TREND TT/KWJ900 User manual

TT/KWJ900
-1-
The following symbols are used throughout this
manual:
Denotes risk of personal injury, loss of
life or damage to the tool in case of non-
observance of the instructions in this
manual.
Refer to the instruction manual of
your power tool.
This unit must not be put into service until it has
been established that the power tool to be
connected to this unit is in compliance with
98/37/EC (identified by the CE marking on the
power tool).
TECHNICAL DATA
Jig thickness 12mm
Cutter size 12.7mm
Workpiece thickness max. 45mm
Worktop width min. 400mm
max. 900mm
Guide bush size 30mm
Weight 5.5kg
☎
If you require further technical
information or spare parts, please call
our technical support department on
01923 224681.
Dear Customer
Thank you for purchasing this Trend product, we
hope you enjoy many years of creative and
productive use.
Please remember to return your guarantee card
within 28 days of purchase.
CONTENTS
TECHNICAL DATA _____________________1
SAFETY ____________________________2-3
ITEMS ENCLOSED __________________4
DESCRIPTION OF PARTS_______________5
ACCESSORIES
– Recommended Cutters ________________6
– Sub-base Set ________________________6
– 30mm Guide Bush ____________________6
– Panel Butt Connectors Bolts ____________7
– Biscuit Jointer for the Router ____________7
– Flat Biscuit Dowels____________________7
– Clamp______________________________7
ASSEMBLY
– Location Bush Identification _____________8
– Margin Distance ______________________8
– Setting out the Joints __________________8
OPERATION
– Setting the Length Stop _______________ 9
– Female Joint_________________________9
– Male Joint__________________________10
– Out-of-Square Joints _________________10
– Cutting the Bolt Recesses _____________11
– Strengthening the Joint _______________11
– Sealing the Joint ____________________12
– Radius Corner ______________________12
– 22.5° Hob Mitre Joint _________________13
– Curved Peninsular ___________________13
– 45° Angle End Cut ___________________14
MAINTENANCE ______________________15
RECYCLING & GUARANTEE ___________15
SPARE PARTS
– Spare Parts List _____________________16
– Spare Parts Diagram _________________16
TROUBLESHOOTING _________________IB
MANU-TT-900 v2 17/7/06 4:18 pm Page 1

TT/KWJ900
-2-
SAFETY
Observe the safety regulations in the
instruction manual of the Power Tool to
be used or connected to this
attachment. Also observe any
applicable additional safety rules. Read
the following safety instructions before
attempting to operate this product.
PLEASE KEEP THESE
INSTRUCTIONS IN A SAFE
PLACE.
The attention of UK users is drawn to
The Provision and Use of Work
Equipment Regulations 1998, and any
subsequent amendments.
General
■Disconnect power tool, when not in
use. Before servicing and when
changing accessories such as
cutters. Disconnect power tool and
attachment from power supply.
Ensure the machine is switched off
before plugging tool in or
connecting to a power supply.
■Always mount the power tool,
accessory or attachment in
conformity with the present
instructions.
■Keep children and visitors away. Do
not let children or visitors touch the
tool, accessory or attachment.
Keep children and visitors away
from work area.
■Make the workshop child proof with
padlock and master switch.
■Dress properly. Do not wear loose
clothing or jewellery, they can be
caught in moving parts. Rubber
gloves and non-skid footwear is
recommended when working
outdoors. Wear protective hair
covering to contain long hair.
■Consider working environment. Do
not use the product in the rain or in
a damp environment. Keep work
area well lit. Do not use power tools
near gasoline or flammable liquids.
Keep workshop at a comfortable
temperature so your hands are not
cold.
■The accessory or attachment must
be kept level and stable at all
times.
■Keep work area clean. Cluttered
workshops and benches can cause
injuries
■Use the attachment with the power
tools and accessories specified in
this manual only. Do not force the
tool or attachment to do a job for
which it is not designed.
■Secure idle tools. When not in use,
tools should be stored in a dry and
high or locked up place, out of
reach of children.
■For best control and safety use
both hands on the power tool and
attachment. Keep both hands away
from cutting area. Always wait for
the spindle and cutter to stop
rotating before making any
adjustments.
■Always keep guards in place and in
good working order.
■Remove any nails, staples and
other metal parts from the
workpiece.
■Maintain tools and cutters with
care. Keep cutters sharp and clean
for better and safer performance.
Do not use damaged cutters.
Follow instructions for lubricating
and changing accessories. Keep
handles dry, clean and free from oil
and grease.
■Maintain accessories. Do not use
damaged accessories. Only use
accessories recommended by the
manufacturer.
■Check damaged parts. Before
operation inspect the attachment,
the power tool, the cable, extension
cable and the plug carefully for
signs of damage. Check for
alignment of moving parts, binding,
breakage, mounting and any other
conditions that may effect its
operation. Have any damage
repaired by an Authorised Service
Agent before using the tool or
accessory.
■Do not use tool if switch does not
turn it on or off. Have defective
switches replaced by an Authorised
Service Agent.
■Don't over reach. Keep proper
footing and balance at all times.
■Don’t abuse the cable. Never carry
power tool or accessory by cord or
pull it to disconnect from the
socket. Keep cord from heat, oil
and sharp edges. Always trail the
power cord away from the work
area.
■Connect dust extraction equipment.
If devices are provided for the
connection of dust extraction and
collection facilities, ensure these
are connected and properly used.
■Check all fixing and fastening nuts,
bolts and screws before use to
ensure they are tight and secure.
Periodically check when machining
over long periods.
■Stay alert. Watch what you are
doing. Use common sense. Do not
operate tools when you are tired,
under the influence of drugs or
alcohol.
■Personal Protective Equipment
(PPE). All PPE must meet current
UK and EU legislation.
■Do not leave tools running
unattended. Do not leave tool until
it comes to a complete stop.
■Always clamp workpiece being
machined securely.
■Only use cutting tools for
woodworking that meet EN847-1/2
safety standards, and any
subsequent amendments.
Routing Safety
■Disconnect router power tool.
When not in use, before servicing
and when changing accessories
such as cutters, disconnect router
and attachment from power supply.
■Ensure router cutter has stopped
rotating before changing it. Never
use the spindle lock as a brake.
■Remove adjusting keys and
spanners. Form the habit of
checking to see that keys and
adjusting spanners are removed
from the router tool, cutter and
attachment before turning router
on. Make sure cutter can rotate
freely.
■Check all ball bearing and blade
fixing screws before use to ensure
they are tight and secure.
Periodically check when machining
over long periods.
■When using a template guide bush
ensure it cannot come into contact
with collet and nut.
■Noise. Take appropriate measures
for the protection of hearing if the
sound pressure of 85dB(A) is
exceeded. Routing sound pressure
may exceed 85dB(A), so ear
protection must be worn.
MANU-TT-900 v2 17/7/06 4:18 pm Page 2

TT/KWJ900
-3-
■Eye protection. Wear safety
goggles, spectacles or visors to
protect the eyes from ejected
waster particles.
■Respiratory protection. Wear a face
or dust mask, or powered
respirator. Dust masks/filters should
be changed regularly.
■Do not switch router on with the
cutter touching the workpiece.
■The direction of routing must
always be opposite to the cutter's
direction of rotation.
■After work, release the router
plunge and allow spindle to stop
rotating before putting machine
down.
■Check before cutting that there are
no obstructions in the path of the
router. When cutting through the full
thickness of the workpiece, ensure
there are no obstacles beneath
workpiece, and that a sacrificial
work surface is used.
Additional Safety Rules For
Router Cutters
■Cutting tools are sharp. Care
should be taken when handling
them.
■Always use cutters with a shank
diameter corresponding to the size
of the collet installed in your tool.
■Always run router cutters at the
spindle speed recommended and
marked accordingly. Ensure cutter
has reached correct speed before
entering workpiece. Recommended
speeds can be found on the
packaging, in cutter instructions or
in the Trend Routing Catalogue.
■Always use router cutters in a
router. Router cutters must not be
used in a drill. Drill and boring bits
must not be used in a router.
Router cutters must only be used
for the material cutting application
for which they are designed. Do not
use on metal or masonry.
■Never use cutters with a diameter
exceeding the maximum diameter
indicated in the technical data of
the powertool or attachment used.
■Do not drop cutters or knock them
against hard objects. Do not use
cutters that are damaged.
■Cutters should be kept clean. Resin
build up should be removed at
regular intervals with Resin
Cleaner®. The use of a dry
lubricant (Trendicote®PTFE) will
act as a preventative. Do not use
PTFE spray on plastic parts.
■Cutter shanks should be inserted
into the collet to the mark line on
the shank. This ensures that at
least 3/4 of the shank length is held
in the collet. Do not over-tighten the
collet nut as this will score the
shank and create a weakness and
fracture point.
■Observe the correct assembly
instructions in the router instruction
manual for fitting the collet and nut.
Observe the router power tool
manual instructions on fitting
cutters correctly.
■It is advisable to periodically check
the collet and collet nut. A worn,
distorted or damaged collet can
cause vibration and damage the
shank, and should be replaced.
Worn collet nuts should be
replaced.
■Do not take deep cuts in one pass;
take several shallow or light passes
to reduce the side load applied to
the cutter. Too deep a cut in one
pass can stall the router.
■Very small diameter cutters must
be handled and used with care.
■Always return cutter to its
packaging after use.
■Should you experience excessive
vibration during use stop
immediately. Have the eccentricity
of the router, router cutter and
clamping system checked.
■All fastening screws and nuts
should be tightened using the
appropriate spanner or key in
accordance with the manufacturers
instructions.
Using Routers In A Fixed
Position
■After work, release the router
plunge to protect the cutter.
■Always use a push-stick or push-
block for last 300mm of the cut.
■Whenever possible use a work
holding device or jig to secure
component being machined.
■Ensure attachment is securely fitted
to the workbench, with table
surface at approximately hip height.
■Ensure a No-Volt Release Switch is
fixed to or adjacent to the
attachment and that it is used
correctly.
■Check the direction of the
workpiece is always opposite to the
cutter's direction of rotation.
■Do not use awkward or
uncomfortable hand positions.
■Do not reach underneath table or
put your hands or fingers at any
time in the cutting path while tool is
connected to a power supply.
Useful Advice When Routing
■Judge your feed rate by the sound
of the motor. Feed the router at a
constant feed rate. Too slow a feed
rate will result in burning.
■Take many light passes rather than
one deep cut to reduce the side
load applied to both router and
router cutter.
■Trial cuts should be made on waste
material before starting any project.
■When using some attachments
including a router table or dovetail
jig, the use of a fine height adjuster
is highly recommended.
■When using a template guide bush,
ensure there is sufficient clearance
between cutter tip and inside edge
of bush. Ensure cutter and guide
bush are concentric.
Router Cutter Maintenance
■Composite cutting tools (brazed tip)
must be maintained by a competent
person i.e. a person of training and
experience, who has knowledge of
the design requirements and
understands the levels of safety to
be achieved.
■The design of composite tools must
not be changed in the process of
maintenance.
■Replacement parts must meet
Trend specification.
■Tolerances which ensure correct
clamping by the collet shall be
maintained.
■When re-grinding the tool, care
must be taken not to cause
weakening of the body or the
connection between the cutting
edge and the body.
Version 4.1 08/2003
MANU-TT-900 v2 17/7/06 4:18 pm Page 3

TT/KWJ900
-4-
ITEMS ENCLOSED
x1
x1x1x3
650600500400
616
700 900
R
RRP
F
F
A
A
A
P
P
H
F
M
M
H
BBB
router accessories
-TECH
T
TM
MANU-TT-900 v2 17/7/06 4:18 pm Page 4

TT/KWJ900
-5-
DESCRIPTION
OF PARTS
h
l
ld n n k k j
h
na m b
e
i
g g gf f f ko
c
e
oddo
650600500400
616
700 900
R
RRP
F
F
A
A
A
P
P
H
F
M
M
H
BBB
router accessories
-TECH
T
TM
Jig body
Label
Postform joint slot
Female joint bush location hole
Male joint bush location hole
Bolt recess bush location hole
Connecting bolt recess slot
Alloy location bush
Location hole code
Radius corner slot
Radius corner bush location hole
22.5° Mitre (Hob) joint bush location hole
Curved peninsular slot
Curved peninsular bush location hole
45° Angle end cut bush location hole
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
MANU-TT-900 v2 17/7/06 4:18 pm Page 5

TT/KWJ900
-6-
t
r
e
n
d
3
0
m
m
R
UNIBASE
Recommended Cutters
Ref. NLE50RB or TT/50X1/2TC
A 12.7mm (1/2”) diameter cutter must be used,
which has a 50mm cutting reach and plunge cut
facility.
Router must be plunged in stages of maximum
8mm in one pass.
Sub-base Set Ref. TT/UNIBASE
To obtain a perfect accurate close fitting joint, a
30mm guide bush must be used. The guide
bush must always be fitted concentric with the
cutter. This can be achieved using a T-TECH
Universal Sub-base and 30mm outside diameter
guide bush ref. TT/GB30.
The T-TECH Universal Sub-base has a central
recess to allow fitting of the T-TECH guide bush
to most makes of routers and is available ready
to fit the most popular makes.
The Sub-base contains screws, a line up bush
and two line up pins. The line up pins and bush
ensure exact alignment of Sub-base with router
spindle, when fitted with the relevant collet.
ACCESSORIES
Fits following Router Models
Performance Pro CLM1250R >11/2003, CLM2050R
T-TECH TT/R127 Atlas Copco OFSE2000 Bosch GOF
1300ACE, 1600A, 1700ACE Casals FT2000VCE DeWalt
DW625EK, 629 Draper R1900V Elu MOF 31, 77, 98,
131, 177(E) Felisatti TP246(E), R346EC Festo OF2000E
Freud FT2000E Hitachi MI12V, M12SA, TR12 Makita
3612BR, 3612(C) Metabo OF1612, OFE1812 Ryobi
RE600N, R600N, RE601, R500, R502 Skil 1875U1
Wadkin R500
General instructions for fitting
Sub-bases to Router
1. Fit line up guide bush onto sub-base, with
screws supplied.
2. Fit 12.7mm (1/2”) shank line up pin into collet
of router. Plunge router until pin projects
through base and lock plunge.
3. Locate guide bush and sub-base assembly
over protruding pin.
4. Line up fixing holes and fit screws.
5. Now tighten up screws.
6. Remove line up bush and line up pin.
Alignment should now be correct. Fit 30mm
guide bush and cutter.
7. Periodically check the sub-base is concentric
to the spindle of the router.
30mm Guide Bush
Ref. TT/GB30/B
Description Order Ref.
Universal sub-base TT/UNIBASE
Description Order Ref.
30mm guide bush to fit sub-base TT/GB30/B
MANU-TT-900 v2 17/7/06 4:18 pm Page 6

TT/KWJ900
-7-
100mm (4”) min.
throat depth
Panel Butt Connector Bolts
Ref. TT/PC/10M (Pack of ten)
Panel butt connectors are essential for
connecting worktops. They fit into the recess on
the underside of the worktop and are tightened
with a 10mm spanner. The jig has integral bolt
recess slots to allow the bolt recess to be cut in
the underside of the worktop, using the standard
router cutter. The recess is elongated to allow
easy access for the spanner.
Biscuit Jointer for the Router
Ref. TT/48X1/2TC
Worktops with inadequate support below them
need additional stability by biscuit jointing the
edges. The T-TECH biscuit jointing set for the
router together with the No.20 biscuits will
ensure worktops do not sag or warp in time.
Whenever fast action clamps are used,
ensure they do not foul the router path
and that they are securely tightened.
Clamp
Two heavy duty quick action or gripper clamps
with throats of at least 100mm (4”) are required
to secure the jig to the worktop.
Flat Biscuit Dowels
Ref. TT/BSC/20 (Pack of 100 biscuits)
Biscuits are used to strengthen the joint. When
used with PVA glue they expand ensuring a tight
joint.
No.20
MANU-TT-900 v2 17/7/06 4:19 pm Page 7

TT/KWJ900
-8-
ASSEMBLY
Location Bush Identification
Three location bushes are used in different holes
in the jig to align the correct template aperture
for the application.
The holes are coded for easy identification with
dots as follows:
F – Female Joint
M – Male Joint
H – Hob Mitre Joint
B – Connector Bolt Recess
A– 45° Angle End
P– Curved Peninsular
R– Radius Corner
Setting out the Joints
When cutting a joint ensure location bushes
contact the postformed edge of the worktop. For
certain joints the worktop will need to be inverted
so that all cuts are made into the postformed
edge, never out through it. When routing worktop
the balancing paper on the underside may feather
edge – this feather edge should be removed with
abrasive paper.
Location bushes are held in position by ‘O’ rings.
Insert the smallest end of the bush into the hole
by lightly pushing and turning at the same time.
If the bushes are tight use a lubricant on the ‘O’
ring. Ensure bushes are fully home before use.
When using jig ensure location bushes do not
foul workbench.
In order to prevent breakout of the
laminate, rotation of the cutter and
feed direction must always be into the
postform edge of the worktop.
Margin Distance
Allow 8.5mm when cutting joints. Measure or
use a batten of this
thickness to aid
setting out.
Cutter
Sub base
Guide bush
30mmØ
Location
bush
Worktop
Template
8.5mm
28mm
Plan view
of joints
Right hand joint
Male
Female
Male
Female
Cut male with laminate down
Cut female with laminate up
Postform edge
The joint takes up 28mm, this should
be allowed for with extra material in the
length of the male worktop.
Male
Female Postform edge
PENINSULAR
Postform edge
Postform edge
Male
Female
Left hand joint Cut male with laminate up
Cut female with laminate down
O ring
Location
bush
MANU-TT-900 v2 17/7/06 4:19 pm Page 8

TT/KWJ900
-9-
650
600
500
400
616
700 900
R
RRP
F
A
A
A
P
P
H
M
M
H
BBB
router accessories
-TECH
T
TM
FF
Location bushes in
female hole
Postform
edge
Length stop bush
Quick action
clamp here Router feed
direction
Setting the Length Stop
Routing the female part of the joint
OPERATION
Setting the Length Stop for the
Female Cut
Carry out the setting operation first:
■With the label side uppermost fit the length
stop bush in one of the two holes
depending on the width of the worktop. If
worktop is not 400mm, 500mm, 600mm,
616mm, 650mm, 700mm or 900mm a
packing piece, or a new hole to correct
position will suffice.
Female Joint
■Fit two location bushes in female holes (F)
as shown. (The label must be uppermost)
Leave the length stop bush in position.
■Place the template onto the worktop to be
cut, ensuring the location bushes are
touching the worktop. Now cramp securely
in position using two quick action clamps
(with minimum of 100mm throat) ensuring
they will not foul the router path.
■Set cutter depth.
■Plunge router and cut joint in a series of
passes, feeding left to right.
When cutting a joint, hold the
router guide bush hard against the
template and cut from left to right.
It is recommended that the depth
stops of the router are used to set
the depths of cut. Several shallow
passes of the router should be
made and it is not necessary to
lean heavily on the router or the
jig. Allow the weight of the router
to rest on the part of the template
which is resting on the worktop.
Ensure router remains parallel and
upright at all times.
650600500400
616
700 900
R
RRP
F
F
A
A
A
P
P
H
F
M
M
H
BBB
router accessories
-TECH
T
TM
650600500400
616
700
RRP
F
F
A
B
router accessories
-TECH
T
TM
MANU-TT-900 v2 17/7/06 4:19 pm Page 9

TT/KWJ900
-10-
Cutting male joint on out-of-
square joints
Shown exaggerated
Quick action
clamp here
Direction of
router travel Male joint on
cut line
Male Joint
Depending on accessibility lay female worktop
into position on units. Lay male worktop on top
and support other end. Using a pencil draw
round the female cut onto the male. If
inaccessible lay female onto male. Depending
on a right or left hand joint, the pencil line may
need to be transferred on to the other side. Due
to the difference between the cutter and the
guide bush diameters, the cutter path (or cut
line) will be 8.5mm over from the edge of the
template, therefore either measure 8.5mm or
use a packing piece of this size to offset the
template by this amount to ensure the cutter cuts
along the pencil line.
The postformed edge of the worktop must
always be in contact with the location bushes,
this means that to cut a male right hand joint, the
worktop must be inverted. Remembering to cut
into the postformed edge.
■Insert two location bushes into male holes (M)
as shown, label facing down.
■Place template across the width of the
worktop and clamp securely to worktop.
■Set cutter depth. Plunge router and cut the
male joint before finally cutting the work-top to
length. A series of passes should be made
feeding from left to right.
Routing the male part of the Joint
Quick action
clamp here
Direction of
router travel
Location
bushes
in male
hole
Out-of-square Joints (max. 3°)*
It may not be possible to position all joints at
90°, in this case it is the male part of the joint
that has to be adjusted.
The length stop has a mitred end which is used
to set up for an out-of-square joint up to 3°.
To mark out an out-of-square joint, first lay the
female worktop on the cupboard carcass in its
correct position. Next lay the male section of the
worktop on the carcass and on top of the female
section of the worktop. Support the other end of
the male worktop. Using a pencil and from
underneath the worktop mark around the female
joint onto the male section of the worktop, if
access is difficult lay the female worktop onto the
male worktop, support other end and mark with
pencil from above. This drawn line is the male
joint cut line.
Postform edge
*Please Note:
Out-of-square joints are possible, but the
finished joint will not be as good as a 90° joint.
MANU-TT-900 v2 17/7/06 4:19 pm Page 10

TT/KWJ900
-11-
Routing the bolt recess in the
male part of the joint
Location bushes in bolt
recess hole
Direction of
router travel
Quick action
clamp here
Underside of worktop
Postform edge
Worktop Recess
Thickness Depth
30 22mm
40 28mm
Best results are achieved when the
centre line of the bolt corresponds
to the centre line of the worktop.
Clamp jig securely to worktop.
Routing the bolt recess in the
female part of the joint
650600500400
616
700 900
R
RRP
F
F
A
A
A
P
P
H
F
M
M
H
B
BB
router accessories
-TECH
T
TM
Location bushes in bolt
recess hole Direction of
router travel
150mm
Underside of worktop
Quick action
clamp here
Cutting the Bolt Recesses
When the joint has been tested, proceed as
follows to cut the recess for panel butt
connectors on the underside of the worktop.
The same cutter and guide bush are retained
and used with the integral bolt recess slots in the
jig to produce the recesses for the panel butt
connectors. The bolt recess position can be
gauged approximately 150mm from the edge of
the postform edge, or where access is possible
with kitchen units. Mark with pencil both
positions on the underside of the worktop.
Insert the location bushes into the bolt recess
holes (B) as shown.
■The template may need to be inverted when
cutting some bolt recesses.
■Securely clamp jig to worktop.
■The bolt recesses should be approximately
20mm deep although this will depend upon
the thickness of worktop.
■Once one bolt recess is cut move jig over to
the remaining pencil lines and repeat.
■Repeat the procedure for the male joint.
Strengthening the Joint
If the joint between the worktops is not
supported underneath, after some time the joint
may ‘sag’ and become misaligned; to reduce this
the joint should be reinforced with a loose
tongue or biscuit dowels. The biscuit jointing
cutter set T-TECH Ref. TT/48 can be used with a
portable router. The size of biscuit used should
be No. 20.
Ref. TT/BSC/20 (100 biscuits)
A 650mm worktop should have at least 5 biscuits.
Underside View
MANU-TT-900 v2 17/7/06 4:19 pm Page 11

TT/KWJ900
-12-
Radius Corner
Special Note: Due to the nature of this
particular edge laminate, the radius corner
will be more awkward to laminate.
Insert the three location bushes in radius
holes (R) as shown opposite. Locate the
template on the worktop as illustrated
ensuring the location bushes are touching the
worktop edge. Clamp into position with quick
action clamps.
When cutting the radius hold the router guide
bush against the template radius. Feed left to
right.
It is recommended that the
router depth stops are
used and three or four
cuts are taken.
Cut with laminate
down
Cut with laminate
up
Routing the Radius Corner
Quick action
clamp here
Postform edge
Location bushes in
radius holes
Direction of
router travel
Sealing the Joint
The cut edges of the joint should be coated with
a water-resistant adhesive, or sealant before
assembly, to prevent moisture seeping into the
core of the worktops, which would swell, and
disfigure the worktop.
Use a fine grit abrasive paper to clean up the
torn wood chips of both mating surfaces. Lightly
run the abrasive paper along the edges to de-nib
the cut chipboard edge. This will ensure a tidy
joint is achieved.
No.20
PVA
SEALANT
Waterproof
Biscuit
MANU-TT-900 v2 17/7/06 4:19 pm Page 12

TT/KWJ900
-13-
650600
500
400
616
700 900
R
R
R
P
F
F
A
A
A
P
P
H
F
M
M
H
B
B
B
routeraccessories
-TECH
T
TM
Routing the Hob Mitre Joint
Cut with
laminate
down
Cut with
laminate up
Cut with
laminate
down Cut with
laminate up
Postform edge
Postform edge
Postform edge
Quick action
clamp here
Postform edge
Direction of
router travel
Location bushes in
hob holes
Plan View of
Corner Joint
Cuts
22.5° Hob Mitre Joint
■For the left hand part of the 22.5° hob mitre joint
fit bushes into holes marked hob (H). The label is
uppermost.
■Clamp jig using quick action clamps or accessory
clamps.
■When cutting keep guide bush against edge of
template. Feed left to right into the postform
edge.
■For opposing joint keep bushes in the same side.
■Repeat above operations for remainder of joint.
Curved Peninsular
Insert the three location bushes in peninsular
holes (P) as show.
Locate the template on the worktop as illustrated
ensuring that location bushes are touching the
worktop edge. Clamp into position with quick
action clamps.
When cutting the curved peninsular, hold the
router guide bush against the edge of the
template. Cut from left to right.
It is recommended that depth stops are used
and at least three or four cuts taken.
650600500400
616
700 900
R
RRP
F
F
A
A
A
P
P
H
F
M
M
H
BBB
router accessories
-TECH
T
TM
Quick action
clamp here
Postform edge
Location bushes peninsular holes
Direction of
router travel
Cut with laminate down Cut with laminate up
Postform edge
Postform edge Postform edge
Postform edge
Peninsular
Peninsular
End Cuts
Routing the Curved Peninsular
In order to prevent break out of the
laminate, rotation of the cutter and
feed direction of the router must
always be into the postform edge of
worktop.
MANU-TT-900 v2 17/7/06 4:19 pm Page 13

TT/KWJ900
-14-
45° Angle End Cut
Insert the three location bushes into Angle
holes (A) as shown.
Locate the template on the worktop as
illustrated ensuring that bushes are touching
the worktop edge. Clamp using two quick
action clamps.
It is recommended that depth stops are used
and three or four cuts taken. Cut from left to
right. Label must be facing down.
Routing the 45° Angle End Cut
Quick action
clamp here
Postform
edge
Location bushes in
angle holes
Direction of
router travel
Cut with
laminate
down
Cut with
laminate
up
Postform edge
Postform edge
Postform edge
Postform edge
Peninsular
Peninsular End Cuts
In order to prevent break out of
the laminate, rotation of the
cutter and feed direction of the
router must always be into the
postform edge of worktop.
MANU-TT-900 v2 17/7/06 4:19 pm Page 14

TT/KWJ900
-15-
MAINTENANCE
The jig has been designed to operate over a
long period of time with a minimum of
maintenance. Continual satisfactory operation
depends upon proper tool care and regular
cleaning.
■Cleaning
Regularly clean the jig with a soft cloth.
■Lubrication
Your jig requires no additional lubrication.
RECYCLING
Jig, accessories and packaging should be sorted
for environmentally friendly recycling.
GUARANTEE
The jig carries a manufacturers guarantee in
accordance with the conditions on the enclosed
guarantee card.
MANU-TT-900 v2 17/7/06 4:19 pm Page 15

TT/KWJ900
-16-
TT/KWJ900 - SPARE PARTS LIST v1.0 03/2004
No. Qty. Desc. Ref.
1 1 TT/KWJ900 TT/KWJ900
2 1 Alloy Bush for KWJ (pack of 3) TT/KWJ/BPK
3 1 Combi Jig ‘O’ Ring Set for Bushes (pack of 5) CJ/ORS
4 1 Manual MANU/TT/900
TT/KWJ900 - SPARE PARTS DIAGRAM
1
234
650600500400
616
700 900
R
RRP
F
F
A
A
A
P
P
H
F
M
M
H
BBB
router accessories
-TECH
T
TM
v1.0 03/2004
MANU-TT-900 v2 17/7/06 4:19 pm Page 16

TT/KWJ900
-IB-
Fault Cause Remedy
■Joint does not fit correctly Cutter or guide bush is the Check concentricity of cutter
at the radius. incorrect diameter or location with guide bush. Cutter 12.7mm
bushes are not against diameter with 30mm diameter
worktop edge. guide bush. Ensure location
bushes touch worktop.
■The back edge of the joint Either the length stop or Check position of length stop
does not line up. template was in the incorrect and re-cut joints.
position, or the worktop has
not pushed up against the
length stop when the joint
was cut.
■When clamped together the The guide bush has drifted away Check with a straight edge
joint has irregular gaps. from the edge of the template which part of the joint is uneven
whilst cutting either part of the and re-cut (this can only be
joint, or wood chips in particle done on the male cut) ensuring
board have torn slightly. that the guide bush is kept
against the template by
machining from left to right. Use
abrasive paper to remove torn
wood chips.
■Chipped laminate Can be caused by a blunt cutter Always use sharp cutters and
or removing too much material when cutting through the
at one pass or exiting out of laminate cut 3–4mm of material.
postform edge. Maintain correct feed direction,
to ensure cutter enters
postform edge.
■Jig slipping on material Clamps not secure or too deep Check clamps for wear. Clamp
a cut being made or cutter is securely, take shallow passes,
blunt. use a sharp cutter.
■Cut joints not square Router has tilted or operator Ensure jig is supported and do
has leaned heavily on router not push hard on router taking
causing jig flex. shallow passes. Ensure weight
of router is on supported part
of jig and that the router is
upright.
■Assembled joint not flush Worktop different thickness or Ensure worktop is same
or bowed worktop not flat (cupped). thickness and flat.
TROUBLE SHOOTING
MANU-TT-900 v2 17/7/06 4:19 pm Page 17

© Copyright Trend 2006. No part of this publication may be reproduced, stored or transmitted in any form without prior permission. Our
policy of continuous improvement means that specifications may change without notice. Trend Machinery and Cutting Tools cannot be
held liable for any material rendered unusable or any form of consequential loss. E&OE
Trend Machinery & Cutting Tools Ltd.
Technical Hotline: ______________01923 224681
Email: [email protected]
Web: ________________www.trendmachinery.co.uk
RECYCLABLE
MANU/TT/900 v2.0
MANU-TT-900 v2 17/7/06 4:19 pm Page 18

INCLUDES:
3 x Setting Bushes
1 x Instruction Manual
REQUIRES:
1/2” Collet Plunge Router
1/2” x 50mm TCT Router Cutter
Ref. TT/50X1/2TC
30mm Guide Bush
Ref. TT/GB30/B
Universal Sub-base for Guide Bush
Ref. TT/UNIBASE*
Two 100mm (4”) Throat Clamps
Panel Butt connectors
Ref. TT/PC/10M
*For certain makes and models of routers
900mm PROFESSIONAL
KITCHEN WORKTOP
JIG
Made from durable
12mm thick phenolic.
FOR CREATING A
KITCHEN WORKTOP
JOINT WITH A
ROUTER
400, 500, 600, 616, 650, 700, 900mm
JOINT
Trend Machinery & Cutting Tools Ltd.
Technical Hotline: ____________01923 224681
Email: [email protected]
Web: ____________www.trendmachinery.co.uk
WORKTOP WIDTH
400mm 900mm
Curved Peninsular
45° End Cut
Corner Radius
22.5° Mitre Joint
TT/KWJ900
MANU-TT-900 v2 17/7/06 4:19 pm Page 19