socket screws.
PAGE 4

Using a pencil, establish the
centerline of the mortise pocket
as shown at left. Put the
mortise unit on the door and
align as shown on the right.
Tighten the clamp knobs top
and bottom alternating
between the top and bottom
clamp. Do not attempt to
tighten one clamp all the way at
once.
Touch the bit to the door edge
and measure the depth that you
want to drill. Tighten the stop
collar, this will limit the depth of
the mortise pocket.
Attach a drill motor to the cutter
shaft and tighten the chuck.
PAGE 5
Copyright 2012—Major Manufacturing Inc
Start at the bottom and drill a
hole to depth. Back out the bit to
clear the chips, do not attempt to
drill the hole to depth all at once.
Use a moderate drill speed 350
to 500 rpm.
Drill a second hole above the first
and continue up the door.

Once you have several holes
drilled you can drill out between
the webs.
Once the webs have been
drilled out the cutter can be
moved in and out up and down
to clean out the pocket.
PAGE 6
Copyright 2012—Major Manufacturing Inc
When the pocket has been
completed, the lock function
holes can be drilled. Make sure
the mortise bit has been pulled
out of the pocket!
The template shown is for a
Schlage Mortise Lock, most of
our HIT-66 Series will work with
the mortiser. Follow the direc-
tions for the template used.
Here the spindle hole is being
drilled to the mortise pocket.
Thru bolt holes being drilled on
both sides of the door.

Thru bolt holes for the trim being
drilled half way from both sides of
the door.
Mortise cylinder hole being
drilled to the pocket on the
outside of the door.
Thumb turn hole being drilled on
the right. This hole is drilled on
the inside of the door to the
pocket.
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Copyright 2012—Major Manufacturing Inc
When all holes have been
drilled, remove the template
from the door.
Completed install shown at right.

The prep is now ready for
faceplate routing.
PAGE 8
That’s all there is to it!
Copyright 2012—Major Manufacturing Inc
This was the original layout line
that we drew in the beginning. It
can be used to center one of our
router jigs to route the faceplate
opening.
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