TOPMAQ MS3840 User manual

MS3840 MORTISING MACHINE １
HEAVY-DUTY MORTISER
Model MS3840
Instruction Manual & Parts List

MS3840 MORTISING MACHINE２
This manual has been prepared for the owner and operators of Model MS3840 Mortiser.
Its purpose, aside from proper machine operation, is to promote safety through the use of
accepted correct operating and maintenance procedures. Completely read the safety and
maintenance instructions before operating or servicing the machine. To obtain maximum
life and efficiency from your mortiser, and to aid in using the machine safely, read this
manual thoroughly and follow all instructions carefully.
TABLE OF CONTENTS
Safet
y
Rules 2
Specifications 5
Receivin
g
the Mortise
r
5
Installation 5
Adjustments Installin
g
Chisel & Bit 6
Work Stop 6
Operation 7
Maintenance/ Sharpenin
g
Chisel & Bit 9
Parts Lists & Exploded Views
Mortiser 12
Stand Assembly 15
Clamping Bar Assembly 16
Work Stop 17
SAFETY RULES
As with all power tools there is a certain amount of hazard involved with the operation and use of
the Mortiser. Use the tool with the respect and caution demanded where safety precautions are
concerned. This will considerably lessen the possibility of personal injury. When normal safety
precautions are overlooked or completely ignored, personal injury to the operator can result.
Know your tool. Read the owner’s manual carefully. Learn the tools applications and limitations,
as well as the specific potential hazards peculiar to it.
Keep guards in place and maintained in working order.
Ground all tools. If tool is equipped with three-prong plug, it should be plugged into a three-hole
electrical receptacle. If an adapter is used to accommodate a two-prong receptacle, the adapter
plug must be attached to a known ground. Never remove the third prong.
Remove adjusting keys and wrenches. Form habit of checking to see that keys and adjusting
wrenches are removed from tool before turning it on.
Keep work area clean. Cluttered areas and benches invite accidents.
Avoid dangerous environment. Don’t use power tools in damp or wet locations, or expose them
to rain. Keep work area well lighted.
Keep children and visitors away. All children and visitors should be kept a safe distance from
work area.
Make workshop childproof - with padlocks, master switches, or by removing starter keys.
Don't force tool. It will do the job better and be safer at the rate for which it was designed.

MS3840 MORTISING MACHINE ３
Use proper tool. Don’t force tool or attachment to do a job for which it was not designed.
Wear proper apparel. Do not wear loose clothing, gloves, neckties, or jewelry that can get caught
in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long
hair
Use safety glasses. Also use face or dust mask if cutting operation is dusty.
Secure work. Use clamps or a vise to hold work when practical. It’s safer than using your hand
and frees both hands to operate tool.
Don't overreach. Keep your proper footing and balance at all times.
Maintain tools in top condition. Keep tools sharp and clean for best and safest performance.
Follow instructions for lubricating and changing accessories.
Disconnect tools before servicing and when changing accessories such as chisel and bit.
Use recommended accesories. Consult the owner’s manual for recommended accessories. The
use of improper accessories may cause hazards.
Avoid accidental starting. Make sure switch is in “OFF” position before plugging in cord.
Never stand on tool. Serious injury could occur if the tool is tipped or if the cutting tool is
accidentally contacted.
Check damaged parts. Before further use of the tool, a guard or other part that is damaged
should be carefully checked to ensure that it will operate properly and perform its intended function
- check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and
any other conditions that may affect its operation. A guard or other part that is damaged should be
properly repaired or replaced.
Never leave tool running attended. Turn power off. Don’t leave tool until it comes to a complete
stop.
Drugs, alcohol, medication. Do not operate tool while under the influence of drugs, alcohol, or
any medication.
Health hazards. Some dust created by power sanding, sawing, grinding, drilling and other
construction activities contains chemicals known to cause cancer, birth defects or other
reproductive harm. Some examples of these chemicals are:
- Lead from lead-based paint.
- Crystalline silica from bricks and cement and other masonry products.
- Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To
reduce your exposure to these chemicals, work in a well-ventilated area, and work with approved
safety equipment, such as those dust masks that are specifically designed to filter out microscopic
particles.

MS3840 MORTISING MACHINE４
MODEL MS3840 MORTISER

MS3840 MORTISING MACHINE ５
SPECIFICATIONS
Motor See Nameplate 750w (input), 1PH, (220 V,50 Hz)
Spindle speed See Nameplate ( 1400 rpm )
Chisel capacity 6.35—25.4mm
Chisel shank 19.05mm
Maximum chisel stroke 220mm
Distance, fence to center chisel 140mm
Chuck capacity 16mm
Bushing size 19.05mm
Table movement Long-ways 170mm
Cross-ways 140mm
Table size 400x150mm
RECEIVING THE MORTISER
Remove mortiser and stand from the shipping cartons. Check for damage and ensure all parts are
intact. Any damage should be reported immediately to your distributor and shipping agent. Before
assembling, read the manual thoroughly, familiarizing yourself with correct assembly and
maintenance procedures and proper safety precautions.
Contents of shipping cartons:
Stand carton
1 Stand
1 Hardware package
Mortiser carton
1 Mortiser with motor
1 Operating handle
2 Handwheel handles
1 Chuck key
1Chisel
1 Wooden table
INSTALLATION
The mortiser should be secured to the stand with four M12 x 120 hex head screws (provided)
using the holes in the base. Make sure there is enough room on each side of the mortiser for the
size stock you plan to use.
WARNING: The mortiser has a two-prong plug and requires a grounded outlet.
In the event of a malfunction or breakdown, grounding provides a path of least resistance for
electric current to reduce the risk of electric shock. If you are not sure whether your outlet is
properly grounded, consult a qualified electrician.

MS3840 MORTISING MACHINE６
ADJUSTMENTS
INSTALLING CHISEL & BIT
1. Loosen lock screw, shown in Fi
g
ure 2.
2. Insert chisel bushing (with the hole facing forward) into the head. Tighten the screw just
enough to hold the chisel in place.
!
NOTE: Set the slot in the side of the chisel to the left or right, NOT to the front or back. This will
allow chips to escape when cutting mortises.
3. Push the chisel up as far as possible into the head. Then lower the chisel approximately 0.8mm
to 1.6mm, depending on the type of wood being worked. Tighten the screw
to hold chisel in place.
4. Push bit up through the chisel opening as far as it will go. Lock the drill bit in place with the
chuck key.
5. Loosen screw and push chisel up against the bushing, then tighten screw. This should provide
the proper distance between the points of the chisel and the bit.
WORK STOP
The work stop can be mounted to the table , as shown in Figure 3. It is tightened into place .

MS3840 MORTISING MACHINE ７
OPERATION
1. Set depth stop to the required depth o
f
cut. See Fi
g
ure 4.
FIGURE 4

MS3840 MORTISING MACHINE８
2. Place workpiece on table and clamp it with the vise. Use the left handwheel to move table
forward or backward to suit the position of the mortise on the workpiece.
3. Adjust the table stops, Figure 5, according to the length of cut required, then tighten the thumb
screws.
FIGURE 5
4. Turn on machine and feed chisel and bit steadily into workpiece by pulling down the operating
handle.
NOTE: The rate of feed must be fast enough to prevent burning at the tip of the bit, but not so fast
as to cause the machine to slow or stall. The different rates of feed for different woods must be
learned through experience.
5. After the first cut, the workpiece is moved along with the right handwheel for each successive
cut. The direction of movement must allow the chips to clear freely. Move the workpiece so that the
slot in the chisel is releasing chips into the already cut part of the workpiece. See Figure 6.

MS3840 MORTISING MACHINE ９
FIGURE 6
CAUTION: Do not have the chisel slot against the blind end of the mortise, as the chips will
not be able to clear the chisel. This can cause overheating and possible breakage of chisel
or bit.
When cutting deep mortises, make the cut in several stages of approximately 1" each, to allow
chips to clear. To prevent breakout at the back of the workpiece when cutting through mortises,
use a piece of scrap material under the workpiece as support.
!
MAINTENANCE
The Mortiser requires only minor maintenance, such as cleaning and lubrication and routine
adjustment and sharpening of the chisel and bit.
Dust the machine down after each use and, as necessary, use light applications of oil or grease to
lubricate linkages, moving parts, etc.
SHARPENING CHISEL & BIT
The chisel and bit should be kept sharp for best performance. Blunt edges will give inaccurate
mortises and can lead to overheating and breakage to chisel or bit. If chisel and bit are badly worn
and become difficult to sharpen, they should be replaced.
1. Sharpen the bit by using a small, smooth file, following the original shape of the bit. File the
inside edge of the spur, the sides of the brad point, and the cutting edge inwards toward the flute of
the bit. See Figure 7.

MS3840 MORTISING MACHINE１０
FIGURE 7
Do not file the outside edge of the spur as this will affect the diameter of the bit.
2. Sharpen the chisel with a mortise chisel cutter with the correct size pilot. (Pilot size will differ
depending on the size of your chisel). Two or three turns of the cutter in a carpenter's brace chuck
should be enough to sharpen the chisel, as shown in Figure 8.
FIGURE 8

MS3840 MORTISING MACHINE １１
3. Use a small, triangular, smooth file to relieve the inner corners of the chisel. See Figure 9.
Remove any burrs from the outside of the chisel with a fine oilstone.
FIGURE 9

MS3840 MORTISING MACHINE１２
PARTS LIST: MS3840 Mortiser
NO. Description Quantity NO. Description Quantity
A-1 Base 1 A-51 Handle 1
A-2 Middle Base 1 A-52 Motor 1
A-3 Drift 1 A-53 Handle Grip 1
A-4 Set Screw, M6x35 4 A-54 Power Cord 1
A
-5 Hex Nut, M6 4
A
-55 Strain Relie
f
Bushing 1
A-6 Washer, 10 4 A-56 Switch Box 1
A-7 Wave Washer, 10 4 A-57 Switch 1
A-8 Cap Screw, M10x40 4 A-58 Screw, M4x15 2
A-9 Column 1 A-59 Screw, M6x25 4
A-10 Screw 1 A-60 Chuck, 16mm 1
A
-11 Gas Spring 1
A
-61 Screw, M6x10 1
A-12 Set Screw, M6x35 3 A-62 Cover 1
A-13 Hex Nut, M6 3 A-63 Gear 1
A
-14 Drift 1
A
-64 Shaft 1
A-15 Screw 1 A-65 Connecting Bend 1
A-16 Rack 1 A-66 Spring 1
A-17 Screw,M6x10 4 A-67 Screw 1
A-18 Fence 1 A-68 Headstock 1
A-19 Washer,10 4 A-69 Screw 1
A
-20 Wave Washer,10 4
A
-70 Rule
r
mark 1
A-21 Cap Screw, M10x25 4 A-71 Screw 1
A-22 Localizer 1 A-72 Setting Collar 1
A-23 Washer, 6 2 A-73 Screw, M4x12… 2
A-24 Screw, M6x15 2 A-74 Setting Rod 1
A-25 Screw, M6x10 2 A-75 Setting Collar 1
A-26 Pin 2 A-76 Screw, M6x25 1
A-27 Hex Nut, M10 1 A-77 Bushing 1
A
-28 Washer, 10 1
A
-78 Mistising Chisel
A
nd Bit 1
A-29 Screw 1 A-79 Pin 1
A-30 Screw 1 A-80 Clamp Plate 1
A
-31 Setting Collar 1
A
-81 Spring 1
A-32 Setting Rod 1 A-82 Spring Cover 1
A-33 Setting Collar 1 A-83 Handle 1
A-34 Hex Nut, M10 1 A-84 Cover 1
A-35 Washer, 10 1 A-85 Screw, M5x10 4
A-36 Screw 1 A-86 Cover Base 2
A
-37 Screw, M6x15 1
A
-87 C
—
Spring C-20 2
A-38 Screw 1 A-88 Handle 1
A-39 Screw, M4x12 1 A-89 Shaft 1
A-40 Depth Ruler 1 A-90 Clamping Block 1
A-41 Screw, M4x12 1 A-91 Nut ,M10 1
A-42 Screw, M6x15 1 A-92 Screw, M8x25 2
A-43 Screw, M6x15 2 A-93 Locking Shaft 1
A-44 Washer, 6 2 A-94 Handle 1
A-45 Localizer 1 A-95 Wood Table 1
A-46 Hex Nut, M12 1 A-96 Screw, M8x25 2
A-47 Washer, 12 1 A-97 Table 1
A
-48 Spring 1
A
-98 Washer , 10 2
A-49 Washer, 14 1 A-99 Screw, M10x25 2
A-50 Connecting Bend 1 A-100 Rack 1

MS3840 MORTISING MACHINE １３
NO. Description Quantity NO. Description Quantity
A-101 Screw, M6x10 3 A-112 Screw, M8x10 1
A-102 Gear 1 A-113 Collar 1
A-103 Drift 1 A-114 Lead Screw 1
A-104 Nut , M6 4 A-115 Lead Nut 1
A-105 Screw, M6x15 4 A-116 Washer 10 2
A
-106 Pin 1
A
-117 Screw, M10x25 2
A-107 Gear Shaft 1 A-118
A-108 Collar 1 A-119
A
-109 Handwheel 1
A
-120
A-110 Screw, M8x10 1 A-121
A-111 Handwheel 1 A-122

MS3840 MORTISING MACHINE１４
MS3840 Mortiser

MS3840 MORTISING MACHINE １５
PARTS LIST: Stand Assembly ( MS3840 Mortiser)
NO. Description Quantity
B-1 Base 1
B-2 Stand 1
B-3 Door 1
B-4 Door Latch 1
B-5 Hex Nut, M10 4
B-6 Stand Base 4
B-7 Hex Nut, M10 4
B-8 Washer , 10 4
B-9 Wave Washer 10 4
B-10 Cap Screw, M12x40 4

MS3840 MORTISING MACHINE１６
PARTS LIST: Clamping Bar Assembly (MS3840 Mortiser)
NO. Description Quantity
C-1 Shaft 1
C-2 Setting Piece 1
C-3 Spring 1
C-4 Clamping body 1
C-5 C-Clip 1
C-6 Locking handle 1
C-7 Locking Screw 1
C-8 Pin 1
C-9 Stop Disc 1
C-10 Screw 1

MS3840 MORTISING MACHINE １７
PARTS LIST: Work Stop Assembly ( MS3840 Mortiser)
NO. Description Quantity NO. Description Quantity
D-1 Table 1 D-8 Length Setting Block 1
D-2 Cap Screw M6x25 2 D-9 Handle Screw (big) 1
D-3 Rear Length Setting Rod 1 D-10 Nut M6 1
D-4 Handle Screw 1 D-11 Stop Disc 1
D-5 Handle Screw (big) 1 D-12 Front Length Setting Rod 1
D-6 C-Clip 1 D-13 Washer 1
D-7 C-Clip 1 D-14 Stop Disc