Wadkin SUPER 220 XJS User manual

At the Cutting Edge of Industry
SUPER 220 XJS
THROUGH FEED FOUR
SIDE PLANING
MACHINE
INSTRUCTION MANUAL No.2020/4
MIC.SERIAL Nos.6150 onwards

THROUGH FEED FOUR
SIDE PLANING
MACHINE
MODEL:220XJS
Wadkin ULTRACARE Ltd.
Tel: [phone]
Fax: [phone]
E-111ail: [email protected]
Web: WW'\V.wadkinultracare.com

IMPORTANT
SAFETY PROCEDURES AND CONSIDERATIONS
To ensure safe working conditions, persons operating and assisting wfth the
operation of this machine must ensure that they read and fully understand the
instructions given within this manual and have received sufficient training in the use
of the machine and the safety aspects to be obseived.
Note:- Persons under the age of 18 years must not operate the machine except
during the course of training underthesupervision of a trained operator.
A) POINTS TO NOTE BEFORE OPERATING OR ASSISTING WITH. THE
OPERATION OF THE MACHINE.
1) You have read and understand the operation and safety aspects of the machine
and have been checked out by a qualified supervisor.
2) The machine is supplied with full safe guarding. The machine shall not be
operated unless the safe guardings are in position and are functional.
3) Cutters/blades are the correct type, suitable for the machine and working
conditions, rotate in the correct direction of cut, are sharp and correctly fitted.
4) Correct spindle and speeds are setectE>d for the cutter equipmont and working
conditions.
5) Loose dothing is either removed or securely fastened back and jewellery
ramovod.
6) Adequate working space and lighting is provided.
7} All dust extraction equipment is switched on, properly adjusted and worKing
adequately.
8) The machine is securely installed (refer to installation section within this
manual).
9) The machine should only be used for cutting wood or materials with physical
and technological characteristics similar to wood, and for which thP. chip or
particle removal process is similar.
1 O) Only use tooling that complies with prEN 847-1. Sawblades made of High Speed
Steel (HSS) MUST NOT be used.

8) DURING MACHINING:-
1) Wear suitable protective clothing e.g, approved eye protection, ear defenders
and dust masks. Gloves shall be worn when handling tooling.
2) Stop the machine using the emergency stop or at the mains isolator before
making adjustments, cleaning or carrying out maintenance.
3) Keep the floor area around the machine clean and free lrom wood refuse. Do
not allowthe floor around the machine to be come slippery.
4) Stop the machine and report immediately to a person in authority any actual or
potential malfunction or op·erator hazard. Do not attempt to repair or rectify the
machine unless qualified or authorised to do so.
5) The operator must not leave the machine running whilst unattended.
6) Never by-pass interlocks.
WARNING:-
Failure to observe correct operatin!;J procedures prior to and during operation of
this machine can result in severe injury. ·
DO NOT attempt to operate the machine while under the Influence of anything
that reduces your alertness.

Wadkin
Ill _____ _
PREFACE
IMPORTANT
IT JS OUR POLICY AND THAT OF OUR SUPPLl·E . RS TO
CONSTANTLY REVIEW THE DESIGN AND CAPACITY OF OUR
PRODUCTS. WITH THIS IN MIND WE WOULD REMIND OUR
CUSTOMERS THAT WHILE THE DIMENSlONS AND PERFORMANCE
DATACONTAINED HEREIN ARE CURRENT AT THE TIME OF GOING
TO PRESS, IT IS POSSIBLE THAT DUETOTHE INCORPORATION OF
THE LATEST DEVELOPMENTS TO ENHANCE PERFORMANCE,
DIMENSIONS AND SUPPLIERS MAY VARY FROM THOSE
ILLUSTRATED
THIS MANUAL IS WRITTEN AS A GENERAL GUJDE. DUE TO THE
NUMBER OF VARIATIONS {OPTIONS) AVAILABLE A TYPICAL
MACHINE IS SHOWN TO ILLUSTRATE THE·MAIN FEATURES.
Wadkln Leicester
Green Lane Works, Leicester LE5 4PF, England .
Telep hone: 01162769111

Wndkln
Ill~------
SAFEGUARDING MACHINES
To comply with the Woodworking Machines Regulations 1974, operators must ensure
that they fully understand .the instructions given and have received sufficient training in
the use of the machine and the particular safety instructions to be observed.
NOTE: Persons under the age of 18 years must not operate the machine except
under supervision during a course of training.
BEFORE OPERATING THE MACHINE ENSURE THAT:·
All guards and fences are securely fitted and correctlyadjusted in accordance with the
Regulations.
Cutters / Blades are the correct type and rotate In correct direction of cut, are sharp
and securely fastened.
Correct spindle speed is selected for the cutter equipment.
Loose clothing is either removed orfastened and jewellery removed.
Suitable jigs and push stlcks are available as appropriate.
Sufficient working space i:s provided and lighting is adequate.
All dust extraction equipmentis switched on, properly adjusted and working efficiently.
DURING MACHINING:·
Wear suitable protective equipment. e.g. goggles, ear defenders, and dust mask.
Stop the machine before making adjustments or deaning chips from the work area.
Keep the floor area around the machine clean and free from wood refuse.
Do not allow the floor to become slippery with oil or grease
Report lmmedlately to a person in authority, any machine malfunction or operator
hazard. Do not attempt to repair the machine unless qualified to do so.
Ensure all power sources are isolated before commencing any maintenance work
WARNING: Failure to comply with the Regula!lons is a criminal offence and could
result in legal proceedings.

HEALTH AND SAFETY
This machlng is designed and conslrue!lild using
the principles of safeguarding and practlcal
11uldance· conlalnad• in the British· Standard
Codes of Practice 855304: 1988· "Safeguard_ of
machinery•, BS6854: 1967 "Safeguard
woodMJrklng machines• and cumint guidance
issued by the Healllt and Safety Executive.
The Health and Safety at Work etc Act t9T4
places duties In deslgnera. manufacturers and
suppliers to ensure that-
1.
2
Arlides supplied for use at work are, so far
aa ie roas<inebly practicable, safe ancl
without risks to health during selfing, use,
cleaning and maintenance.
Persons supplled wit11 the artii:les are
provided with adequate Information about
the use for which they are designed, amt
about conditions necasseiy to ensure that
they will be safe and without risks to health.
Theseduties lire transferredto you If you rasupply
Iha machine by way of sale, laass, him or hlro-
purchase.
Persons wtlo Install this machine ror use- al work
hc\IO o duty under the l-lealtll and Safely al Wolk
etc Act 1974, to ensure so far as Is reasonably.
practicable, that nothing aboutthe way in whlcll-it
is installed makes It unsafe or-a rfsk to health.
This inCludes such aspects as correct" assembly,.
electrical lnstallatfon, construction of enclosures,,
nttlng of guards and exhaust ventilation
equipment. When installlng the machlnl>',,
consideration must be given to the- provision at·
adsqual& lighting and wcrl<in9 space.
The Jeg;al duUee af designers, manufacturer.s;
importers, supplfera, erectors and installers. are.
explained in1he free Health and Safety Executive
leaHet IND (G) 1 (L) 1987.
Tha machine is supplied complete with all·
necessary safeguards to enable Iha usar to
comply with the Woodworking Machines·
regulations 1974. Details of correct installaUon
end use, together with guidance on fitung and·
proper adjustment of guards ara described In
Sectlon:ii 1 to 4 of this manual.
You ara reminded that lha Woodworking
MachinesRegulations place absolute legaf duties,
an employers and employees to, ensure. that.
guanfs;and.any other safety devices am securely
fiHeci', correctly,adjusted and properf~, maintained.
Repai~s and maintenance. must. only be
undertaken by suitably qualifiect. and' competent
tsclmlcians. ensure.. that all power supplies. are.
Isolated bofor..- an.y maintenance work
commences •. Instructions. of• rouUnamalntenance
·are given in Section 4 of !his manual;
Macnine operators must have. received.sufficient
fralnlll!Jamtlnstrucliona:; lo lha:dangera.arising: in.
connectlon with the machine. the precautions. to
be obseoved and Iha requirement., of tho
Woodworldng Machines Regulations whioh
apply-. except whera they work under the
adequate super.vision· of a person wha ha&. a
thoroua.h-. knowlodgo. end. experiencs.- of. ttle-
machlnB'- ancl the requiredsafguards-
Parsons under tha aga of 1& years mus!
oucce~fully complet& an approvBd; course· of
tralnlnii befilre operaUna this machlna- at work,
unfe~. parUcipaUn11 In a cours&. of.lrainlns- under
adquarasupennslon-. (N-.S. Thl&.paragraplt<isonly
mlevant to; circularsaw!ll!J(machlnes. an1fsawing
ma chins& filled!. wttll e circularblade-. any planing
machine 1b~ surracinQ. whlclt Is. notmecllanlcally
fed or amr vertical spindle maudlln1lmachine.)
Beforecommencin!lwork; ensurethat Iha cutters/
blade era. sat b cul. Jn. the correct dlrectton,
svcurgly-fitlod',,oharp, and• a.-..comp<iUtllawlill·Illa
machineanclspindle speed.
Dust
Woocl dust can· be hannful l<l health. by inhalation
and skincontactancl:cconcentraUons of small•. dust
pal1icles in the, air can fonn an· explosive, mi><tu.-...
These concentrations usually occur in. dust
extraclfon equipment whlclT may ba destroyed
unle$$ explosion: precauuamr hava been taken In
111 .. design and fnslallaHon af Iha equipment

------'''
Employees have duties ·under the Factcl1es Act
1961 andHealth and:SaretyoatWork·elc·Act 1974
to control·wcod•dust in·lhe wcrkplaceandfnlm ·1st
October1989·more speclfic-.requlrsments .will :be
lmpose.di>y:lhe .Contrnl'llr·substancasHaxardous
Jo Health 'Rl!iJUlatlons ·~988.
·smployers sho.uld ·carry •out -an adequate
<1ssessmant nf .the ;possible :risks cto llealth
<1SSCclated with wood ·dust ·Jo :enable -a viilld
daclsfori' io ta ·.mad_e about ·,Jha, -measures "kl
-ccnlroLthe •dust ~l,may·tie necassaryfo :provide
eTiectlve -exhaust appliances.
Prevention -or 'COnfrol .tJf ·wood •dust -axposure
should •so far as ·is ·•reasonably piaclicable, be
ilchievad hy ·.measu~ss -OTHER •than the
·provisionsonf personal-.prolect!ve:equipment
Airborne cdust •levals •should ·-not •exceed :S mg/
cubm
·P.urt11er Jntormstion and mference -.to .:praUcal
-guidance· ara -.:contained Jn '!ha fOllQW!ng <free
lea!lsts·'finm ihe Healih and 'Safa1JrEiceCUtive:-
Wco1:hiust -IND(S) 10 (L) 1987
HaxarC!s .<1nd :precuations
ContrOI +tardwood·Dust •IND{S) :21 :(L) 1988
Noise le.vels ·can ;vaiy wldaly lrom . .ma<;hlna lo
nlt1'c)1iinO'"d<>pendlng -on •co11\llllOn:1 l,f i.ISS.
f'.B\¥iis sxposed <Ul'l)!Jlh '11Qla;e iavals; -e'l!an :for a
;;l!orf .Urns, :may nXpllrfence temporary -,partial
hearing '1Ps5 and ~nlinuous 'elq)OSUFB ic :high
1evei$.·c?JJ ':res~1i· ctn ,pQmian,mins.ari119 -damage.
TlieW~ng ,machines -~ulaucns require
,,)mployars lo ;take .reasona61.Y'-.practlcable
measures ·to reduce ,noise· levels <whem any
parson Is likely ic 'be exposed 'kl .a •conUnuoue
~qulvalant •noise level 1;1f 9D·dB(A) ·er rnore,•1;1ver
an ·8·ho~r worl<lng day. Addlllon11lly, lil.Ulf,able 'E!ar
pioiocton:·'must <ba -pn>vfded, ·maintained l!lnd
worn.
t\n•adi;iqu,;ileass.11ssment of likelynoise exposure
sliOulq 'be ~ad1nis!n1;1_,manurai:turers :date ·and If
nece8$aJY, :a noise ·s11r:vey should'be ~nistl out
by 'a ·'competent person. It •may,JJe naceSsary 1o
ainslruct a -suitable noise enclosum, In which
case professionaladvice should be .saughl
Machines Identified as.generating unhaaljhy noise
levels should be appropria!ely marked with a
warning rif the need to wear hearing protection
""d ;1 'may •b9 nacoooary 1c dea{gnato .partlcul"r
.areas ,of the workplace as "Ear pr:olectlons
:zones". Suitable waml119 signs .are i;pecifiad in
;the SafetySigns 'Regulations 1980.
Further Information and ,mfarsnce .are <:cntalned
Jn Iha :free Haallh and Safety ExecuUve leaflet -
Noise at Wcodworl<lng Machines IND(S) 22(l)
1!188.
][n order to protect the cutter block -1'
and spindle against failure of the
hydraulic pressure, safety drive
collars must be used. Failure to use
safety drive collars can result in
seizure of the cutter block on the
spindle in the event of the operator -I
failing to pressurise the cutter block
before running the spindle or failure
of the hydraulic pressure.

Wadkln
Ill _____ _
Note: Because of the modular contruciion of the XJS only the secilons relevent to each
machine are included. It is also not possible to cover all the options and customers special
requests that may have been added to thier machine. If you should require information not
contained within the manual please contact Wadkin at the address given on the front page.
SECTION 1
CONTENTS
OPERATING PRACTICES
General notes
Machine feed systems
NoiSe
Leading particulars
SECTION l! LIFTING AND TRANSPORTATION
SECTION 3
SECTION4
SECTION 5
Unloading
Moving
Unpacking
Cleaning
INSTALLATION
Major dimensions and weight
Locations and foundations
Suppl/es and services
GENERAL OPERATING INSTRUCTIONS
Safety
Safety drives
Warnings - before machining
-during machining
M achlne controls
Dial a size electronic positioning
99 Setting programmable memory positioning
HEAVY DUTY PUSH FEED MODULE
General
Adjusting infeed table height
Adjusting side. pressure
Bottom infeed roller adjustments
Top lnfeed roller adjustment
PAGE NO.
1-1
1-2
1-5
1-7
2-1
2-1
2·1
2-2
3-·J
3-1
3-1
4-1
4-1
4-1
4-2
4-3
4-4
4-7
5-1
5-1
5-·t
5-1
5-2

Wad kin
_______ Ill
CONTENT(cont)
SECTION 5 Maintenance
(cont)
Routine maintenance
Changing feed rolls
Replacing top teed rouer Shatt .bearings
Replacing bottom feed rollershalt bearings
Illustrated partslist
Bollom inleed rollers
Top infeed rollers
Pneumatic 'skid' type side pressure
Side roller pressure
Spring operated 'skid' type side pressure
SECTIONS BOTTOM HEAD MODULE
General
Bottom head vertical and horizontal adjuslmenl
Adjustment to top ond bottom through feed rollers
Adjustment to side pressure after bottom head
Mounting the cutterblocks
General
To change aculterblock
Maintenance
Routine maintenance
Vee belt drive tensioning
Replacing drive bells
Remove and refit of drive pulleys
Changing outboard bearing
Illustrated parts list
Bottom head rise and fall
Bottom head lateral adjustment
Pneumatic 'skid' type side pressure
Spring operated 'skid' type side pressure
Outboard bsaring -bottom head
SECTION 7 STAGGERED SIDE HEAD MODULE (300mm CENTRES)
General
Fe nee side head
Near side head
Near side head chipbreaker and side pressure
Side pressure opposite fence slde head
Top roller pressure - fence side head
Adjustment to top and bottom through feed rolls
PAGE NO.
5.3
5.3
5.4
5.5
5-11
5-13
5-15
5-17
5-19
6-1
6-1
6-2
6-2
6-5
6-6
6-9
6-9
6·10
6-10
6-11
6-19
6-21
6-23
6-25
6-27
7-1
7-1
7-2
7-3
7-3
7.4
7.4

Wad kin
Ill _____ ~-
SECTION7
(cont)
CONTENT(cont)
Mounting the cutterblocks
General
To change cutlerblocks on fence and near slde heads
Safety collars
Maintenance
Routine maintenance
Vee belt drive tensioning
Replacing vee bells
Illustrated pans llst
Fence side head carriage adjustments
Spindle barrel locks for fence and near side heads
Near side head carriage adjustment
Motor rise and fall for slde heads
Spring operated 'skid' type side pressure
Pneumatic operated 'skid' type side pressure
SECTION 8 CLOSE COUPLED STAGGERED SIDE HEAD MODULE (SOmm
CENIBES)
General
Fence side head
Near side head
Near side head chlpbreakar
Side pressure opposite fence side head
Top roller pressure - fence side head
Adjustment to top and bottom through feed rolls
Mounting the cutterblocl<s
General
To change cutterblocl<s on fence and near side heads
sarety collars
Maintenance
Routine maintenance
Vee belt drive tensioning
Replacing vee belts
Illustrated parts llst
Fence side head carriage adjustments
Spindle barrel locks for fence and near side- heads
Near side head carriage adjustment
Motor rise and fall for side heads
Spring operated 'skid' type side pressure
Pneumatic operated 'skid' type side pressure
7-5
7-6
7-6
7-9
7-10
7-10
7-13
7-17
7-19
7-23
7-25
7-27
8-1
8-1
8-2
B :l
8-3
8-4
8-4
8-5
8-5
8-6
8-9
8-10
8-10
8-13
8-17
8-19
8-23
8-25
8-27

Wad kin
-~----Ill
SECTION 9
CONTENT (cont)
TOP HEAD MODULE
General
Top head vertical and horizontal adjustment
Top head chipbreaKer and pad pressure
Adjustment to top and bottom through feed rollers
Mounting the cutterblocks
General
To change the cutlerblock
Malntenance
Routine maintenance
Vee belt drive tensioning
Replacing drive belts
Removal and refit of drive pulleys
Preparation prior to fitting bearings
Outboard bearing change top head
Outboard bearing housing removal
Illustrated parts list
Top head axial adjustment
Top head power rise and fall
Pad pressure aner top heao
Top head chipbreaker
Outboard bearing
PAGE NO.
9-1
9-1
9-3
9-3
9-5
9-5
9·9
9-10
9-10
9-11
9-12
9-12
9-13
9-17
9-19
9-23
9-25
9-29
SECTION 10 TOP HEAD/BOTTOM HEAD MODULE
~oo~ 1M
Top head vertical and horizontal adjustment 10-1
Top head chipbreaker.and pad pressure 10-3
Bollom head vertical and horizontal adjustment 1o-3
Adjustment to top and bottomthrough feed rollors 10-5
Adjustment to side guide 10-5
Mounting the cutterblocks
Gonoral 10·7
Cutterblock change to top and bottom heads 10-7
Maintenance
Routine maintenance 10-11
Vee belt tensioning 10-11
Replacing drive belts 10-12
Removal and refit of drive pulleys 10-13
Preparation prior to titting bearings 10-13
Outboard bearing change to top and bottom heads 10-14
Outboard bearing housing removal - top and bottom heads 10-16

Wad kin
Ill ______ _
CONTENT (cont)
SECTION 10 Illustrated parts llst PAGE NO.
{cont) Top head axial adjustment 10-19
Top head power rise and fall 10-21
Pad pressure after top head 10-25
Top head chlpbreaker 10-27
Outboard bgaring -top hoad 10-29
Bottom head axial adjustment
10-31
Bottom head rise and fall adjustment 10-33
Outboard bearing- bottom head'
10-35
SECTION 11
UNIT 'G' SPLITTING HEAD MODULE
General 1t-1
Replacing/setting saws
11-1
Vertical saw adjustment
11-1
Lateral saw adjustment 11-2
Anti-KicK oacK lingers 11-2
Adjustment to top pad pressure and riving knives 11-2
Machining permali, bedplate and top. pad· pressure 11-3
Side guide setting 11-3
Maintenance
Routine maintenance 11-5
Chanoino cutterblocks 11-5
Replacing and tensioning drive belts
11-7
Illustrated paris list
Spindlo unit ('V' bolt)
11-11
Spindle unit {timing belt) 11-13
Spindle rise and fall
11-15
Axial spindle adjustment' 11-17
Chain tensioner to axial spindle adjsulmenl 1
·1-19
Top pad pressure and riving knives 11-21
Anti-kick back fingers 11-23
Outboard bearing 11-25
SECTION 12
DRIVEN BED ROLLS AND TOP THROUGH FEED ROLLS
General
12-1
Setting driven bedrolls
12-1
Adjusting top through feed rolls
12-2
Maintenance
General
12-3
Changing top through feed rolls
12-3
Changing bedroll• 12-4
Preparation prior to fitting bearings
12-4
Bearing change to top through feed rolls
12-4
Bearing change to bed rolls
12-6

W~d.kln
______ Ill
CONTENT {cont)
SECTION 12 Illustrated parts list PAGE NO.
(cont) Intermediate bed roll 12,11
Shaft mounted feed roll
12~13
Flange mounted feed roll
12-15
SECTION 13 GEARBOXES AND DRIVE SHAFTS
General 13-1
Replacing feed roll drive shaft and coupling insert t3-1
Replacing ·drive ·belt to bottom feed rolls 13-1
Replacement of main teed drivebelt (hydraulic drive)
13-3
Tachometer belt replacement
13-3
Replacing chain drive to beam rise and fall 13-3
Illustratedparts llsl
Gearbox couplings 13-7
Hydraulic drive transler·to teed roll gearboxes 13-11
Belt Drive to ·bottom·feed :rolls
13-13
Drfva shafts io beam rlac. and 1o.ll
13·15
Baam:power:risa and·fall
13-17
Gear drive to bottom feed rolls 13-19
Direct hydraulic driveto teed mil gearboxes
13-21
SEC'TION 14 SPINDLES
General
14--1
::;p1no1e removal
14--1
Preparation priorto filling bearings 14-2
Changing cuttarblock spindle bearings 14-2
Illustrated parts llsl
Spindle 14-7
SECTION 15
BEDPLATES AND FENCES
General
15-1
lnfaed fanco removal and replacement 15·1
Intermediate and outleed fences
15-1
Bedplate removaUreplacement 15-2
Bed lubrication 15-2
SECTION 16
JOINTERS
Principia and practice
16-1
Straigh1 jointing
16-3
Profile jointing
16-3
Jointer - fence side head
16-4
Jointer - near side head
16-4
Jointer -top head
16-5
Jointer - second bottom head
16-6

Wad kin
Ill ______ _
CONTENT (cont)
SECTION 16 Maintenance PAGE NO.
(cont) General 16-7
Illustrated pans llst
Fence side head jointer 16-11
Near side head jointgr
10-15
Second bottom head jointer t6-17
Top head jointer 16-19
SECTION 17 HYDRAULIC DRIVE
General 17-1
Maintenance
General 17-3
Hydraulicfeed drive belt 17-3
Changing the pressure fluid 17-3
Changing the filter 17-3
Pressur&fluids 17-3
Fault finding procedure for pump and motor
17-5
Illustrated pans llst
Hydraullc drive unit
17-15
Hydraulic drive transferto feed roll gearboxes 17-17
Direct hydraulic drive to feed roll gearboxes 17-19
SECTION 18
GENERAL OPERATING AND WORKFAULTS
Common operating problems 16-1
Mechanical faults 18-3
Elimination of vibration 18-3
Electrical faults 18-3
General workpiece faults 18-9
Faults caused by tools 18-9
Faults in grinding and setting 18-9
SECTION 19
TABLES
Approved lubricants 19-1
Drive belt data
19-2
SECTION20 OPTIONAL EXTRAS
Throating neat:I
Setting and adjustment 20-1
Illustrated parts list
20-2
Univers::t.1 He3d
20-g

Wad kin
Ill _____ _
SECTION 1 GENERAL DESCRIPTION
OPERATING PRACTICE
General notes on all models of Wadkin
Planing and Moulding Machines
Aplaning and moul<ling machine produces planed
or moulded surfaces on all four sides of lengths of
timber, both hard and softwood, at feed speeds
determined by the cutterequipment and quality of
surface finish requried.
A series of'ridges' (cuttermarks) Is created on 1he
surface of the timber as II is moved past a rotating
cutterblock (see Fig 1). The quality of surface
finish Is determined by the numberotknife marks
per 25mm (1 ") (the pitch of the cuttermarks). The
closer the pitc.h thA Mtter the qualfty of surface
finish.
FIG 1
From experience a good qualitysurface flnish has
knife """"" al a pltoh or 1.C! to 2mm. Reduelng
the pitch Improves 1he surface finish but Increases
the wear on the cutters, increasing the pltcll
reduces the quality.
The number of cutter knives In a cutterblock will
only ba effective. when all are rotating In, precisely
the same culflng circle. TWo main faclors
influence this.
a. The fit of the cutterblock on the spindle
b. The concentricity of grinding
The conventional method of mounting a
cutterblock Is lo lock a plain bore block on to a
plain ground oplndle with a locknut. The
tolerances In each component give a possible
0.05mm (0.002") clearance in the bore and thus
eccentric running (see Fig 2).
FIG2
The Wadkln hydrolix locking system eliminates
this clearance by pressurising the bore of the
curcert>loelc onto: the spindle (sea Fig 3).
Axial locking is not required end a simple safety
collar is, recommended.to prevent !he cutterlllack
moving. axially,, or rotating on: the spindle, if the
hydraulic pressure is not applied.
FIG 3
'
-'
l'r•J!;.;,1
1
~
i-
- -.-----·-----1·-f-&-
l~ + i H t~ft.::
- i
Because the Hydrofix Jocking is also used while
the knives In 1he cutterblock are ground in Iha
toolroom, it can be seen that the high accuracy of
Ille grinding process. is transferred direclly to the
planing and moulding machine. This accuracy,
together with the true running of the precls:ion
spindle oflhe moulder, reduces the running of the
knives to within 0.002 to 0.005mm of the true
cutting cin:le. However, this minimum run-out is
still such that only ono knife leaves a finishing cut,
no matter how many are in the block.
To ensure that all the knives in acutterblack run in
an abwlutely true cutung circle, tne tecnique of
jointing Is used, In which the jointing 'stone' trues
all 1he knives while rotating atcutting speed in the
planing and moulding machine (see Fig 4).
1-1

Wadkln
OPERATING PRACTICES Ill
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FIG<
It can be seen that for a given spindle speed and
quality of surface finish (pitch of knife marks), the
feed speed may be increased in direct relationship
to the number of knives in the cutterblock.
Cuttermar1< pitch ~ Feed speed in mm per min
Bloc!{ rpm x No of cutters
For example
12 ~ 1000
6000 x 1 = 2m pitch
for a spindle running at 6000 rpm and a feed
opggd of 12m/mln and.unjolnlod (1 knifo finishing)
Jointing a 4 knife block .and Increasing the feed
speed to (4x12) ie: 48M/mln gives the same
reoultin9 pitch (finish).
Jointing can be carried out on stralght planing
blocks -'straight' jointing, and on profile blocks -
'plunge' jointing.
The process of jointing, which can be repeated
several limes, produces a heel on the knives. In
the interests of quality this must not be allowed to
exceed a certain width. This is approx O.Smm on
softwood and 0.7mm on hardwood (see Fig 5).
fl(i 5
Both high speed steel and carbide knives may be
jointgd but rGquim a difforont oompoaition of
jointing stone.
An alternative method of Increasing output Is to
lncrea:5e the splndle speed thus permlttlng a
faster feed speed for a given quality of surface
fini~h. 'W~dkln' can offor altem~Uve spindle
speeds up lo a maximum of 15000 rpm. This
highest spindle speed, achieved with very high
precision, lubricated for life bearings, permits a
2 1/2 x (250%) increaoe in output without jolnUng.
Typical surface finish pitch values for different
applications are listed:
Sawmilling
Joinery
Strip moulding
Furniture
1.5 to 2.5mm
1 .5 to 2.0mm
1.3 to 2.0mm
1.0 to 1.Smm
Machine Feed Systems
Push Feed (Fig 6)
This original method of feeding a planing and
moulding machine is still pro\l:idad, and consists of
two top driven and two opposed bottom driven
feed rolls at Iha infeed end of the machine. An
idle roller and pad pressures between the
clJffiarh9adG controls tho timbor down to the bed
and across to the fence as it passes through the
machine. It follows that if bowed or twisted stock
is fed lo the cutters, that while a perfect profile will
be produced1 the component will be as twisted or
bowed as it entered.
·€)· 83· ·--.-~·.
ElJ-·. EB· ·r ··· ---
. . l .
'
FIG 6
The pushfeed machine has the disadvantage that
the last -piece of timber Is alW41Y~ left Jn th.a
machine; traction stops .as 1he trailing end ·1eaves
the feedworks. The last piece can only be
retrieved by following with a scrap length or by
reverse feeding, In which case the component is
unfinished.

Wadkln
'I' OPERATING PRACTICES
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Through feed (fig 7)
Through food Wa9 developed to overcomo the-
handicap of lhe last piece remaining in cut, an<tto
eliminate the heavy top and side pressures.
Drtve rolls belWeen eacn cutterhead feed the
components through the machine.
MG7
A long lnfeed table before the first bottom head,
together with the much lighter loading on the
timbar, enables stni:lghtaning of the componenlfa:
the underside being. straightened·(surfacad) at the
first bottom head, and the adg.e (fenceside} being
straightened at he first side·head: (see. Fig B).
FIG 8
An alternative method of straightening combines
underside and fenca side straightening, using a
single cutterblock, planing the underside In the
normal way and machining a referenc::a edge with
a rebating disc on the. same block (see Fig 9).
FICO
The abov<> straightening lechniques are· most
successful on tlmbe• which is. bowed and has
oquar<> ends,. lyplcal or sonwood. For timber
which Is lwistad and· has out-<if-square ends,
typical of some hardwoods, an alternative
technique is provided.
Groovedbed straightening (Fig 10)
In this design, grooving cuttera on the first bottom
head pennit support in the fonn of rails right
through. thacut. lhus preventlng· 'dipping in' on the
twisted;timberi or 'buckling' as out-of;.square: ends
come into contact wiUl. each· other. The, arnoves
on the· undersideare. subsequently machined out
on a second bottom head, which is obligatory.
Fitung a standard lip plate. and· cullarblocl<
converts. th9 machine; to ccnvantioncl u.::ie.
FIG 10
Hopper Feeding (Fig 11)
Ta enableth1>operator to feed timber at relatively
fu.st feed speeds and ~till maintain butt' up, (U1is
may be difficult on shortlengths), various types of
hopperfeed: are available.
fIGll
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1-4
Wad II In
OPERATING PRACTICES Ill
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Components are stacked in a hopper at the lnfeed
end ofthe mai:::hlne and automatic.ally fed onA at a
time from the bottom ·of the stack at a rate to
ensure 'butt-up'. A ·slipping device ·prevents the
hopper ieed trying to overide 1he machine feed.
Feeding at very high feed speeds, typically on
flooring, cladding etc, also presents problems to
the operator, again a special feeding device (fast
feed table Fig 12) can be provided.
The fast feed ·fable, in line with the machine feed,
receives timber from a tilt hoist and cross chains,
the driven rollers In the fast .reed 1able and an
overhead hydraulically driven nip roll ensure 'butt
up' before entry into the machine ·feedworl<s, a
slipping arrangement prevents overiding.
FIGU
Outfeed Equipment
Generally used on hlghfeed speed machines, this
equipment can be provided at the outfeed end of
'Wadkin' moulders to transferto another process,
le: stack, bundle, wrap, count, etc. Oul!eed
equipment can be provided and programmed to
print on each. component some identifying
infomiatlon. eg. Job No. Date, etc. Combinations
ofthese facilities enable the ·finished components
to be pressented In a variety of ways at the
outfeed ·end of the machine.
Extra Head Positions
Typically a planing and moulding machine has
four hgads; to machine all four faces, thoso can bo
augmented with the add!Don of other heads. The
mast common is a second bottom head to ensure
clean up an the underside. Where the amount of
1imberto be ren1oved i.s great, or wh~re ·the mould
detail is complex It may be necessary to provide
an extra bottom hgad, available a~ :;in option.
Splitting (Fig 13)
Splitting is a common operation, usually done o
the last ·bottom head, and often requiring very
large horse j)OWers. Such a head is avallable and
-may be fitted with anti kick-back fingers to prevent
ejec:ilan toward~ the uperalor. Only one saw can
be fitted on the smaller machines, ie. GC.
FlG 13
Universal Head
A universal head, either three or four position
(always last head on the machine) can be
provided to order, or the machine prepared to fit
the head at a laterdate. Ihe three position head
may be used as a top head, bottom head or near
side head and at anyangularposition in between.
The four position head has the added capability of
use as a fence side head.
The universal head gives greater flexibility ror
spllttlng and moulding on a conventional machine,
and special pressures, chipbreakers, etc can be
provided to ensure perfect control of the
workpiece.
Dial-a-Size Positioning (Fig 14)
On machines which are used for a large variety of
sm:ill qu:intlty b.o.tohoc; of equaro droGccd
matertal, the set up time can be reduced by
fitting Dlal-a-51ze positioning.
FIG 14

Wadkln
'I' OPERATING PRACTICES
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The near side head horizontal adjustment is
motorised and fitted with an ecoder, the
motorised vertical movement of the top head
and feed Is also fitted with an encoder.
A programmable memory stores the widths and
thicknesses of the worf<pieces to be produced,
and on command the two heads are repositioned
to the preset dimensions. In a similar manner,
where components of random width are machined
(eg. Table tops, see Fig 15)
The machine can be arranged to sense the width
of the incoming pieces and automatically move
the outside head to the required position.
Whilst being a slow operaHon, (butt feeding is not
possible and the feed speed Is slow), the facility
does have great ad\lantage to some users.
FTG 15
Feed Enhancement
The 'Wadkin' push feed and through feed systems
are the result ofyears of experience In the planing
and moulding industry, and for the great majority
of work aro exemplary. However1 the great
vartety of Umbers available, and the different
conditions In which they are presented to the
machine Is acknowledged In Iha various options
avallable to tn1hance raedtng and minimise bed
wear.
Bed lubrication
A lubricant Is Introduced to the surfaoe of the
machine bed, from a manual or auto pump; this
reduces friction, Improves feeding capability and
reduces bed wear.
An alternative; of introducing alr between the
limber and the bed of the machine, can be
prollided for those machines that do not have a
second bottom head to machine off the small
amount of oil introduced to the underside of the
limber, or where tho motorlal being machined
must not Jn any circumstances be contaminated
with. oil.
Feed rolls
The top driven feed rolls of a through foad
moulder are normally spring loaded down onto
the workpiece. The required amount of load can
vary with the nature of the work being run,
although as a general rule It must be as light as
practicable, and variation in rough timber
thickness will of course increase the load as the
feed rolls yield more. Adjustment of the loading is
done at each Individual roll.
Pneumatic loading can be provided; this has a
number of advantages. The loading.does not vary
With.any vaMatlon In lift, am:t the amount of loading
can be changed more easily, using an air
regulator valve.
One regulator controls the loading to rolls before
the lop head, and the other regulator controls the
rolls after lo top head.
Noise
Planing and moulding machines,by llirlue of the
number of cutter heads and the speed of the
heads, produce high noise levels, typically
between 95d8 and 115dB when cutting.
The woodworking machine regulations require
that an operator Is not to be subjected to noise
levels above 90dBA for 8: houra, oomc
precautions are therefore requried and a safety/
acousUc cover can be supplied for this purpose.
It should be noted howevt:1r, that even with a
sound enclosure, under some circumstances,
because of 'break our (al say the lnfeed end),
the noise level al the operating positions will be
above so d8A.
For personal safety reasons the operator should
wear ear defenders.
WARNING Before operating the machine read the
Preface and Notice to Operators In section 3,
Operating Instructions.
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