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MANUFACTURERS E.C. DECLARATION OF CONFORMITY

The following machine has undergone "Conformity Assessment" and

is

"self' certified

in

accordance with:-

Supply of Machinery (Safety) Regulations 1992

and Amendment

No.

2063

COMPANY

WADKIN LTD

Green Lane Road

Leicester

LE54PF

RESPONSIBLE PERSON

Mr A C Lotl (Managing Director)

MACHINE DESCRIPTION

TYPE THROUGH FEED FOUR SIDE

PLANING MACHINE AND MOULDER

MODEL GA

DIRECTIVES COMPLIED WITH

Supply

of

Machinery (Safety) Regulations 1992

Amendment

No.

2063 1994

Draught Proposal CENITC 142

ISO

9001

Part 1

SIGNED

ON

BEHALF OF WADKIN PLC

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Through Feed Four Side

Planing and Moulding Machine

Model GA

OPERATION AND MAINTENANCE MANUAL

Wadkin

Limited

Green Lane Road,

Leicester

LE54PF

Telephone

0044(0)116 2769111

Fax 0044(0)116 2742310

www.DaltonsWadkin.com

C Contents

r:

CONTENTS

~

EXTENT OF MANUAL

~

Section

Page

C 1 HEALTH AND SAFETY

1-1

1.1

Heal

th

and Safety

1-1

0 1.1.1 Factories Act 1-1

1.1.2 Health and Safety at Work Act 1-2

1.1.3 Electricity Regulations 1-2

~

1.1.4 Provisions and use of Work Equipment Regulations 1-2

1.1.5 Woodworking Machines Regulations 1-2

1.1.6 Other Documents for Reference 1-2

C 1.2 Supply of Machinery (Safety) Regulations 1992 1-3

1.3 Specific Information 1-3

1.3.1

Noise 1-3

C 1.3.2 Dust 1-4

C 2 MACHINE SPECIFICATION

2-1

3 INSTALLATION

3-1

C

3.1

Receipt

of

the Machine

3-1

3.2 Preparation for Installation

3-1

C 3.3 Lifting and Locating the Machine

3-1

3.4 Connecting the Services 3-2

3.4.1 Electrical Supply 3-2

0 3.4.2 Pneumatic Air Supply 3-3

3.4.3 Dust Extraction 3-3

0 4 MACHINE USAGE AND CONTROLS

4-1

Safe Practices

4-1

0 4.1.1 Pre-operation Checks

4-1

4.1

.2 Checks During Operation 4-1

4.1.3 Safety Devices 4-2

0 4.2 Machine

Co

ntrols 4-2

4.2.1 Machine Control Panel 4-2

4.2.2 Infeed E

nd

Controls 4-4

0 4.2.3 Optional Equipment 4-4

0 5 SETTING-UP THE MACHINE

5-1

5.1

General

5-1

C Page 1

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5.1

.1 Preparation

5-1

Section Page

[ 5.1.2 Remove/Refit Cutter Block

in

Spindle

5-2

5.2 Setting First Bottom Head

5-3

C 5.3 Setting Fence Side Head 5-4

5.4

Setting Near Side Head

5-6

5.5 Setting First Top Head

5-8

C 5.6 First Top Head Pad Pressure and Chipbreaker 5-10

5.7 Setting Second Bottom Head

5-11

5.8 Setting the Feed Rolls 5-12

[ 5.9 Infeed Table and Fence Adjustment 5-14

6 OPERATION

6-1

[

6.1

General

6-1

6.

1.1

Pre-operation Checks

6-1

[J 6.1.2 Setting Controls and Adjustments

6-1

C 7 MAINTENANCE

7-1

7.1

General

7-1

C 7.2 Scheduled Maintenance

7-1

7.2.1

Daily

7-1

7.2.2 Monthly

7-2

[ 7.2.3 Three-Monthly

7-2

7.3 Unscheduled Maintenance

7-3

7.3.1

Re-tension Top/Bottom Head Drive Belt

7-3

C 7.3.2 Re-tension Fence/Side Head Drive Belt

7-4

7.3.3 Replace Top/Bottom Head Drive Belt

7-4

7.4.3 Replace Fence/Side Head Drive Belt

7-4

C 7.3.5 Replace Outfeed Bottom Drive Belt

on

Machine fitted

with Straightening Infeed Table

7-4

7.3.6 Replace Shaft-Mounted Top Feed Roll

7-5

[ 7.3.7 Replace Flange-Mounted Top Feed Rolls/Spacers

7-5

7.3.8 Replace BottomiTop Head Spindle 7-6

7.3.9 Replace Fence/Near Side Head Spindle

7-6

C 7.4 Fault Finding

7-8

7.4.1 General

7-8

7.4.2 Workpiece Faults

7-8

C 7.4.3 Machine Faults

7-9

7.5

Lubrication Chart

7-11

7.5.1

Lubricants Specified

7-11

0 7.5.2 Approved Lubricants

7-11

7.6

Tool and Toolholder Care 7-12

0 8 ADDITIONAL EQUIPMENT APPENDICES

C

8.1

Universal Head

8-1

Page 2

C

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[ 8.2 Splitting Bedplate 8-9

8.3 Infeed Nip Driven Roller System 8-10

r Section Page

8.4 Push Feed System

8-11

['

8.5 Grooved Bed 8-12

8.6 Unit G 8-14

8.7 Intermediate Feed Roll 8-19

G GLOSSARY

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Extent of manual

EXTENT OF MANUAL

This Operation and Maintenance Manual

is

intended to provide users with all relevant

information concerning the operation and maintenance

of

a Through Feed Four Side

Planing and Moulding Machine, Model GA.

The document

is

produced

in

seven sections.

Section One gives advice general safety aspects

of

the machine usage including

references

to

the various current statutory and safety regulations

in

force, advice

on

record keeping

of

machine operation and maintenance, and also instructions

on

recommended procedures when accepting and receiving the machine from the

manufacturer.

Sections Two to Seven provide the information necessary to install, operate and

maintain the machine including procedures for fault finding.

At the end

of

the manual

is

a Glossary of terms used throughout the body

of

the manual.

Also, depending upon any special machine features and/or nature

of

operation,

Additional Equipment Appendices are included to complement the standard sections

within the manual.

The

policy

of

the

Company

is

one

of

continuous

development,

and

the

company

reserves

the

right

to

alter

specification

without

prior

notice.

No

part

of

this

publication

shall

be

produced

in

any

way

without

the

express

permission

of

the

Company.

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1.1

1.1.1

Health and safety

1 HEALTH AND SAFETY

This Section covers all aspects

of

safe operation and safe use

of

woodworking

machinery. It refers

to

various statutory Health and Safety regulations, and also includes

information and advice derived from many years' experience

in

the

in

the building,

operation and maintenance of woodworking machinery.

It

is

of

the

utmost

importance

that

the

user

or

employer

reads

this

Section

of

the

document

and

understands

clearly

all

of

the

stated

requirements

concerning

safe

operation

of

the

equipment.

Health and

Safety

There are a number

of

statutory regulations which apply

to

the safe operation

of

woodworking machinery

in

the UK. These regulations are listed below, and the user

is

advised

to

refer

to

the relevant parts

of

these regulations and ensure that the

requirements are complied with.

Where the machinery

is

used outside the UK, then the regulations of that country will

apply, and should

be

complied with.

Note:

The

list below relates

to

the

most

recent published editions

of

the regulations including

all amendments

and

supplements.

Factories Act.

Health and Safety at Work Act.

Electricity Regulations.

Provision and use of Work Equipment Regulations.

Woodworking Machines Regulations.

Factories

Act

This Act requires that rotating machinery shall

be

of

good mechanical construction and

that it shall

be

properly

maintained

and

serviced

by

competent

and

experienced

persons.

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1.1.2

1.1.3

1.1.4

1.1.5

1.1.6

Health and safety

Health

and

Safety

at

Work

Act

This Act imposes obligations to apply similar standards to those

of

the Factories Act as a

minimum requirement,

especially

where

a

machine

is

installed

in

a place

of

work

where

no

suitable

legislation

applies.

Electricity

Regulations

These regulations place general requirements

on

the installation and maintenance

of

electrical equipment. Users should

be

aware

of

the requirements concerning the

availability

of

lighting and free working space for maintenance personnel, and the

importance

of

personnel being fully competent and trained when working on electrical

equipment.

Provision

and

use

of

Work

Equipment

Regulations

Compliance with these regulations

is

necessary for equipment to

be

considered to

be

conforming with the

EC

declaration of conformity.

The regulations also place obligations

on

the user (see Section 1.2).

Woodworking

Machines

Regulations

These regulations place absolute legal requirements

on

employers and users to ensure

that

all

fitted

guards

and

safety

devices

are

always

used,

securely

fitted,

correctly

adjusted

and

properly

maintained.

The regulations also require that

maintenance

be

undertaken

only

by

suitably

qualified

and

competent

personnel,

and

that

all

power

supplies

are

isolated

from

the

machine

before

any

maintenance

is

undertaken.

It

is

also required that

operators

(users) receive

suitable

training

and

instruction

into

the

possible

dangers

arising

from

machine

usage

and

that

local

working

practices

are

followed.

Other

Documents

for

Reference

Other documents which refer to woodworking machinery operation and maintenance in

the UK include:

Noise at Work Regulations.

Control

of

Substances Hazardous to Health Regulations.

Code

of

Practice 8S5304 -Safeguard of Machinery.

Code

of

Practice 8S6854 -Safeguard of Woodworking Machines.

Health and Safety Executive note IND(G) 1(L). Page 1-2

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1.2

1.3

1.3.1

Health

and

safe

ty

Supply of Machinery (Safety) Regulations 1992

A machine manufactured

in

accordance with the Essential Health and Safety

Requirements

of

the Supply of Machinery (Safety) Regulations 1992, complies with the

EC

conformity requirements and can thus have the CE mark appended (Harmonised

Standard PREN 12750: 1997) .

These regulations also impose legal requirements

on

both the employer and the user

of

the machine with regard

to

proper usage, user working conditions, risks

of

injury and

many more. These requirements are wide ranging, and

in

some cases specific to only

certain types of machine or process. Some

of

the more general requirements which

app

ly

to woodworking machinery are briefly detailed below.

1 An employer shall ensure that the equipment

is

constructed/adapted as

to

be

suitable for the purpose that it

is

used.

2

In

selecting the equipment, the employer shall have due regard

to

the

working conditions and the risks to health and safety of persons which

exist in the premises

in

which the equipment

is

to

be

used.

3 The employer shall ensure that the equipment

is

used for the operations

for which, and under the conditions for which it

is

suitable.

Other requirements include provision of suitable training

of

users, provision

of

suitable documentation (information and instructions), and declarations

of

any

specific risks.

Specific Information

Section 4 of this manual -Machine Usage and Controls identifies and details

general safe working practices and specific local practices which should

be

adopted when using the machine.

In

addition to this information two hazards,

specific to woodworking machinery should

be

considered

in

more detail.

Noise

Noise levels can vary widely depending upon the machine and the conditions

of

use.

Planing and moulding machines produce high noise levels, typically

in

the region

of

95dB

to

115dB when cutting.

The Noise at Work Regulations require that

an

operator

is

not subjected to

continuous noise levels above 90dB over

an

8 hour period. Thus, some form

of

noise protection

is

necessary.

A machine manufacturer may supply (or provide information) a suitable sound

enclosure. It

is

possible that, given the types

of

materials available

in

the works

(ie sawmill), a suitable enclosure may

be

produced

on

site.

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1.3.2

Health a

nd

safety

It should

be

noted however, that even with

an

enclosure, noise levels might still

exceed the

gOdS

limit (especially at the machine infeed end).

As a precaution suitable ear protection should

be

worn by all machine

operatives.

Refer to use of ear defenders

in

Section 4.1.2

of

this manual.

Dust

Wood dust can

be

harmful

to

health through inhalation and also skin contact.

The Control of Substances Hazardous to Health Regulations place legal

requirements

on

employers

to

prevent exposure

of

the user to substances

hazardous to health or, where prevention

is

not practicable, to adequately control

the exposure. Adequate control should

be

achieved by measures other than

provision

of

personal protective equipment.

The Regulations require that airborne dust levels should not exceed 5mg/m3•

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Specification

2 MACHINE SPECIFICATION

Machine Details

Model

Dimensions

Services

Capacities and Adjustments

Maximum timber size admitted

Maximum finished work size

Feed speeds

Pneumatic Air Requirement

GA170/GA220

Refer

to

machine Foundation Plan

Refer to the machine Specification

Plate located on the machine frame

180/

230mm

x 130mm

170/220mm x 120mm

6

to

36m/min (standard)

0.

25

m3/min

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3.1

3.2

3.3

In

sta

ll

a

ti

on

3 INSTALLATION

Receipt

of

the Machine

Before accepting the machine at its destination check the packages/items against the bill

of

loading. Confirm that all listed fittings/accessories have been received and carry out a

visual inspection of the packages/items for obvious signs of damage.

Report any omissions or damage; note these for any future reference.

Preparation for Installation

Ensure that all the necessary external services are available

ie

electricity, pneumatic air,

etc., as identified

on

the machine Specification Plate and

in

Section 2 Machine

Specification.

Check also that adequate space

is

available

on

the installation site for lifting and

manoeuvring access.

Ensure that any covers or guards are removed and stored away from the machine.

Check that the following lifting equipment

is

available and

of

is

of

adequate capacity:

crane or approved lifting equipment

45mm diameter steel rods, 1.2m long (certified as suitable for lifting purposes)

lifting slings (capacity according

to

machine Foundation Plan)

wooden chocks.

Refer to the Foundation Plan for details

of

the floor area required

al1d

for any special

foundations necessary

Ensure that the final location

of

the machine has been levelled.

Lifting and Locating the Machine

Place the steel rods through the holes

in

the machine base.

Position the lifting slings on the crane/lifting equipment hook.

Locate the slings securely

on

the steel rods. Insert the wooden chocks between the

slings and the machine base to prevent damage to the base.

Position a steel levelling plate at each machine jacking screw point (refer to the machine

Foundation Plan).

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Installation

Lift and position the machine on the prepared location, and remove any transit clamps

that may have been fitted.

Level the machine (as detailed below) using

an

engineer's lev

el

by adjusting the jacking

screws located at each machine foot position.

Levelling longitudinally

With the engineer's level lengthways

on

the table

of

the machine, adjust the

machine longitudinally by adjusting the jacking screws. Check level at

appro

xi

mately every 300mm along the machine length. Deviation should not

exceed

0.1

mm

/

m.

Levelling transversely

Position the engineer's level across the table (at right angle to the fence), and

adjust the machine transversely by adjusting the jacking screws. Repeat this

action at

pOints

similar to the longitudinal checks. Deviation should not exceed

0.1mm/m.

WARNING:

The

machine

must

be

firmly

bolted

down

before

connecting

any

services.

Connecting

the

Services

Electrical

Supply

The customer

is

responsible for

an

electrical supply suitable to meet the power

requirements of the machine. These requirements are shown on the machine

Specification Plate

on

the machine frame, and are also shown

on

the electrical

schematic/connection diagram accompanying the machine.

Electrical connections should

be

made

to

the isolating switch

on

the electrical control

cubicle.

WARNING:

Connection

of

the

supply

must

be made

by

a

competent

and

experienced

electrician.

The connection procedure should include, but not

be

limited to:

Confirm that the supply

is

of

the correct voltage, phase and frequency to that identified

on

the machine Specification Plate.

Check that the incoming fuse ratings can accommodate the full load current shown

on

the machine SpeCification Plate.

Connect the incoming supply to the relevant terminals

on

the electrical control cubicle

(L

1,

L2

and L3).

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3.4.2

3.4.3

Insta

ll

ation

Make a good earth connection to the machine.

WARNING:

Before continuing further, refer to Section 4 for advice

on

safe operation

of

the

machine. Also, ensure that when undertaking any

of

the following operations all

relevant safety requirements and procedures detailed

in

Section 1 are complied

with.

Close the isolator

on

the electrical control cubicle, and run each spindle

in

turn to ensure

direction

of

rotation

is

correct:

Bottom horizontal spindles -clockwise when viewed from front.

Top heads -counterclockwise when viewed from front.

Fence side head -counterclockwise when viewed from above.

Near side head -clockwise when viewed from above.

Note:

Incorrect rotation

of

the spindles can be corrected

by

reversing any two

of

the incoming

supply connections

to

the terminals

of

the electrical control cubicle.

WARNING:

Phase changes must be made by a competent and experienced electrician.

Pneumatic Air Supply

The customer

is

responsible for a pneumatic air supply suitable to meet the

requirements

of

the machine as shown

on

the machine Foundation Plan

(O.25

m

3/

min).

The air supply connection

in

the machine base

is

%BSP female.

Check the condition

of

the air connectors, confirm their cleanliness, and make the air

connection.

Dust Extraction

The customer

is

responsible for the supply

and

fitting

of

suitable dust extraction

equipment.

The number and length of the flexible connections from the exhaust hood to the machine

should

be

as shown

on

the machine Foundation Plan.

See the machine Foundation Plan for:

Airflow requirements

in

m3/hour.

P

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stallation

Cross-sectional dimensions

of

machine extraction connections.

Duct air velocities

in

m/second.

Average pressure drop at machine extraction connections are shown below.

Duct Diameter (mm)

120

150

Required Air Volume

(m3/hour at 30m/sec)

1222

1909

Pressure Drop

(Pa)

1000

850

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4.1

4.1.1

4.1.2

Machine usage and controls

4 MACHINE USAGE AND CONTROLS

Note:

Refer also to Section 1 for information on general statutory requirements when operating

woodworking machinery.

Safe

Practices

Safe and proper working practices must

be

followed when setting-up and operating the

machine. Adequate advice and information are readily available

in

the form of local

working practices, notices, warnings and the information contained

in

this manual.

IT IS THE OPERATOR'S RESPONSIBILITY TO USE THE MACHINE FOLLOWING

THE PROCEDURES LAID DOWN AND ONLY FOR THE PURPOSES FOR WHICH IT

WAS DESIGNED.

Pre-operation Checks

All

guards

and

fences are

fitted

securely

and

properly

adjusted

to

suit

their

purpose.

Dust

extraction

equipment

is

working

correctly.

Machine

controls

are

functioning

correctly

(see

Section

4.2).

Adequate

working

space

is

provided

and

lighting

is

available.

Checks

During

Operation

Proper

protective

equipment

is

available

and

employed

(goggles,

ear

defenders,

face mask, etc).

Area

around

the

machine

is

kept

clean and free

of

wood

refuse.

Any

machine

malfunction

is

recorded

and

reported

to

person

in

authority.

Machine

is

made

stationary

and

electrically

isolated

before

any

cleaning

of

work

area

or

ANY

adjustments

are

made

to

the

machine

or

ancillary

equipment.

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4.1.3

Ma

chi

ne

usage a

nd

controls

Safety Devices

In

order to avoid injury or accidental damage

to

personnel or equipment, a number

of

interlocking features have been incorporated into the machine operation. These are:

1 Infeed trip device (1) (see Figure 4.1.2) will trip the operation

of

the machine

feed. The spindles will continue

to

run. This trip level

is

set through the height of

the beam setting.

2

3

4

5

Before attempting to restart the machine electrically isolate the machine. The

feed must

be

restarted at the control panel after removal

of

the cause

of

the trip.

1

Figure

4.1.2

A splinter catching device protects against splinters at the machine infeed (fitted

when the machine

is

specified for splitting use).

If the enclosure door

is

opened during normal operation all spindles and feed

rolls stop.

With the enclosure open, the machine may

be

used for setting-up and test

purposes only.

The machine feed does not operate unless the spindles are running and the

enclosure

is

closed.

6 Brakes are fitted to all spindles.

Page 4-2

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c 4.2

[ 4.2.1

[

r

r.

[

c

D

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0

C

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Mac

hin

e

usage

and

co

n

tro

ls

Machine Controls

Machine Control Panel

Before using the machine, operators should familiarise themselves with the machine

control panel and other controls.

The machine control panel

is

mounted at the infeed end

of

the machine and consists of

a number of buttons, switches and indicators (see Figure 4.2.

1).

Depending upon the

model

of

the machine and special features fitted, the illustration

of

the control panel may

differ slightly from the panel

on

the machine being installed.

Feed Stop/Start (1)

Toggle start/stop button with indicator lamp which controls the operation

of

the feed

ro

ll

s.

Inch Forward/Reverse (2)

Two buttons and a keyswitch enable the feed to

be

inched forward or backwards -for

setting-up or other maintenance purposes.

3 6

2

1 7

~2

c.

",

L.J

' • 5

4

Figure 4.2.1

Beam Raise/Lower (3)

Two buttons enable the beam to

ra

i

sed

or

lo

wered within predetermined limits.

Similar buttons are also

on

the local control panel located beneath the first top head (see

Figure 5.5).

Page 4-3

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Wadkin GA User manual

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