4000 machining center...butt router dewalt 616 15-174 1-3/4 115 11.0 face plate router dewalt 616...

Effective S/N: MC-4122 Release 05

Document Number 17-283

4000 4000 Machining CenterMachining Center

PARTS MANUAL

First release Second release May 2006 Fourth Release March 2015

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Norfield Industries

P.O. Box 459 Chico CA, 95927

Technical Support: (530)-891-4214 Parts: (800) 824-6242

Serial No.: Date Sold:

Norfield Industries is the name that represents Quality, Reliability, Support, Innovation and True Customer Service. We have been dedicated to providing quality products and excellent customer service for more than 40 years. Norfield Industries has earned a reputation in the pre-hanging industry for setting standards for reliable machinery, full technical support, machine parts, full line industrial woodworking tools and supplies and a team of customer care repre-sentatives to support you! Our factory-trained technical personnel are ready to assist you on the telephone or in your shop.

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TABLE OF CONTENTS Safety ..................................................................................................................................................... 6 Lockout Procedures ................................................................................................................................ 9 Restoring Equipment and/or Circuits to Service ..................................................................................... 10 Specifications ........................................................................................................................................ 12 Parts Replacement Policy ..................................................................................................................... 14 Limited Warranty ................................................................................................................................. 14 Contact and Order Information .......................................................................................................... 15 Part and Assembly Schematics ............................................................................................................ 17 General Assembly (Front) ...................................................................................................................... 18 General Assembly (Rear) ........................................................................................................................ 19 Frame & Miscellaneous Components ..................................................................................................... 20 Slide Rod Assembly ............................................................................................................................... 21 Butt Router Assembly ............................................................................................................................ 22 Router Micrometer ................................................................................................................................. 23 Drill Section Assembly ........................................................................................................................... 24 Drill Carriage Assembly ......................................................................................................................... 25 Vacuum Box assembly ........................................................................................................................... 26 Width Index Cylinder Assembly ............................................................................................................. 27 Latch Drill Assembly .............................................................................................................................. 28 Face Plate Router Assembly ................................................................................................................... 29 Lock Drill Assembly .............................................................................................................................. 30 Door Clamp Assembly ............................................................................................................................ 31 Jamb Clamps And Chip Breaker ............................................................................................................. 32 Door Clamp & Ref. Bars ........................................................................................................................ 33 Left Hand Door Stop Assembly .............................................................................................................. 34 Right Hand Door Hand Assembly ........................................................................................................... 35 Filter Regulator Lubricator Assembly (FRL) .......................................................................................... 36 Foot Pedal Assembly .............................................................................................................................. 37 Powerfeed Assembly (Infeed) ................................................................................................................. 38 Powerfeed Assembly (Outfeed) .............................................................................................................. 39 Jamb Stop Assembly Left Hand .............................................................................................................. 40 Jamb stop Assembly Right Hand ............................................................................................................ 41 Jamb Clamp Assembly ........................................................................................................................... 42 Butt Router Horizontal Stops Assembly ................................................................................................. 43 Oil Reservoir #1 ..................................................................................................................................... 44 5901-705 Pneumatic Assembly ............................................................................................................... 45 5901-706 Pneumatic Assembly ............................................................................................................... 46 5901-708 Pneumatic Assembly ............................................................................................................... 47 Powerfeed Support Roller ....................................................................................................................... 48 Power Supply Enclosure ......................................................................................................................... 49 Control Panel Assembly ......................................................................................................................... 50 Main Control Panel ................................................................................................................................. 51 Electrical & Pneumatics Schematics ....................................................................................................... 52 4000 Electrical Power Schematics .......................................................................................................... 52 4000 Controller Wiring........................................................................................................................... 54 4000 Pneumatics ..................................................................................................................................... 56 Drill Stops …………………………………………………………………………………………………...62

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Notice indicates important information that if not followed may CAUSE damage to the equipment.

Danger indicates an imminently hazardous situation, which if not avoided, WILL result in death or serious injury.

Caution indicates a potentially hazardous situation which, if not avoid-ed MAY result in minor or moderate injury. It may also be used to alert against unsafe practices.

Caution, without the safety alert symbol, indicates a potentially haz-ardous situation which, if not avoided may result in property damage (i.e. not personal injury).

Mandatory Action conveys an action step that should be taken to avoid the hazard.

Warning indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

Safety considerations are an important element of machine installation and operation. Actively maintaining a safety mindset about yourself and others while working around or on the equipment is of primary importance. Operators and

maintenance personnel should refer to the safety information on the following pages to familiarize themselves with warning labels and practices providing for safe operation and servicing of this machine.

SAFETY

ALERT MESSAGES

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Do not operate this machine unless all guards are in place and working cor-rectly. If any guards or hazard labels are missing or damaged call Norfield's Service department immediately and request a replacement at 800-824-6242.

Read and understand the operator's manual before using this machine. Failure to follow proper operating instructions could result in death or serious injury.

Only trained personal that have read and understand the operator's manual and all the safety precautions may operate this machine.

This machine, when in operation, produces wood chips and dust. The operator and all persons in the work area MUST wear approved eye protection with permanently attached, rigid plastic side shields. These safety glasses must conform to ANSI Z87.1 standards and will have "Z87" printed on the lens.

This machine, when in operation, produces a noise level greater than 85dB. The operator and all persons in the work area MUST wear approved hearing protection. OSHA has determined that a noise level in excess of 85dB average in 8 hours can cause permanent hearing damage. We recommend that hearing protection be worn even if the decibel level is below 85dBA.

Certain types of wood dust can cause allergic reactions, Sawdust has been de-termined to be a Group A carcinogen by the International Agency for Re-search on Cancer (IARC). A dust collection system or an approved personal dust mask MUST be used during the operation of this equipment.

This machine has moving parts that loose clothing and long hair can become entangled in. Take care not to become caught between the work material and the feed mechanisms or any other moving components.

Before beginning any service repairs, general maintenance, or adjustments you MUST follow proper Lockout Tag-Out procedures. OSHA regulation 1910.147 establishes a minimal lockout tag-out procedure to assist employers in development of their own procedures.

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Inspect the machine at the beginning and end of each shift for damaged or cracked components such as, but not limited to, saw blades, router bits, drill bits, and boring bits.

Never leave this machine unattended while it is in operation. Make sure that all electrical and air is in the off position when the machine is not in use or is unattended and that any cutting blades have come to a complete stop.

Do not attempt to clean material from this machine until all the cutting blades have come to a complete stop. Even when the machine has been turned to the off position it may take up to several minutes for the blades to coast-down to a complete stop.

Woodworking machinery is inherently dangerous, common sense and good safety practices are your best defense against injury.

If you have any questions regarding the correct operation of the machine and safety procedures in this manual call the Norfield Industries Service Depart-ment at 800-824-6242.

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LOCKOUT PROCEDURES

All employees will comply with these procedures. All equipment and/or circuits will be locked out to protect against accidental or inadvertent operation when such operation of the equipment and/or circuits could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating device bearing a lock. Lockout Responsibility

The primary responsibility for the proper lockout of equipment and/or circuits on a project belong to the project Supervisor and/or Foreman. However, this does not alleviate the field employees from insuring that proper lockout procedures are followed at all times. The Supervisor and/or Foreman will insure that each employee is properly instructed in the safety significance of lockout procedures.

PREPARATION FOR LOCKOUT OF CIRCUITS AND EQUIPMENT

Employees will be certain as to which switch, valve, or other energy isolating devices apply to the equipment and/or circuits being locked. More that one energy source (electrical, mechanical, or others) may be involved. Any questionable identification of sources will be cleared by the employees with their Supervisor or project Foreman. Before lockout commences, authorization from the customer and project Supervisor will be obtained.

SEQUENCE OF LOCKOUT PROCEDURES

In the following steps, when more than one individual is involved with the project and required to lock out the equipment and/or circuits, each employee will place their own personal lock on the energy isolating devices. A lock for each involved is the preferred method for locking out energy sources. If this is not feasible, the designated individual of the work crew (e.g. the project Supervisor or Foreman) with complete knowledge of who is on the crew may be designated by the work crew as the individual responsible for carrying out all steps of the lockout procedure. That individual will inform the work crew when it is safe to work on the equipment and/or circuits. Additionally, the designated individual will not remove a crew lock until it has been verified that ALL individuals are clear.

1. Notify all affected employees and customer that a lockout is required and the reason therefore.

2. If the equipment is in operation, after obtaining approval, shut it down by the normal stopping procedures.

The following is an example of the minimum requirements for a lockout/tag-out procedure, Norfield strongly recommends that your company establish it own written procedure. OSHA regulation 1910.147 establishes a minimal lockout tag-out procedure to assist employers in development of their own Lockout procedures.

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3. Operate the switch, valve, or other energy isolating devices so that all energy sources (electrical, mechanical, pneumatic, hydraulic, etc.) are disconnected or isolated from the equipment and/or circuits. Stored energy, such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc., must also be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc.

4. All affected employees are then required to lockout the energy devices with their individual lock.

5. After insuring that no personnel are exposed and as a check on having disconnected the energy sources, operate the push button or other normal operating controls to make certain the equipment will not operate. In the event that electrical circuits have been locked out, insure that the circuits are de-energized by applying an appropriate voltage tester that itself has been tested on live circuits. Be sure to return all operating controls to the neutral position.

The equipment and/or circuits are now locked out.

RESTORING EQUIPMENT AND/OR CIRCUITS TO SERVICE

1. When the job is complete and the equipment or circuits are ready for testing or normal service, check the equipment and/or circuits to insure that no one is exposed.

2. When the equipment and/or circuits are clear, remove all locks. The energy isolating devices may be operated to restore energy to the equipment and/or circuits.

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SPECIFICATIONS

AC Line Voltage Phase Hertz Amperage

208/230/460 3 60 15/15/10 without Vacuum

208/230/460 3 60 30/30/20 with Vacuum

230 1 60 50 with 4200

Electrical Requirement

230 1 60 30 without 4200

3 Phase Motor Specification

Application Motor Part Number HP Volt Amp

Latch Drill Baldor M3546T 5923-007 1 208/230/460 3.2/2.8/1.4

Lock Drill Baldor M3558T 6801-021 2 208/230/460 5.8/5.6/2.8

Single Phase Motor Specification Butt Router Dewalt 616 15-174 1-3/4 115 11.0

Face Plate Router

Dewalt 616 15-174 1-3/4 115 11.0

Powerfeed Dayton 65352 15-104 1/4 115 4.0

Air Requirements

15 CFM @ 90 PSI 1/2” minimum supply line 25 CFM @ 90 PSI with Auto Screw-feeder

Machine Cycle Rate 30 Sec 45 Doors /hour

Shipping Weight Approx. 3400 Lbs. (Machining Center)

Minimum Floor Space Requirement (Width x Length x Height)

6’-6” x 9’-0” x 6’

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Machine Capabilities

Door Width 1’-6” to 3’-6” Max.

Door Height 6’-6” to 7’-0” Max.

Door Thickness 1-3/8 to 1-3/4” Max.

Jamb Width 2-1/2 to 10-1/2” Max.

Jamb Length 6’-6” to 7’-0”

Jamb Thickness 1/2” to 1-1/2” Max.

Stop Thickness 1/2” Max.

Butt Spacing 29” to 33” Max. center to center spacing.

Butt Radius 5/8” only

Butt Size 3-1/2” & 4”

Lock Backsets 2-3/8” to 2-3/4”

Faceplate Routing (Width X Length) 1-1/8” Max. X 3-3/4” Max.

Lock & Deadbolt Bore 1-1/2” to 2-1/8” Max.

Latch Bore 7/8” to 1-1/8” Max.

Door Types (Wood Only) Flush, Stile & Rail, and Louvered

Jamb Types (Wood Only) Flat, Split, and Rabbeted

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PARTS REPLACEMENT POLICY

The following will explain Norfield Industries policy for handling warranty claims. Our "Limited Warranty" is stated below for your reference.

Our warranty covers the replacement of defective parts; however, the labor to replace the parts on the machine is not included.

Upon notification of a warranty claim, Norfield will either refer the customer to a regional repair facility or replacement parts will be shipped from the factory. Parts shipped from the factory will be invoiced to the customer's account until the warranty claim is verified. To obtain verification, the defective parts must be returned to Norfield within thirty (30) days from the date of the claim for inspection. Before returning the defective parts, please contact Norfield to obtain a "Return Material Authorization Number".

All parts manufactured by Norfield and found to be defective will be given appropriate credit. All parts not manufactured by Norfield are covered by their respective manufacturer's warranty and will be sent to the original manufacturer for credit. When, and if, credit is issued to Norfield, we will in turn issue credit to your account.

LIMITED WARRANTY

Norfield warrants any and all such parts manufactured by them against defects in material or workmanship for a period of one-year from date of purchase. Norfield's liability under this warranty shall be limited to replacing free of charge, F.O.B. Chico, California, any parts proved to be defective within the period of the warranty. Norfield will not be responsible for transportation charges or consequential damages.

Norfield will not in any case or under any circumstances be liable or responsible for any injuries to persons or property suffered as a result of the use or operation of the machine, or losses or costs resulting from any period of non-operation for any reason.

Parts which are claimed to be defective, but show tangible evidence of abuse or negligence will not be replace on a no-charge basis.

Norfield reserves the right, at its own discretion without notice and without making similar changes in machinery previously manufactured, to make changes in material, design, finish and/or specifications.

Any changes, alteration or installation of additional equipment to this machine without first obtaining written consent from Norfield may void this warranty. Determination of the effect of any alteration on this warranty is left to the discretion of Norfield.

Norfield makes no written or implied warranty with respect to electrical equipment, including motors or other purchased components used in the manufacture of the machine. All such parts are covered by their respective manufacturer's warranty. We do endeavor, at all times, to purchase only those components manufactured by responsible manufacturers which we have found to be reputable in their handling or warranties.

Norfield expressly disclaim any warranty, expressed or implied, other than those which are expressly made in this limited warranty.

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CONTACT & ORDER INFORMATION

Norfield Industries is the name that represents Quality, Reliability, Support, Innovation and True Customer Service. We are dedicated to providing world class customer care. Norfield has been providing quality care in the pre-hanging door industry for over 40 years and has earned a reputation for setting the standard for innovation, reliably, full technical support, machine parts and a full line of industrial woodworking tools and accessories. Our team of Customer Care Representatives is available to support you.

If the need should arise that you need to contact the Norfield Service department, please have the following information available:

e Serial number of the machine.

e Model of the machine.

e Date of purchase or date that the machine was installed.

e Voltage of the machine.

e A description of the problem and what part of the machine is the problem occurring.

For warranty issues and service questions contact the Norfield Service Department at 800-824-6242.

To order replacement components, and consumables, such as drill and router bits, saw blades and other accessories contact a Norfield Tools and Supply Customer Care Repre-sentatives at (530) 879-3137 or fax us at (530) 879-3140. You may also order over the web at www.norfield.com .

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ASSEMBLY SCHEMATICS

ELECTRICAL & PNEUMATIC SCHEMATICS

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* Add one additional component with specific options.

Item Part No. Description QTY

1 11-118 ITE E0408ML 1125S2 LOAD CENTER 1

2 11-346 ITE Q21515 CIRCUIT BREAKER 2

3 5079-006 MODIFIED COVER PLATE (OPTIONAL) 3

4 11-111 BRYANT 5279 RECEPTACLE 4

5 5079-005 MODIFIED ENCLOSURE 3

6 11-467 IDI 1050A1 125VAC 1/2W LAMP 3 to 4

7 11-1677 LEVITON 2513 LOCKING FEMALE CONNECTOR 1

8 11-1676 LEVITON 2511 LOCKING MALE PLUG 1

9 11-053 FURNAS 52PA2A2 EMERGENCY STOP 1

10 11-049 FURNAS 52PA8A3 GREEN PUSH BUTTON 1

11 11-050 FURNAS 52PA8B2 RED PUSH BUTTON 1

12 11-048 FURNAS 52BAJ CONTACT BLOCK 4 to 5

13 11-047 FURNAS 52BAK CONTACT BLOCK 2 to 3

14 11-1354 S&S CAK7-9-120-ME-C2 STARTER 2

15 11-1353 S&S CAK7-12-120-MF-C2 STARTER (OPTIONAL VAC.) 1

16 6801-021 BALDOR (MOD. M3558T) 2HP 1725 RPM MOTOR 1

17 5923-007 BALDOR (MOD. M3546T) 1HP 1725 RPM MOTOR 1

18 11-052 FURNAS 52SA2AA3 SWITCH 1

19 15-104 DAYTON 6K352 MOTOR 1 to 2

20 11-708 JET DC-1900 (OPTIONAL) 1

21 11-853 AB 1492-GH070 CIRCUIT BREAKER 1 to 2

22 11-305 CRYDOM RELAY TD 2425 4


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Item No. Part No. Description Qty

1 11-047 FURNAS 52 BAK CONTACT BLOCK 7

2 11-048 FURNAS 52 BAJ CONTACT BLOCK 2

3 11-400 FURNAS 52 PA8 B3 PUSH BUTTON 1

4 11-401 FURNAS 52 SA2 BAB SWITCH 1

5 11-052 FURNAS 52 SA2 AAB SWITCH 3

6 11-049 FURNAS 52PA8 A3 PUSH BUTTON 2

7 11-451 OMRON E2E-X2E1 PROXIMITY SENSOR 1

8 11-413 SELECTA SS-209-8 SWITCH (OPTIONAL) 1

9 10-386 ARO 59891 AIR TO ELEC. INTERFACE 5

10 10-061 ARO A-222-SS-012D ARO VALVE 17*

11 11-305 CRYDOM TD 2425 RELAY 4

* Add 4 additional components with selected options.


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1 10-061 ARO A-222-SS-012D VALVE 17

2 10-449 ARO MKN END PLATE 4

3 10-318 ARO A-212-PD VALVE 2

4 10-414 CLIPPARD PB-85 ADAPTOR 2

5 10-047 CLIPPARD MJV-3 VALVE 2

6 10-315 CLIPPARD PL-P2F-B PUSH BUTTON 2

7 10-071 ARO 5030-06 VALVE 5

8 10-362 ARO 5830-0399-02 VALVE 1

9 10-031 CLIPPARD MJSV-1 VALVE 1

10 10-135 BIMBA 092-DP CYLINDER 1

11 10-164 BIMBA D-167 PIVOT BRACKET 1

12 10-309 WILKERSON ROO-01-000 REGULATOR 1

13 10-386 ARO 59891 AIR/ELEC SWITCH 5

14 10-003 MONNIER 2-1750 RESERVOIR 2

15 10-005 MONNIER 11-520 NONNIER BRACKET 2

16 10-004 MONNIER 2-1000 RESERVOIR 1

17 10-221 CLIPPARD MJTV-3 VALVE 1

18 10-165 BIMBA D-226 BRACKET 1

19 10-665 ALLENAIR ES-2X12-NT-CS CYLINDER 1

20 10-471 BIMBA FO-31-1.00 CYLINDER 2

21 10-429 BIMBA 124-D CYLINDER 3



24 10-397 BIMBA 091.5-D CYLINDER 4

25 10-438 BIMBA 313 DXP CYLINDER 3


27 10-470 BIMBA 2420-DP CYLINDER 1

28 10-683 ALLENAIR E-2X4-B-D CYLINDER 1

29 10-401 BIMBA 315-DXP CYLINDER 1

30 10-398 BIMBA 1710-DX CYLINDER 1

31 10-404 BIMBA BF-091-D CYLINDER 1


33 10-472 BIMBA 1714-DX CYLINDER 2


Continued on next page


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35 10-426 BIMBA FO-70-.5 CYLINDER 1


37 10-357 BIMBA D-508 NUT 2

38 10-562 SMC NAS 2201F-NO1-07S FLOW CONTROL 28

39 10-018 SMC AS-3000 FLOW CONTROL 2

40 10-523 WILKERSON F26-04-FMO FILTER 1

41 10-539 WILKERSON M-26-04-FMO FILTER 1

42 10-528 WILKERSON R26-04-GOO REGULATOR 1

43 10-524 WILKERSON L26-04-DOO LUBRICATOR 1

44 10-038 HUMPHREY 250A VALVE 1

45 10-456 WILKERSON GRP-95-147 BRACKET 1

46 10-483 ARO 5041-21 VALVE 1

47 10-485 MONNIER 11-038 BRACKET 1

48 10-551 WILKERSON GPA-95-098 VALVE 1

49 10-661 SMC NAS 2201F-NO2-07S FLOW CONTROL 16

50 10-017 SMC AS-2000 FLOW CONTROL 3



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1 10-061 ARO A-222-SS-012D VALVE Varies


3 10-562 SMC NAS 2201F-NO1-07S FLOW CONTROL Varies

4 10431 BIMBA FO-17-1.5 CYLINDER 3

5 10-488 BIMBA BF-041-D CYLINDER 2

6 10-426 BIMBA FO-70-.5 CYLINDER 1

7 10-462 QUICK DISCONNECT (FEMALE) 1

8 10-482 QUICK DISCONNECT (MALE) 1

Norfield

4000 machining center...butt router dewalt 616 15-174 1-3/4 115 11.0 face plate router dewalt 616...

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