Wadkin CK90 User manual

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CK90
HIGH SPEED
.· CROSS-CUT SAW
· M/CNo
TEST No
. INSTRUCTION MANUAL

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EC TYPE EXAMINATION CERTIFICATE
This is to certify that
Lloyd's Register of Shipping, an Approved Body under the tern is of;
The Machinery Directive 89/392/EEC as amended by Directive 91/368/EEC.
The Supply of Ma.clzinery !Safety) Regzzlations 1992, Statutory bzstnzment 1992 No. 3073
did undertake an EC Type Exa11z-i11atio1I on the stated product for compliance with t!ze essential safety
requirements of the Directive. The product identified beloiv rvas shoiun to comply.
This certificate is issued to
APPLICANT
PRODUCT
DESCRIPTION
TYPE
WadkinPLC
Green LaneRoad
Leicester, LE5 4PF
England
HighSpeed Cross-Cut Saw
CK90
The attached LR Design Appraisal Document No. EC95/00011 details the content of the Technical
Constniction File and shall form a part of this certificate.
Certificate No.
Date of Issue
Sheet
EC95/00011 .
12 April 1995
1 ofl
Lloyd's Register of Shipping
71 Fenchurch Street, London EC3M 485
LR EC Distinguishing Number 0038
NOTICE-This certificate is subject to the terms and conditions overleaf
RE. Rayner

ENGINEERING SERVICES
29 Welleslei; Road, Croydon CRO 2AJ
Telepltone 0181-6814040 Fax [phone] Telex 28636
Pog•
1 3
of
0ocum,., n"rl'.95 I00011
Issue number
1
DESIGN APPRAISAL DOCUMENT
Date
12 April1995 Quote
this reference on all future communlcations
TAI 41169/70851/95/RER
LLOYD'S REGISTER EC EXAMINATION CERTIFICATE.
Type:
Capacity:
Manufacturedby:
WADKINPLC
CK90 HIGH SPEED CROSS-CUT SAW
CERTIFICATE NO. EC95/00011
DATA
CK90
Table size:
Cutting capacity:
Spindle speed:
WadkinPLC
GreenLane Road
Leicester, LES 4PF
England
640mm x 850mm
305mm x 100mm
2200rpm
Specified
Standards: BSEN 292
1/2;
EN 60204-1; BSEN 294; ISO
7957-1987;
BS 308 and ISO 7960
The undemoted documents have been reviewed_ for compliance with the Essential
Health and Safety Requirements ofthe Machinery Directive.
TECHNICAL CONSTRUCTION FILE
Request for LR Product Certificationto EC Directives
CK90 Foundation plan -LH, Drawing No. BG51007
CK90 Foundation plan c RH, Drawing No. BG51008
CK90 Layout, Drawing No. CK90
CK90 Electrical Circuit, Drawing No. D6692
Essential Safety Requirement Cross Refermce Document (CK90)
Checklist document againstCEN/TC142/WG4 Part 3
Wadkins internal check sheet, Issue D
CK90 MainBody Assembly, Drawing No. BGSlOOO
Saw Main Frame- LH, Drawing No.11/M13
Spindle Cover, DrawingNo. 16/M13
Side Cover, Drawing No. 18/M13
Saw AccessPlate, Drawing No. 22/M13
13.12.1994
09.03.1995
09.03.1995
15.03.1995
16.03.1995
07.03.1995
12.09.1994
05.09.1994
10.09.1994
21.04.1994
09.09.1994
FINAL ACCEPTANCE OF ACTUAL ITTM(SJ DEPEND(S) ON SATISFACTORY SURVEY AND TESTING
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ENGINEERINGSERVICES
29 Wellesley Road, Croydon CRO 2AJ
Telephone [phone] Fax [phone] Telex 28636
Page · 3 3
of
Dooumont ""lfC95/ 00011
Issue number
1
DESIGN APPRAISAL DOCUMENT
Date
12 April1995 Quote this reference
on all future communications
· T.A/41169/70851/95/RER
LLOYD'S REGISTER EC EXAMINATION CERTIFICATE.
WADKINPLC
CK90 HIGH SPEED CROSS-CUT SAW
CERTIFICATE NO. EC95/00011
TECHNICAL CONSTRUCTION FILE (Cont'd)
CK90 High Speed Cross-CutSaw Instruction Manual No. 3033
SGS Certificate No. 92/1233 (ISO 9000 Certification)
Wadkin Pk SampleDeclaration of Conformity
LR Machinery Directive ESR Check Sheet
TEST REPORTS
Wadkin Sound Pressure Level Measurement Points
Drawing No. GA11193
Sound Level TestingData for CK90 Machine
WadkinsTestProcedureDocumentfor CK Machines
LR Inspection ReportNo. BHM 410831/3
R.E. Rayner
Type ApprovalDepartment, Extn. 4895
TL
30.09.1992
24.03.1995
16.03.1995
16.03.1995
April1995
FL'IAL ACCEPTA:'-:CE OF ACTUAL ITEM(Sl DEPEND(S) ON SATISFACTORY SURVEY AND TESTING
NOTICE: This document is subject to the terms and conditions overleaf, \Vhich form part of this document.

ENGINEERING SERVICES
29 Wellesletj Road, Croydon CRO 2AJ
Telephone [phone] Fax [phone] Telex 28636
DESIGN APPRAISAL DOCUMENT
Oat,
Page
2 3
of
Docum•nt nu'J'fl'.95 / 00011
Issue number
1
12 April1995
Quote this reference on all future communications
TA/41169/70851/95/RER
LLOYD'S REGISTER EC EXAMINATION CERTIFICATE.
WADKINPLC
CK90HIGHSPEED CROSS-CUT SAW
CERTIFICATE NO. EC95/00011
TECHNICAL CONSTRUCTION FILE (Cont'd)
AccessPlate Strip, Drawing No. 31 /M13
Rotation Label- LH, Drawing No. BG463
SawAccess Cover, Drawing No. BG472
Saw Mainframe- RH, Drawing No. 45 /Ml3
Rotation Label-RH, Drawing No. BG464
Table Insert (LH) Drawing No_ KKS103
Table Insert (RH) Drawing No. KKS 104
OutfeedTable Assembly Drawing No. BG51005
CK Roller Table Leg, Drawing No. 2/M13
CK90 Drive and Spindle Assembly Drawing No. BG51001
LH CKCrosscut Spindle Sub-Assembly Drawing No. BG468
LH SawSpindle, Drawing No. BG465
RearSaw Flange CK, Drawing No. BG471
FrontSaw Flange CK, Drawing No. BG470
Saw Spindle Nut, Drawing No. BRA44
RH CK CrosscutSpindle Sub-Assembly Drawing No. BG469
RH Saw Spindle Drawing No. BG466
Saw Spindle Nut RH Drawing No. BG467
Top Oamp and Trim Stop Assembly Drawing No. BG51004
TrimStop Pad Drawing No. KKSlOl
Trim Stop Pad Drawing No. KKS102
TableFence Drawing No. 52/M13
Infeed/Outfeed Guard- LH, Drawing No. BG477
Infeed/Outfeed Guard- RH DrawingNo. BG478
Sawguard Clamp Assembly Drawing No. BG51002
Clamp Pad Drawing No. KKS105
Sawguard Clamp Drawing No. 118 /Ml3
Sawguard Clamp (RH) Drawing No. 119 /M13
Top Clamp Pad (RH) Drawing No. KKS106
Push Stick Drawing No. BG292
CK90 Pneumatic CircuitDrawing No. BG51003
. WadkinPie Standard Listing
09.09.1994
02.03.1995
07.03.1995
04.10.1994
02.03.1995
10.08.1994
04.10.1994
07.03.1995
08.03.1995
20:09.1994
03.03.1995
03.03.1995
. 06.03.1995
06.03.1995
12.05.1994
06.03.1995
03.03.1995
03.03.1995
27.02.1995
01.09.1994
04.10.1994
10.08.1994
10.03.1995
15.03.1995
28.09.1994
10.09.1994
19.05.1994
16.04.1994
04.10.1994
21.07.1994
20.01.1995
FINAL ACCEPTAl>:CE OF ACTUAL ITTM(SJ DEPEND(SJ ON SATISFACTORY SURVEY AND TESTING
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MANUFACTURERS E.C. DECLARATION OFCONFORMITY
. The following machine has undergone "Conformity Assessment" and is "self"
certificated 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 Lott (Managing Director)
MACHINEDESCRIPTION
TYPE
MODEL
CROSS CUT SAW
CK90
DIRECTIVES COMPLIED WITH
Supply of Machinery (Safety) Regulations 1992
Amendment No. 2063 1994
Draught Proposal CEN/TC 142
ISO 9001 Part 1
SIGNED ON BEHALF OF WADKIN LTD
. (//
..................... d.~ ............................... .

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PREFACE
IMPORTANT
It is our policy and that of our suppliers to constantly review
the design ana capacity of our products. With this in mind we
would remind. our customers that while the dimensions and
performance data contained herein are correct at the time of
going to press1 it is possible that due to the incorporation of
the latest deve opments to enhance performance, dimensions
and suppliers may vary from those illustrated.
This manual is written as a general guide. A typical machine
is shown to illustrate the mam features. For reason of clarity
certain guards, safety devices and machinef arts may not be
shown on particular illustrations but MUS be fixed to the
machine, correctly set and working before operating
Failure to comP.IY with instructions in this manual may
· ·invalidate the guarantee.

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BE CAREFUL
THIS MACHINE CAN BE DANGEROUS
IF IMPROPERLY USED
Always use guards.
Keep clear until rotation has ceased.
Always operate as instructed
and in accordance with good practice.
Read instruction manual before installing
operating or maintaining machine.
Manufactured by:- WADK/N PLC
Green Lane Road
Leicester
LES
4PF
England
phone no :-0116 2769111
fax
no :-0116 274231O
NAllDll.l.t
Attl!EDIT..UIO/i
Of ClR!IHC.1.11011
SGDIES
CE

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HEAL TH AND SAFETY
The CE mark on 1his machine signifies that an
EC declaration of confonnity is drawn up
indicating that the machine is manufactured in
accordance with the Essential Health and
Safety Requirements of the 'Supply of
Machinery (Safety) Regulations 1992'.
The 'requirements for supply of relevant
machinery' in the General Requirement of the.
Regulations are not only that the machine
satisfies the .relevant essential health and
safety requirements, but also that ~he
manufacture......carries out the necessary
research or tests on components, titting.s or
the complete machine. to determine whether
by its design or construction the machine is
capable of being erected and put into service
safely'.
Persons who install this machine have duties
under 1he 'Provision and Use of Work
Equipment Regulations 1.992'. An indication of
1hese duties is given in the following extracts,
but the user should be familiar with 1he full
implications of the regulations.
REGULATION 5 requires that;
Every employer shall ensure 1hat work
equipmenl is so constructed or adapted as to
be suilable for 1he purpose for which it is used
or provided.
In selecting work equipment, every·employer
shall have regard to the working conditions
and tothe risks to health and safety of persons
which exist in the premises or undertakings in
which that work equipment is to be used and
any additional risk posed by the use of that
work equipment.
Every employer shall ensure that work
equipment is used only for the operations for
which, and under conditions for which, it is
suitable.
In this regulation 'suitable' means suitable in
any respect which It is reasonably foreseeable
will affect heatth orsafety of any person.
The Provision and Use of Work Equipment
Regulations also include requirements as
follows:-
regulation 6 - maintenance
regulation 7 - specific risks
regulation 8 -. information and instructions
regulation 9 -1raining
Note:-
Attention is drawn to those requirements of the
'Woodworking Machines Regulations 1974'
which are not replaced by the Supply of
Machinery (Saf.ety) Regulations or other, eg.;
Regulation 13 of the Woodworking. Machinery
Regulation, -'Training', still applies.
Whilst the prime duty for ensuring health and
safety rests wtth employers, employees too
have legal duties, particularty undersections 7
and 8 of the Health and Safety at Work Act.
They include:
Taking reasonable care for their own health
and safety and 1hat of others who may be
affected by what they do or don't do;
co-operating wtth their employer on health and
safety;
nol intertering with or misusing anything
provided for their health, safety andwettare.
These duties on employees have been
supplemented by regulation 12 of the
Management of Health and Safety at Work
Regulations 1992. One of the new
requirements is that employees should use
correctly all work ttems provided by their
employer in accordance with their training and
the instructions they receive to enable them to
use the items·safely.

Noise
Noise levels can vary widely from machine to
machine depending on the conditions of use.
Persons exposed io high noise levels, even for
a short time, may experience temporary partial
hearing loss and continuous exposure to high
levels can resull in permanent hearing
damage.
The Noise at Work Regulations 1989 place
legal duties on employers to prevent damage
to·hearing.
There are three action levels of noise defined
in regulation 2;
The firs! action level;-
a daily personal noise exposure (lEP.•) of
85dB(A)
The second action level;-
a daily personal noise exposure (LEP.•) of
90dB(A)
Thepeak action level
a peak sound pressure of 200 pascals (140dB
re 20pa)
The exposure level is obviously influenced by
the emission level of all the equipment in'u·se. ··
Emissions levels for machines are provided in
theparticular machine instruction ma.nual.
These levels are measured ·in accordance with
ISO 7960 under certain specified test
conditions, they do not necessarily represent
the highest noise level, which is influenced by
many iactors, eg number of spindles in
operation, type and condition of work piece,
spindle speeds etc.
For regulations and information on relevant
personal protective. equipmenl i.e ear
defenders, employers should refer to the
Personal Protective Equipment at Work
Regulations 1992.
Dust
Wood dust can be . harmful to health by
inhalation and skin contact and concentrations
of small particles in the air can folTTl an
explosive mixture.
The Control of Substances Hazardous to
Health Regulations (COSHH) 1989 place legal
duties on employers to ensure that;-
the exposure of his employees to substances
hazardous to health is either Prevented or,
where this is not reasonably practicable,
adequately controlled.
.....adequate control to exposure of employees
to a substance hazardous to health shall be
secured by measures other than the provision
of personal protective equipment.
where the measures taken in accordance with
the paragraph above do nol prevent or provide
adequale control of, exposure to substances
hazardous to the health of employees, then in
addition to tacking those methods, the
employer shall provide those employees with
such suitable personal protective equipmenl
as will adequately control 1heir exposure to
substances hazardous to health.
.Instructions for Use
Machinery manufactures are .required by the
Supply of Machinery Safety Regulations to
provide comprehensive "Instructions for Use·
of equipment, it is important that this
info1TT1ation is transmitted to the person using
the machine.
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IMPORTANT
SAFETY PROCEDURES AND CONSIDERATIONS
To ensure safe working conditions, persons operating and assisting with the
operation of this machine mustensure thatthey read andfully understand the_
instructions given within this manual. and have received sufficient training. inthe use
of the machine and the safety aspects to be observed.
Note;- Persons underthe age of 18 years must not operate-the machine except
during the course of training underthe supervision 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 sate guardings are in position and are functional.
3)
4)
Cutters/blades are the correct type, suitable for the machine and working
conditions, rotate in the correct direction ol cut, are sharp and correctly fitted.
Loose clothing is either removed or securely fastened back and jewellery
removed.
5) Adequate working space and lighting is provided.
6) All dust extraction equipment is switched on, properly adjusted and working
adequately.
7) The machine is securely installed (refer to instaltation section within this
manual).
8} The machine should only be used for cutting wood or materials with physical
and technological characteristics similar to wood, and for which the chip or
particle removal process is similar.

B) DURING MACHINING:-
1)
2)
Wear suitable protective clothing e.g, approved eye protection, ear defenders
and dustmasks. Gloves shall be worn when handling sharp edge saws.
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 from wood refuse. Do
not allowthe flooraround :the machine to be come slippery.
4) Stop the machine and report immediately to a person in authority any actual or
·potential·malfunction or operator hazard. Do not attempt to repair or reGtify the
machine unless qualified or authorised to do so.
5) The operator must not leave the machine running whilst unattended.
6) Neverby"pass interlocks.
7) A push stick or handled push block must be used to feed the trailing edge of a
workpiece pastthe cutting blade. · ·
WARNING:-
Failure to observe correct operating procedures prior to and during operation of
ihis machine can result in severe injury. · . ·
DO NOT attempt to operate the machine while ·under the influence of anything
that reduces your alertness.
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SECTION 1
SECTION2
SECTION 3
SECTION4
CONTENTS
GENERAL INFORMATION
General Description
Foundation and Machine Dimensions
Noise Emission Values
Page
1-1
1-1
1-2
Machine criteria 1-2
Machine cutting criteria 1-2
Tooling criteria 1-2
Operator Working Stations 1-3
Machine Specifications 1-5
Electrical Wiring Diagrams 1-7
UNLOADING, UNPACKING, AND INSTALLATION
Unloading
Unpacking
Cleaning
Location and foundation
Machine re-assembly
Supplies and Services
Electrical supply
Exhaust connections
OPERATING INSTRUCTIONS
Safety and Safety Devices
Before operating the machine
During machining
Machine Controls
Typical Machine Operation Cycle
Trim Stop Adjustment
MAINTENANCE
2-1
2-1
2-1
2-1
2-2
2-2
2-3
3-1
3-1
3-1
3-2
3-3
3-4
Scheduled Maintenance 4-1
Weekly 4-1
Monthly 4-1
Yearly 4-1
Two yearly 4-1
Tensioning/Replacing Motor Drive Belts 4-2
Tensioning/Replacing Saw Spindle Drive Belts 4-2
Air Filter and Lubricator Maintenance 4-2
Changing Saw Blades 4-3
Approved Lubricants 4-5

SECTION 5
,/
ILLUSTRATED PARTS LIST
Main Body Assembly
Drive and Spindle Assembly
Top Clamp Assembly
Trim Stop Assembly
Saw Clamp Assembly
Outfeed Table Assembly
Pneumatic Assembly
5-3
5-5
5-7
5-9
5-11
5-13
5-15
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SECTION 1 GENERAL INFORMATION
General Description
The CK machine is a high speed cross
cut saw capable of cutting timber
sections up to 305mm x 1 OOmm.
Timber may be manually or machine
fed into the saw. To ensure the correct
lengths of material are cut a variety of
options are available. These. include
automatic stop systems as well as
manual and pneumatic stops. Once at
the correct cut setting the top guard
clamp is automatically lowered down
as part of the operating sequence and
holds the timber· whilst the saw is
cutting. When the operating sequence
is finished the clamp is released ready
for the timber to be moved to the next
cut position.
The CK90 crosscut saw may be
supplied in either a right hand or left
hand version. The Jett hand version
has the saw blade and outfeed rolle.r
table to the left of the machine. when
viewed from the front, with timber
being feed from the. right. A right
handed machine. is the mirror image of
this. The working area indicated inthe
illustration is for the standard machine
although this may alterif optio'nal roller
tables are fittedandthe machine isstill
maned by a single person.
4 98.5 480
6 HOLES DIAMETER 16
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500
640
FIG 1 FOUNDATION PLAN OF A LEFT HAND MACHINE
DIRECTIOI'< OF
TIMBER FEED
--
1-1

l-2
NOISE EMISSION VALUES
The figures quoted in the noise
emission chart are emission levels and
are not necessarily safe working
.levels.
Whilst there is a correlation between
emission levels and exposure levels ,
this cannot be used reliably to
determine whether or not further
precautions are required to achieve
.safe working levels.
·Factors that influence the actual level
of exposure to the work force include
the duration of exposure, the
characteristics of the work room,
sources of noise etc i.e the number of
machines and other adjacent
processes. Also the permissible
exposure levels can Vary from country.
to country.
Emission levels, however will enable
the user of the machine to make a
better evaluation of the 'hazard and
risk'.
Machine criteria
The machine was free standing on a
concrete floor, not bolted down and not
mounted on any vibration dampening.
A flexible pipe connected the machine
to the dust extraction.
There was no enclosure around the
machine.
Machine cutting criteria
The machine was fitted with a 500mm
main saw rotating at 2200 R.P.M. The
saw blade had 72 carbide tipped teeth
and a cutting width of 4mm.
Feed rate:- 4-8 M/min
Material criteria
Material :- Softwood medium
grade
Moisture content:- 8-14%
Timber size:- 16mm
Timber length:- 1 OOOmm cut once to
500mm
Preliminary machining:- none
. Tooling criteria
The CK90 crosscut saw has been
designed to accept only 500mm
diameter saw blades suitable to fit on a
30mm spindle.
The saw must have a 'pin hole' drive
location.
The saw speed is fixed at 2200 R.P.M.
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Only tools made in conformity to pr
EN847-1 shall be used on the
machine.
It should also be noted that H.S.S
saw blades may be prohibited by
law in certain countries and the
operator should ascertain the
position on this point.
FIG APPROXIMATE WORKING AREA
FOR A LEFT HAND MACHINE
1-3

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MACHINE SPECIFICATION
Usable saw diameter
Saw location
Maximum timber capacity
Table size ·
Table height
Drive motor (standard)
(optional)
Spindle speed
Spindle diameter
Weight
500mm
14mm pin hole at 30mm centre
305mm x 1 OOmm
640mm x 850mm
914mm
5.5Kw (7.5h.p)
7.5Kw (1 Oh.p}
2200 r.p.m
30mm
365Kg
1-5

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ELECTRICAL DrAGRAM
1-7

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SECTION 2 INSTALLATION
Unloading (Fig 1)
Ensure that all lifting equipment used
is capable of lifting the weight of the
machine as a minimum. Refer to
Specifications (Section 1) for machine
weight.
To lift, place a sling either side of the
machine, passing under the
overhanging table and as close to the
main body as possible. Slowly lift the
machine ensurrng it does not tilt and
slings are not slipping.
Alternatively the machine is bolted to
two wooden spacer blocks to allow a
forklift truck to be used.
WARNING DO NOT WALK OR
STAND UNDERNEATH A SLUNG
MACHINE.
FIG1 LIFTING MACHINE
Unpacking
Remove ttie packaging from a11 the
items and ensure that no damage has
occurred during transit.
The wooden spacer blocks secured to
the bottom al the machine must also.
be removed.
Ascertain that the machine is complete
with all fittings, requested accessories
and tool kit. On a standard CK the
outfeed roller table and the wire safety
cage are packed separately to the
main machine.
Contents of standard tool kit:-
Open ended spanner 46mm NF
8mm Long arm Allen key
Push stick (C.E machines only)
General purpose 500mm diametersaw
Cleaning
Before levelling the machine remove
the anti-rust material particularly from
the bright areas. This may be
accomplished using a clean soft rag
soaked fn paraffin. DO NOT use a
substitute as it may participate an
explosion.
Location and Foundation
The machine should be so placed that
the traffic of persons and materials to
and from the saw fits smoothly into the
general work flow. It should not be
sited such that the operator is placed
in a possible hazardous position.
Adequate ctearance around the
machine should be provided to cater
for intended workpieces.
To obtain the best results frorn the
Wadkin machine it is important that
the floor on which the machine is to
stand has been levelled and is dry.
2-1