Charnwood W590 User manual
2
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 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 all keys and adjusting
spanners are removed from the machine before switched it on.
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 task.
11. Wear proper apparel. Avoid loose clothing, gloves, ties, 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 the machine in good condition. Keep the machine clean for best and safest performance. Follow
instructions for lubrication and changing accessories.
15. Disconnect the machine from power source before servicing and when changing the blade.
16. Never leave the machine running unattended. Turn the power off. Do not leave the machine until it comes
to a complete stop.
17. Do not use any power tools while under the effects of drugs, alcohol or medication.
18. 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.
ADDITIONAL RULES FOR PLANER/THICKNESSERS
1. This machine is designed for use with wood. Attempting to plane or thickness any other materials will result
in damage to the machine, potential fire risk and/or health hazards.
3
2. The machine is designed for indoor use only.
3. Connection to a suitable dust extraction system is highly recommended. If you must use the machine on its
own, you will need to stop it, unplug it from the mains and thoroughly clean it at regular intervals. Continuing
to use the machine when it is clogged with shavings will result in damage to it, potential fire risk and/or health
hazards.
4. The machine should only be used on the stand provided.
5. Always hold the work firmly on to the table, using push pads when necessary.
6. Never use the planer/thicknesser with the guard and/or dust hood removed.
7. If planing or thicknessing a long piece of timber, provide additional support at the same height as the table.
8. Switch the machine off and unplug it before removing any debris.
9. Be aware of the possibility of kickback.
10. Do not modify this machine in any way or use it or anything other than its designated purpose. Neither the
manufacturer nor the suppliers will be liable for any damage or injury caused by incorrect assembly, operation
or electrical connection of this machine.
Risk of Injury! Wear Eye Wear Ear
Never reach into Protection Protection
a running cutter block
Rating Description
Trade: Suitable for daily use by professional woodworkers.
Continuously rated, high power and a heavy duty construction. Typically used by several different
operators in a small or medium sized business. Will be used up to the machines maximum limit
with some long work periods. Expected maximum use of 1000 hours annually.
Please Note: Using a product in excess of its rating will void the manufacturer’s free warranty.
Charnwood W590 Specification
Motor (induction) 3000w (4hp), 240v, 50hz
Planer width 305mm (12”)
Maximum planning / Thicknessing cut 3mm / 4.5mm
Fence tilt 0 to 45°
Thicknessing capacity 5mm to 230mm
Number of knives 3 x HSS
Dimensions of knives 310mm x 25mm 3.2mm
Weight 210kg
Noise Level (LpAeq) 87.3 dB(A)
Rating Trade
Warranty 1 Year
4
Unpacking
This product is packed into 1 wooden
crate.
To open the wooden crate, cut the
strapping and lift the lid of the crate up
from the pallet base.
Remove the plastic cover and the loose
items sitting on the thicknessing bed and
underneath the machine.
The machine is fixed to the pallet base
with two bolts.
Use a pair of 13mm spanners to undo the
2 securing nuts and remove the fixings.
This part of the assembly requires 2
people:
Lift the machine off the pallet base.
5
Identify The Loose Parts
Side Fence
Service Tools
Guide Bolts
Knife Setting Jig
Ratchet Handle
Large Washer
Cutter Guard Arm
Cutter Guard
Assembly
Remove the protective paper and clean the rust preventer from the table using WD40 or similar, and a soft
cloth.
Fit the Side Fence:
Use a 6mm Hex key to fit the 4 Guide
Bolts into 4 threaded holes.
Sit the Side Fence onto the tables, with
the back plate in between the 4 Guide
Bolts.
Fit the Large Washers and Ratchet
Handles into the remaining threaded
holes.
6
Fit the Cutter Guard:
Use a 5mm Hex key to remove 2 bolts and
the back plate from the side of the Outfeed
Table.
Fit the back plate, Cutter Guard Arm and
fasten them with the 2 bolts.
Slide the Cutter Guard into the end of the
arm.
7
Using the Planer Thicknesser
Feed Direction
PLANING MODE
Side Fence
Cutter Guard Height Adjuster
Outfeed Table
Cutter Guard Lock
Table Lift Lock
On / Off Switch
Infeed Table
Infeed Table Lock
Planing Depth Scale
Planing Depth Adjuster
Table Lift Lock
THICKNESSING MODE
Feed Direction
Lifting Handle
Dust Hose Connection
Dust Hood
Table Release Catch
Dust Hood Release Pin
Table Lift Lock
Thicknessing Scale
Thicknessing Bed Height Lock
Drive Rollers Lever
Digital Position Indicator
Thicknessing Bed Height Adjuster
16 amp Power Connection
8
Table Release Catch
PLANING MODE
With the machine set up in planing mode:
Use the Cutter Guard Height Adjuster to adjust the height of the Cutter Guard, so that the work
piece can fit underneath.
Set the Planing Depth Adjuster to the desired setting, reading off the Planing Depth Scale. If in
doubt, set the depth to 0.5mm
Connect a dust extractor to the 100mm diameter outlet.
Start the machine, wait for it to get up to full speed.
Lay the work piece flat on the Infeed Table and push it over the cutter block. Use a push stick or
push pad to ensure hands are kept well away from the cutters.
Pick up the work piece and return it to the starting position. Make as many passes as necessary to
achieve a flat planed finish.
When planing deeper pieces, over 75mm, undo the Cutter Guard Lock and slide the Cutter Guard
away from the Side Fence just enough to provide clearance for the workpiece.
SWITCHING MODES
To move from planing mode to thicknessing mode:
Engage the drive rollers by moving the Drive Rollers Lever into the upper position.
Release the tables using the 2 Table Lift Locks. Rotate upwards, pull away from the cutter block
and then lower.
Use the Lifting Handle to move the tables into a vertical position. This process is spring assisted,
but take care as the tables are heavy. The tables are automatically locked in the vertical position.
Swing the yellow Dust Hood up and over the cutter block, until it clicks into place.
THICKNESSING MODE
With the machine set up in Thicknessing mode:
Measure the thickness of the work piece.
Rotate the Thicknessing Bed Height Adjuster anti-clockwise to unlock the thicknessing bed.
Wind the Thicknessing Bed Height Adjuster handwheel clockwise to raise the thicknessing bed.
1 rotation is roughly equal to 4mm adjustment.
Read off the scale or use the Digital Position Indicator, with accuracy down to 0.1mm, to set the
bed at the starting thickness. Then raise the bed another 1 –4.5mm, depending on how much
stock is to be removed.
Tighten the Thicknessing Bed Height Lock.
The feed direction is the opposite direction to planing mode.
9
3
2 4
1
Start the machine, wait for it to get up to full speed.
Lay the work piece flat on the end of the table. Slide it forward until you feel the drive rollers take it
from you. Let go of the work piece and walk to the other end of the machine to support the work
piece as it is fed out of the thicknesser.
A safety bar will prevent you from trying to make too big a cut. If the timber hits the safety bar,
lower the table to take a smaller cut.
Make as many passes as necessary to get the desired finished dimension.
If making multiple components, consistency is best achieved by feeding them all through at one
depth, before adjusting the table height and feeding them all through again.
SWITCHING MODES
To move from thicknessing mode to planing mode:
Disengage the drive rollers by moving the Drive Rollers Lever into the lower position.
Lower the thicknessing bed all the way down.
Pull the Dust Hood Release Pin and swing the Dust Hood underneath the cutter block.
Support the tables with one hand and pull back the Table Release Catch.
Then lower the tables to the horizontal position. The weight is supported by springs, but take care
as they are heavy.
Lock the tables in place with the 2 Table Lift Locks.
General Guide
When faced with a rough sawn piece of timber which requires planning on all 4 sides and taking
down to a specific finished dimension, follow this guide:
•Set the machine up for planing.
•Identify the flattest of the two wider faces on the timber. (Face 1 on diagram)
•Pass that side over the planer as many times as
necessary until a flat and smooth finish is achieved.
•Hold the planed side firmly against the sidee fence and pass the narrow side (Face 2 on
diagram) over the planer as many times as necessary until a flat and smooth finish is
achieved.
•You should now have two planed sides at 90 degrees to each other.
•Set the machine up for thicknessing.
•Pass the timber through the thicknesser with the wider already planed side (Face 1 on
diagram) facing down against the bed. Continue until the desired thickness for the timber is
reached.
•Finally, pass the timber through the thicknesser with the planed narrow side (Face 2 on
diagram) facing down against the bed. Continue until the desired thickness for the timber is
reached.
10
Knife Removal and Replacement
If you are using the optional knife setting jig, please read those instructions first.
Cutter Block Cross Section
A–Square Head Locking Screw
B–Locking Bar
C- Knife
D–Depth Screw
E–Cutter Block
Remove the side Fence.
Undo 2 bolts using a 4mm hex key,
to remove the blue cover to access
the drive pulley.
The pulley can then be turned by
hand to access each of the 3 knives.
Use a marker pen to number each
knife in the cutter block to better
keep track of progress.
To remove the worn knives:
Disconnect the machine from the
power supply.
Raise the tables to get better access
to the cutter block.
11
Note the direction of the beveled cutting edge and
ensure the new knife is installed the correct way
around.
Rotate the cutter block until knife
number 1 is at the 12 O’clock
position with the knife at the top of
its cutting arc.
Use a 7mm spanner, turn the 5
Square Head Locking Bolts in a
direction that winds them deeper
into the locking bar.
Continue until the knife can be
removed.
Fit the new or reground knife into the
cutter block.
When the knife is correctly set, the tip of the knife, in
the 12 O’clock position, will be level with the top of the
outfeed bed.
Sit the Knife Setting Jig onto the
cutter block, so that both curved
cheeks sit against the block.
The tip of the knife should touch the
bottom of the setting jig.
Reground knives will be slightly
smaller than new ones and may
require a height adjustment.
If there is a gap here or the jig is
prevented from sitting on the face of
the cutter block, adjust the depth
screws.
The bottom edge of the knife sits on
2 Depth Screws.
These screws can be adjusted using
a 4mm Hex key.
Once the knife is correctly installed,
wind the square head bolts out, to
lock the knife in place.
12
Troubleshooting
Problem
Cause
Remedy
Machine does not start
Emergency stop activated
Release the emergency stop
Blown Fuse
Replace Fuse
Loose switch terminal
Inspect back of switch
Faulty switch
Replace switch
Cutter Guard not fitted
Check the alignment of the
micro switch
Only starts when Green
button is held down
Faulty switch
Replace switch
Machine hums but does not
start
Start capacitor failed
Replace start capacitor
Cutter block runs at half
speed, with lack of power
Run capacitor failed
Replace run capacitor
Motor running but cutter
block is not rotating
Broken or stretched drive
belt
Replace drive belt
Motor slows down during the
cut
Depth of cut is too great
Take a smaller cut
Dust & Chip collector hood
is blocked
Clear the blockage and
ensure the extractor is
functioning correctly
Planing knives are blunt
Replace or sharpen knives
Excess Vibration
Planing knives out of balance
Reset the height of the knives
13
Declaration of Conformity for CE Marking
Charnwood Declare that Woodworking Planer & Thicknesser, Model W590
Conforms with the following 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. BM
50193812, AN 50193813 have been issued by TUV Rheinland LGA Products GmbH, Tillystrasse 2, 90431,
Nurnberg, Germany.
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: 04/03/2022 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
14
Charnwood W590 Parts Diagrams
Drawing A: Infeed Table Assembly
Drawing B: Outfeed Table Assembly
15
Drawing C: Cutter Block Assembly
Drawing D: Base Assembly
16
Drawing E: Motor Assembly
Drawing F: Thickness Table Assembly
17
Drawing G: Fence Assembly
Charnwood W590 Parts List
Part No.
Description
Part No.
Description
001
Lock Nut M8
002
Washer
003
Outfeed Table Bracket Shaft
004
Outfeed Table Bracket Right
005
Socket Head Cap Screw M8 x 60
006
Eccentric Shaft
007
Table
008
Cutterhead Guard Assembly - Complete
009
Bracket
010
Socket Head Cap Screw M6 x 30
011
Washer
012
Lock Nut M12
013
Socket Head Cap Screw M6 x 20
014
Adjusting Handle
015
Knob
016
Bracket Screw
017
Bracket
018
Eccentric Shaft Bracket
019
Eccentric Shaft Clamp
020
Table Locking Shaft
021
Hex Nut M12
022
Outfeed Table Bracket, Left
023
Socket Set Screw M8 x 10
024
Plastic Disc D6
025
Hex Cap Screw M8 x 30
026
Flat Washer M8
027
Table Support
028
Spring
029
Hex Cap Screw M8 x 16
030
Hex Nut M8
18
031
Big Cam Wheel
032
Socket Set Screw M5 x 10
033
Cutterhead Guard with Cap
034
Socket Set Screw M8 x 12
061
Small Cam Wheel
062
Washer H16
063
Dust Collector Assembly
064
Roll Pin M5 x 18
065
Shaft
066
Washer H16
067
Bearing 6205ZZ
068
Knife (Set of 3)
069
Knife Locking Bar
070
Knife Locking Bar Screw
071
Cutterhead
072
Button Head Socket Screw M6 x 12
073
Belt Cover
074
Screw
075
Spring
076
Hex Cap Screw M8 x 16
077
Hex Hut M8
078
Hex Cap Screw M10 x 25
079
Flat Washer M10
080
Adjusting Washer
081
Anti-Kickback Finger
082
Infeed Roller
083
Anti-Kickback Shaft
084
Cutterhead Cover
085
Cutterhead Bracket, Right
086
Flat Washer M6
087
Socket Head Cap Screw M6 x 12
088
Cutterhead Bracket Cover
089
Button Head Socket Screw M6 x 12
090
Cap Nut M6
091
Spring
092
Stop Pin
093
Support Rod
094
Outfeed Roller
095
Bushing
096
Cutterhead Bracket, Left
097
Wave Washer D52
098
Retaining Ring
099
Washer
100
Drive Chain Sprocket
101
Washer
102
Lock Nut M10
103
Socket Head Screw M8 x 6
104
Key PLN 6 x 16
105
Spindle Pulley
106
Washer D52
131
Carriage Bolt N12 x 65
132
Square Washer
133
Bushing
135
Bearing BRG80101
136
Chain Wheel
137
Lock Nut M12
138
Pan Head Screw M4 x 35
139
Lock Nut M6
140
Flat Washer M6
141
Safety Switch
142
Safety Switch Bracket
143
Lock Nut M4
144
Washer M6
145
Hex Nut M6
146
Safety Switch Rocker
147
Safety Switch Rocker Shaft
148
Socket Head Cap Screw M6 x 25
151
Bolt
152
Hex Nut M8
153
Outfeed Table Lock Handle
154
Retaining Ring CLP20
155
Spring
156
Direction Label
157
Switch 230/60/1
158
Pan Head Screw
159
Flat Head Socket Screw M6 x 16
160
Button Head Socket Screw M6 x 12
161
Washer H6
162
Front Cover
163
Handle
164
Lock Knob
165
Cabinet
166
Infeed Table Lock Handle
167
Infeed Scale
168
Thickness Scale, Inch
169
Washer H8
170
Retaining Ring
171
Washer H12
19
172
Socket Head Screw M8 x 20
182
Infeed Table Bracket Shaft
184
Infeed Table Bracket, Right
190
Infeed Table Bracket, Left
203
Socket Head Cap Screw M8 x 16
209
Socket Head Cap Screw M8 x 40
210
Table Stopper
211
Hex Nut M8
221
V Belt for Cutterhead, 60Hz
222
Drive Chain
223
Cam Wheel Bracket
224
Cam Wheel Shaft
225
Cam Wheel with Sprocket/Key
226
Bushing
229
Washer
230
Retaining Ring CLP15
231
Retaining Ring CLP10
232
Socket Head Screw M5 x 10
233
Flat Belt Feed Roller Pulley
234
Cam Wheel
235
Bearing BRG80100
236
Bearing Spacer
238
Socket Head Screw M8 x 12
239
Motor Pulley, 60Hz
240
Flat Belt Feed Roller
241
Hex Cap Screw M8 x 25
242
Flat Washer M8
243
Motor, 3HP, 230v, 60Hz, 1Ph
244
Washer H8
245
Lock Washer M8
246
Cap Nut M8
247
Capacitor 230/60/1
248
Shaft
249
Lock Washer M10
250
Hex Nut M10
251
Small Motor Pulley
288
Indicator
289
Button Head Socket Screw M6 x 12
290
Socket Head Screw M8 x 12
291
Table Guide bar
292
Socket Head Cap Screw M6 x 20
293
Guide Bar Bracket
294
Flat Washer M6
295
Hex Hut M6
297
Socket Set Screw M8 x 12
298
Indicator Seat
299
Button Head Socket Screw M6 x 20
300
Screw
301
Cover
302
Washer
303
Nut
304
Locking Bar
305
Locking Shoe
306
Crank Handle
307
Handwheel
308
Socket Head Cap Screw M6 x 20
312
Retaining Ring CLP20
313
Retaining Ring
314
Washer
315
Crank Bar
316
Button Head Socket Screw M6 x 12
317
Flat Washer M6
318
Bevel Gear
319
Retaining Ring CLP35
320
Bearing BRG80202
321
Bevel Gear Bracket
322
Flat Washer M8
323
Hex Cap Screw M8 x 35
324
Thread Rod
325
Bolt M6 x 40
326
Hex Nut M6
327
Hex Cap Screw M8 x 35
329
Flat Washer
330
Thread Rod Bracket
331
Column Support
332
Flat Washer M8
333
Socket Set Screw M x 20
334
Hex Cap Screw M8 x 35
335
Column
336
Hex Cap Screw M10 x 35
337
Lock Washer M10
338
Planer Table
339
Scale Ring Assembly, Inch
368
Hinge Pin
369
Square Nut M8
370
Lock Nut M6
371
Fence Mounting Bracket
372
Socket Head Cap Screw M8 x 16
20
374
Flat Head Socket Screw M6 x 16
376
Fence Support, Right
377
Nylon Washer
378
Carriage Bolt M8 x 25
379
Button Head Socket Screw M6 x 12
380
Flat Washer M6
381
Cutterhead Cover
382
Lock Nut M6
383
Socket Head Cap Screw M6 x 12
384
Fence Bracket, Left
385
Locking Handle
386
Special Washer
387
Fence
388
Fence Support, Left
389
Fence Support, Right
390
Fence Scale
391
Complete Fence Assembly
Last Updated February 2022
Charnwood, Cedar Court, Walker Road, Hilltop Industrial Estate, Bardon,
Leicestershire, LE67 1TU
Tel. 01530 516 926 Fax. 01530 516 929
email: sales@charnwood.net website: www.charnwood.net
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