Charnwood W040 User manual

SPINDLE MOULDER
OPERATING INSTRUCTIONS
MODEL: W040
Charnwood, Cedar Court, Walker Road,
Hilltop Industrial Estate, Bardon Hill, Leicestershire, LE67 1TU
Tel. [phone] Fax. [phone]
email: [email protected] website: www.charnwood.net

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Forward
These instructions are important, the information contained herein is essential for the correct build
and operation of the machine and the safety of its operator.
The machine is equipped with various safety devices to protect itself and the operator. However,
these devices cannot cover all eventualities and a thorough understanding of spindle moulding
techniques, good workshop practice plus the controls and operation of this machine are essential
for your safety.
Do not operate the machine until you have read and understood all the instructions in this manual
and are familiar with both the machine and spindle moulding techniques.
Use of the Machine
Purpose
This machine is designed for moulding along and across the grain of prepared timber, using
cutters and limiters, correctly mounted in a standard Euroblock.
It is designed for use by one operator.
Operator Qualifications/Training
Operators of this machine should have a suitable qualification in the use of woodworking
machinery, including spindle moulders or should have been trained by someone holding such
qualifications.
GENERAL SAFETY RULES
WARNING: Do not attempt to operate the machine until you have read thoroughly and understood
completely all instructions, rules, etc. contained in this manual. Failure to comply may result in
accidents involving fire, electric shock, or serious personal injury. Keep this owner's manual and
review it frequently for continuous safe operation.
1. Know your machine. For your own safety, read the owner's manual carefully. Learn
its application and limitations, as well as specific potential hazards pertinent to this
machine.
2. Make sure all tools are properly earthed.
3. Keep guards in place and in working order. If a guard must be removed for
maintenance or cleaning, make sure it is properly replaced before using the
machine again.
4. Remove adjusting keys and spanners. Form a habit of checking to see that the
keys and adjusting spanners are removed from the machine before switched it on.

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5. Keep your work area clean. Cluttered areas and workbenches increase the chance
of an accident.'
6. Do not use in dangerous environments. Do not use power tools in damp or wet
locations, or expose them to rain. Keep work areas well illuminated.
7. Keep children away. All visitors should be kept a safe distance from the work
area.
8. Make workshop childproof. Use padlocks, master switches and remove starter
keys.
9. Do not force the machine. It will do the job better and be safer, at the rate for
which it is designed.
10.Use the right tools. Do not force the machine or attachments to do a job for which they
are not designed. Contact the manufacturer or distributor if there is any question about
the machine's suitability for a particular job.
11.Wear proper apparel. Avoid loose clothing, gloves, ties, rings, bracelets, and jewellery
which could get caught in moving parts. Non-slip footwear is recommended. Wear
protective hair covering to contain long hair.
12.Always use safety glasses. Normal spectacles only have impact resistant lenses. They are
not safety glasses.
13.Do not over-reach. Keep proper footing and balance at all times.
14.Maintain machine in good condition. Keep machine clean for best and safest
performance. Follow instructions for lubrication and changing accessories.
15.Disconnect the machine from its power source before servicing and when changing
accessories.
16.To avoid accidental starting, make sure the switch is in the OFF position before plugging in
the mains cable.
17.Never leave the machine running unattended. Turn the power off. Do not leave the
machine until it comes to a complete stop.
18.Do not use any power tools while under the effects of drugs, alcohol or medication.
19.Always wear a face or dust mask if operation creates a lot of dust and/or chips. Always
operate the tool in a well ventilated area and provide for proper dust removal. Use a
suitable dust extractor.
EXTRA RULES FOR SPINDLE MOULDERS
1. A spindle moulder should never be used by an untrained operator. Proper training is
essential for the operator’s safety.
2. The machine must be properly maintained and the correct fitting of all guards checked.

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3. Guards should be of such a design and fitted in such a way that they keep fingers out of an
area of 50 mm (2 inches) beyond the sweep of any cutter that might be used.
4. Always ensure that you use safe working procedures and that you understand what you are
doing.
5. Wear appropriate clothing. Long loose sleeves, long hair or anything else that could get
caught in the machine should be tied back or otherwise secured.
6. Never use this spindle moulder for curved work.
7. NEVER use a cutter block without limiters.
8. Feed the workpiece to the cutter block or router bit against the direction of rotation.
9. Never draw the workpiece back during cutting. Wait until the block stops rotating before
pulling the workpiece back.
Risk of injury! Wear Eye Wear Ear
Never reach into Protection Protection
moving tooling.
Specification
Main table surface 600 x 400mm
Sliding beam surface 1,000 x 200mm
Sliding beam stroke 620mm
Table height 870mm
Dimensions (WxDxH) 1000mm x 1070mm x 1280mm
Weight Net/Gross 82/85kg
Spindle diameter 30mm
Rotation speeds 4(1400/4000/6000/9000) rpm
Spindle length available for tooling 105mm
Spindle rise and fall 110mm
Table aperture (with inserts) 160mm ( 110/75mm )
Table aperture depth 50mm
Motor (induction) 240V, 1500W single phase
Fence size 125 x 700 mm
Extractor outlet 100mm
Rating Light trade
Warranty 1 year
Rating
Light Trade: Suitable for professional woodworkers where the machine will not be in daily use.
Mid-range machines with a heavier build and more power. Typically used by 2 or 3 people within a
small business and also for the dedicated hobbyist with a larger budget. It is expected to be used
up to the machines maximum limit with occasional long work periods. Suitable for income
generation.
Expected maximum use of 300 hours annually.

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Unpacking
This product is shipped in 4 Pieces:
1 wooden crate and 3 cartons.
To open the wooden crate cut the
strapping and lift the lid of the crate
from the base.
Remove the loose items which are
packed in the table recess.
Open the hinged blue door situated on
the side of the machine.
Remove the loose items packed inside
the cabinet.

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The machine is fixed to the pallet with
two brackets.
Use a pair of 13mm spanners to undo
the securing bolts and remove the
brackets.
Close and secure the blue door.
Please Note: This part of the assembly requires 2 people.
Clear a floor area and invert the body of the machine, so it sits upside down on the cast iron
table.
Use a screwdriver to remove the
rectangular blue access panel.
Feed the On/Off switch through the
access hole, so that the cable lies in
the slot.
Remove 4 bolts. which will be used
to secure the On/Off Switch, from
the side of the cabinet.
Remove 4 screws which hold the
On/Off switch cover to the case.
Mount the On/Off switch case to the
cabinet.
Refit the On/Off Switch cover.
Refit the blue panel.
Unpack the components and familiarise yourself with them

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Assembly
To assemble the base.
Locate:
4 x Panel
4 x Feet
8 x M6 Bolt, Washer and nut
4 x Joining Bracket
Screw the 4 feet into the threaded
holes in the 2 side panels of the
base.
Use a 17mm spanner to tighten
them.
After full assembly of the machine,
the feet can be adjusted to level up
the machine.
Use 8 of the bolts, washers and nuts
to join the 4 panels together.
Fit all 8 bolts finger tight only at this
stage.
Assemble the cabinet base upside
down as shown. Check that all 4
panels are touching the floor with no
gaps underneath.

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Turn the cabinet base the correct
way up.
Remove all of the bolts from the 4
joining brackets.
Use 2 bolts to attach each joining
bracket to the assembled base.
Fit the base to the cabinet.
The projecting part of each joining
bracket aligns with a hole in the
main cabinet.
Use 4 bolts to fix the joining
brackets and tighten with a 10mm
spanner.
Tighten all the remaining cabinet
base bolts.
Please Note: This part of the assembly requires 2 people:
Turn the assembled cabinet upright.
Remove the protective paper from the cast iron table top and wipe clean the grease, using a
rag and some WD40 or similar de-greaser.
Fit the hand wheel to the rise and
fall control shaft and tighten the
grubscrew.

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Slot (See below)
Remove one of the nylon stops from
the underside of the sliding beam,
using a no.3 Philips head
screwdriver.
Lower the retractable sliding beam
lock, by moving the lever down and
to the left, slide the beam onto the
guide rollers. Refit the nylon stop.
Note: The thin edge of the beam is
closest to the main table.
When the retractable lock is in its
raised position, it will engage with
the slot in the underside of sliding
carriage.
This will lock the beam in position
and stop it from sliding when not
required.
Here you can see the tapered end
of the spindle.

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Locate the spindle lock bar on the
right hand side of the machine.
Rotate the tapered spindle slowly
whilst pressing the locking bar
inwards. When the lock engages the
bar will slide in around 10mm and
the spindle will be locked.
Pull the bar out to unlock the
spindle.
With the tapered spindle locked, fit
the upper spindle.
Use a flat screwdriver to unscrew
the locking ring in the centre of the
upper spindle.
Place the upper spindle over the
taper and tighten the retaining screw
by passing a 6mm Allen key into the
centre of the spindle.
Next use the flat screwdriver to
tighten the locking ring down onto
the head of the retaining screw.
Warning: Failure to tighten the
locking ring may result in the arbor
and cutter block coming loose.
If the bolt holding the upper and
tapered spindle together ever
comes loose, it will be necessary to
use the special spanner provided to
hold the upper spindle in place
whilst unlocking the top bolt.

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The router collet is mounted in the
same way.
When changing the router cutter,
take the precaution of checking the
centre retaining screw is tight
Assemble the fence;
Fence depth locking screw
Fence depth Adjusting screw.
Fence fixing plate.
Fence width lock.
On top of the hood, you will find four
screws.
Remove the screws and attach the
hinged top cover as shown below.
At the rear of the cutter hood is the
connection for a 100mm diameter
dust extraction hose to be fitted.

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Fit the 2 long bolts through the slots
in the hood and then screw them
into a pair of holes in the table.
The hood can be fixed in different
positions depending on the size of
the work piece.
The cover is hinged to provide quick
access to the spindle to change the
tooling.
To lock the cover down, unscrew
the locking knob, slide the clamp
away from the centre of the hood so
that the tongue fits under the hood,
tighten the locking knob.
Do the same on the other side.
This cover MUST be closed and
locked when the machine is in
operation.
Loosen the fence depth locking
thumbscrew, and the fence width
lock (silver).
Slide the fence over the fixing plate,
so that the mitred end of the fence is
in the centre of the hood.
Wind the fence depth adjusting
screw, so that the fence sits back
against the hood, then lock it with
the depth locking thumbscrew and
the fence width lock.

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Assemble the front guard and
clamp.
Fit the square bar into the hood
cover and lock it with the
thumbscrew.
Slide the vertical hold down onto the
square bar and lock it with the
thumb screw.
Fit the front spring guard into the
end of the square bar and lock it
with the thumb screw.
With these correctly set, the work
piece is held firmly against both the
table and the fence.
Never operate the spindle moulder
without them.
The end stop can be fitted as shown
into the T-slot on the sliding
carriage.
The angled shape makes it easier to
keep larger workpieces flat on the
table and suits rounded edges too.
The crosscut fence and work clamp
are assembled as shown.
Undo the main locking knob and the
ratchet handle. Slide the base
runner of the crosscut fence into the
T-slot in the sliding carriage.
The crosscut fence may be adjusted
up to 60 degrees in each direction.
There are preset stops at 90 and 45
degrees each way. It is locked in
place with the ratchet handle.
Pull the front pin out to move past
the preset stops.

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The long fence can be adjusted left
and right to suit the diameter of
tooling to be used.
The work clamp can be used to
clamp a work piece. Screw the
thread down to engage the clamp.
The flip over length stop can be
raised or lowered as shown.
Fitting a cutter block
The cutter block (not included) is
shown here assembled.
The larger of the two table inserts is
fitted into the table aperture. Always
fit the smallest table insert which the
tooling allows.
A large selection of spacers, in
varying widths are provided so that
the cutter block can be located at
the required height on the spindle.
When stacking the spacers, ensure
that the one with the roll pin is at the
top of the stack and that the pin
engages with the slot in the spindle.
(Not all of the spacers will be
required)

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Before fitting the cutter block onto
the spindle, engage the spindle lock.
Now fit, (in reverse order):
The locking bolt
The top cap
the spacer with the roll pin
some spacers
the cutter block
some more spacers
The locking bolt must be firmly
tightened.
Once the stack on the spindle is
tight, release the spindle rotation
lock, before starting the machine.
The Spindle Controls
Spindle Height Locking Lever
Rise and fall hand wheel.
One complete turn raises or lowers
the arbor by 2 mm (0.08”).
Spindle Rotation Lock
Changing Speed
The spindle moulder has 4 speeds.
To change speed;
Unscrew the knob and open this
access door.
(The machine is fitted with a micro
switch and will not run when this
door is open)

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Slacken off the locking lever
Reduce the tension on the drive belt
by moving this lever.
Move the drive belt to the pair of
pulleys which give the required
speed, re-tension the belt and then
tighten the locking lever.
Operating the Spindle Moulder
It is assumed that anyone purchasing a spindle moulder has been trained to operate this type of
machine competently. Such training is beyond the scope of this manual.
Spindle rotation speeds:
1500rpm - Drum Sanding *
4500rpm - Moulding Hardwoods
6500rpm - Moulding Softwoods
8500rpm - Routing *
* It should be noted that sanding and routing accessories are optional extras.
Limiters: Never use a cutter block without limiters fitted.
Fences: Close the two fences together so the edges are just missing the cutter. This improves the
support for the work piece and is best practise for safety reasons.
Always adjust the fences so that the work is fully supported. If the cut removes the whole edge of
the work piece, step the out-feed fence forward as appropriate.
Set the vertical hold down to contact the top of the work piece.
Set the front guard spring to hold the work piece up against the fences.
Use a push stick to feed small work pieces through the cutter block.
Always feed the work against the direction of rotation (from right to left).

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Declaration of Conformity
Charnwood Declare that Woodworking Spindle Moulder, Model W040
Conforms with the following EU Directives: Machinery Directive 2006/42/EC
Low Voltage Directive 2006/95/EC
Conforms with the following UK Regulations:
Supply of Machinery (Safety) Regulations 2008
Electrical Equipment (Safety) Regulations 2016
And further conforms to the machinery example for which the EC type examination Certificate No., have
been issued by TUV Rheinland LGA Products GmbH, Tillystrasse 2, 90431, Nurnberg.
I hereby declare that equipment named above has been tested and found to comply with the relevant
sections of the above referenced specifications. The machinery complies with all essential requirements of
the directives and regulations.
Signed: Dated: 01/05/2021 Location: Leicestershire
Richard Cook, Director
Please dispose of packaging for the product in a responsible manner. It is suitable for
recycling. Help to protect the environment, take the packaging to the local amenity tip and
place into the appropriate recycling bin.
Only for EU countries
Do not dispose of electric tools together with household waste material!
In observance of European Directive 2002/96/EC on waste electrical and electronic
equipment (EEE) and its implementation in accordance with national law, electric tools that
have reached the end of their life must be collected separately and returned to an
environmentally compatible recycling facility.
Your local refuse amenity will have a separate collection area for EEE
goods.

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Main Assembly –Diagram A

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No.
Description
Qty
No.
Description
Qty
A01
Foot
4
A31
M8 x 25mm setscrew
1
A02
Front panel
1
A32
Washer
1
A03
L.H. panel
1
A33
Motor
1
A04
M4 x 10 mm setscrew
4
A34
M8 Nut
1
A05
Washer
5
A35
Spring washer
4
A06
M4 nut
4
A36
Washer
4
A07
M6 nut
8
A37
M8 x 25 mm setscrew
4
A08
Washer
8
A38
Washer
4
A09
M6 x 16 bolt
8
A39
Housing
1
A10
Access cover
1
A40
M8 x 12 mm setscrew
2
A11
Knob
1
A41
Washer
2
A12
M4 x 30mm setscrew
2
A42
Cast iron table
1
A13
Washer
2
A43
M8 x 30 mm setscrew
4
A14
Interlock switch
1
A44
Dome headed hex. nut
4
A15
M4 nut
2
A45
Locking washers
4
A16
M6 nut
8
A46
Large washer
4
A17
Washer
6
A47
M8 x 16 mm coach bolt
4
A18
Fishplate
4
A48
Sliding beam assy.
1
A19
M6 x 16 bolt
8
A49
Hood
1
A20
M6 x 12 bolt
4
A50
Washer
2
A21
M6 x 16 bolt
2
A51
M8 flange nut
2
A22
Washer
2
A52
M8 Nut
2
A23
NVR Switch
1
A53
Fixing bolt
2
A24
M6 x 16 bolt
4
A54
Bristol locking lever
2
A25
Washer
4
A55
Spring loaded pin
2
A26
Cover plate
1
A56
Bush
1
A27
Washer
4
A57
M5 nut
4
A28
Bush
1
A58
Washer
4
A29
Bush
1
A59
Cover plate
1
A30
Nut
1
A60
M5 x 12 setscrew
4

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Motor and spindle assembly –Diagram B