Weinig PowerLock 536 User manual

Englisch / English WNW 850 02 – 02.2005.A
Instruction Manual
Weinig Tools

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 1-3
Summary

1-4 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
Michael Weinig Aktiengesellschaft
Weinigstrasse 2/4
D-97941 Tauberbischofsheim
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.weinig.com
Service in my Country: www.weinig.com
Service

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 1-5
1 Safety .......................................... 1-7
1.1 Intended use ................................ 1-7
1.2 General safety instructions ........... 1-7
1.3 Tools and machine ....................... 1-8
2 PowerLock .................................. 2-1
2.1 Weinig PowerLock 536 ................ 2-2
2.2 Weinig PowerLock 538 ................ 2-5
2.3 Weinig PowerLock 539 .............. 2-10
3 Normal clamping ........................ 3-1
3.1 Hydraulic spindle nut (optional) .... 3-1
3.2 Weinig Centrolock 530 ................. 3-3
3.3 Weinig Centrolock 533 ................. 3-6
3.4 Weinig cutterhead 500 / 510 ...... 3-11
3.5 Weinig profile cutterhead
503 / 513 .................................... 3-15
3.6 Weinig tongue and groove
cutterhead 508 / 518 .................. 3-20
4 Hydraulic clamping .................... 4-1
4.1 Weinig Centrolock 534 ................. 4-1
4.2 Weinig hydro cutterhead
501 / 511
and Rotaplan cutterhead
502 / 512 ...................................... 4-9
4.3 Weinig hydro profile cutterhead
504 / 514 .................................... 4-12
4.4 Weinig hydro cutterhead
508 / 518 .................................... 4-17
Contents

1-6 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
This manual applies exclusively for Weinig tools.
Further information, technical data and ordering data concerning the Weinig tools can be found
in the catalogue of Weinig accessories.
Training
No-one may work with the Weinig tools and Weinig machines, not even for a brief period,
without the requisite training either within the company, by our field staff, by vocational
training institutes or in the Weinig Training Centre.
Symbols
These symbols refer to general and specific hazards. Some symbols are
also to be found on the machine. These symbols must be noted and must
remain clearly legible at all times. Never remove any stickers from the
machine.
Danger – This symbol draws attention to exceptional hazards which will invariably lead
to very serious injury if the instructions are disregarded and precautions are not taken.
Warning – This symbol draws attention to a potential hazard which can lead to very
serious injury if precautions are not taken.
Caution – This symbol draws attention to hazardous situations which may lead to
physical injury, damage to the machine or other property or to loss of data (control
systems).
This symbol draws attention to additional information for working, tips for correct
operation.
This symbol draws attention to further instructions, instruction modules, enclosures or
third-party manuals which must be observed.
DANGERDANGER
Foreword, symbols

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 1-7
Safety
1 Safety
1.1 Intended use
1.2 General safety instructions
Weinig tools are designed and built exclusively for use in Weinig planers and moulders.
All further uses are deemed to be non-conforming.
Unprofessional and non-conforming use of the tools can impair the operator's safety
and is therefore prohibited. Note the national regulations (EU Directives).
Note the brochure "Safety". It contains further instructions concerning the intended use
and safe operation.
Weinig cannot accept any liability for damage and losses due to non-conforming use of
the tools. The risk of accidents, damage or losses is borne exclusively by the user in
such cases.
The instructions and rules contained in the operating manual must therefore be noted
without fail. All local safety and accident prevention regulations must also be observed.
Weinig cannot accept any liability for personal injury or property damage due to
misconduct or non-compliance with these safety instructions.
Tools have sharp cutting edges which can also cause injury even when at rest. For this
reason, handle tools with care and wear protective gloves.
Always work away from the tool cutting edge, never towards the cutting edge, when
undoing clamping screws.
Always wear protective gloves and proceed with utmost care when packing or
unpacking tools and when handling them (e.g. fitting them in the machine).
Tools must be transported in a suitable packaging or fixture and stored in a safe place
(e.g. in a tool cabinet).

1-8 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
Safety
1.3 Tools and machine
The max. speed specified on the tool must never be exceeded.
All the tools described here are approved only for machines with mechanical feed.
Never use a damaged or dull tool.
Ensure correct direction of rotation of the tools.
Ensure that the machine cannot start up inadvertently while changing tools or cutters.
Tools must be fitted in the machine and secured as directed by the machine
manufacturer.
Before switching on the machine, ensure that the tools are correctly clamped.
Only switch on the machine when the statutory guards are in position.
Tools must never be fitted with cutters on one side only (asymmetrically), as this may
lead to imbalance. All cutters, clamping ledges and blind lugs, if required, must be fitted
without exception. Ensure that all cutters and blanks are of exactly the same weight.
The cutters must be distributed symmetrically when working with less than the full cutter
complement.
Ensure that the clamping areas are clean.
Ensure that parts are fitted correctly when changing cutters.
Ensure that cutters and tool are fitted flush (no protruding edges at the side of the tool).
Tools which have been heated as a result of cleaning in a washing machine or in any
other way must be allowed to cool before being installed. The tool clamp may loosen or
be reduced as the tool shrinks when cooling.
Only use original cutters and replacement parts.

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 1-9
Safety
1.3.1 Hydraulic tools
This operating manual must be read through completely by every authorized user before
working with Weinig tools. This must be confirmed in writing.
The Instruction Manual has been read and thoroughly understood.
Date: Signature:
Owner ................................ .......................................................
Operating personnel ................................ .......................................................
................................ .......................................................
................................ .......................................................
................................ .......................................................
Important:
This manual must be retained for future reference!
Hydraulic tools may only be clamped on the mounting arbor or spindle.
The clamping pressure (300 bar) on the hydro cutterhead and on the outboard bearing,
if applicable, must be checked daily with the aid of a high-pressure grease gun before
starting up the machine.
A safety collar must be used on the spindle.
The safety collars must not clamp the tool in axial direction. It must be clamped via the
hydraulic sleeves (300 bar).
The permissible clamping length must be taken into account when clamping hydraulic
tools on spindles without outboard bearing (see operating manual for the planer).
Further information on accident prevention is available on request from your employers'
liability insurance association. Please request this information.

1-10 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
Notes

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 2-1
PowerLock
2 PowerLock
PowerLock tools have a tapered mount (1).
They are clamped via a hollow conical shank
interface (HSK) with hydro-mechanical or electro-
mechanical tool clamp.
The required clamping force is generated by a spring
assembly (2).
DOKK0544
2 1

2-2 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
PowerLock
2.1 Weinig PowerLock 536
2.1.1 General
The Weinig PowerLock 536 is a heavy-duty cutter. All
the relevant safety regulations and the instructions in
this operating manual must be closely followed in order
to ensure safe use and handling of this tool.
Please read these instructions through carefully before
using the tool.
2.1.2 Intended use
The planer head with reversible cutters is only approved
for mechanical feed systems and is used for the
following purposes:
Planing and edge-jointing work on solid wood (hard and
soft wood) and wood substitutes.
Applications: see technical data.
Chapter 1 Safety must be read through
carefully and observed before using the
tool.
1Straightening
2Edge-jointing on the right
3Planing the left
4Profiling on the right
5Planing the top
6Planing the bottom
536
DOKW0038
DOKW0039
1
2
3
5
6
4

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 2-3
PowerLock
2.1.3 Mechanical design of the tool
Planer head with reversible cutters for 2-fold use.
Solid body of steel. Robust, reliable construction for
low-noise, vibration-free operation.
2.1.4 Removing and fitting the cutters
Removal:
1. Release clamping screw (1).
2. Release clamping ledge with striker (2).
3. Pull reversible cutter out with striker (2).
1Body
2Clamping ledge
3Clamping screws
4Reversible cutter
Reversible cutter
(2 cutting edges)
Right or left clamping ledges are used,
depending on the direction of tool rotation.
DOKW0025
12
3
4
1
2
DOKW0040

2-4 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
PowerLock
Installation:
1. Remove dirt and resin from clamping ledges and
guide grooves.
2. Insert clamping ledges and reversible cutters.
3. Mount setting device (3) on tool and axially press
against shoulder.
4. Axially position clamping ledge and reversible cutter
against setting device.
5. Secure clamping ledge and reversible cutter by
tensioning the front clamping screw.
6. Remove setting device and simultaneously tension
the clamping ledge to 25 Nm from both sides using
two Allen keys (4).
2.1.5 Technical data
– Tool body of high-strength steel
– Fitted with two straight reversible cutters
– Optionally fitted with HSS or carbide
– Positive, form-fitting clamping of the cutters
– Hardened clamping ledges with ground clamping
area
– Cutting angle 12° / 27°
– Cutter cutting circle dia. 93 mm
– Max. speed n = 12,000 rpm
up to tool length 240 mm
– Max. speed n = 8,000 rpm
for tool length over 240 mm
(see legend on tool)
Subject to change without notice!
Never tension the complete cutter groove in
one operation, otherwise the tool could
become deformed.
Do not use damaged Allen keys or keys on
which the hexagon head has become round,
as this may result in damage to the clamping
screws.
3
DOKW0041
4
4
DOKW0042

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 2-5
PowerLock
2.2 Weinig PowerLock 538
2.2.1 General
The Weinig PowerLock 538 is a heavy-duty cutter.
All the relevant safety regulations and the instructions in
this operating manual must be closely followed in order
to ensure safe use and handling of this tool.
Please read these instructions through carefully before
using the tool.
2.2.2 Intended use
The profile cutterhead is only approved for mechanical
feed systems and is used for the following purposes:
Planing and profiling work on solid wood (hard and soft
wood) and wood substitutes.
Applications: see technical data.
2.2.3 Special safety instructions for tool 538
• Always use at least two clamping screws to tension
the clamping ledges and profiled cutters.
• When using slim profiled cutters, select clamping
ledges of a length corresponding with that of the
profiled cutters.
• Remove any unused clamping screws when using
shorter clamping ledges.
• Check that the profiled cutters are correctly seated in
the serration.
• Insert all cutters in the serration in the same position
(distance from bottom of groove).
• Leitz DoubleBack system:
Chapter 1 Safety must be read through
carefully and observed before using the
tool.
Max. blank height 60 mm for Z = 2
Max. blank height 70 mm for Z = 4
Z4 tools have four holes at the end. The extent
to which the cutters protrude can be seen here
(max. from last serration to beginning of hole
edge). The holes are also used for cleaning
(with compressed air).
538
DOKW0043

2-6 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
PowerLock
2.2.4 Mechanical design of the tool
Profile cutterhead with profiled cutters. Solid steel body.
Robust, reliable construction for low-noise, vibration-
free operation.
2.2.5 Removal and installation of cutters on tools
with four cutters
Important when using tools with four cutters:
Blanks with a thickness of 5, 6 and 8 mm are fitted with
the same clamping ledge.
10 mm thick blanks have a thinner clamping ledge which
may only be used with the 10 mm blanks.
When using 8 or 10 mm blanks, the bottom part of the
clamping ledge must be supported on the inclined
clamping area.
2.2.6 Removal and installation of cutters on tools
with two cutters
All blanks are fitted with the same clamping ledge
regardless of thickness in tools with two cutters.
1Body
2Clamping ledge
3Clamping screw
4Profiled cutter
Solid HSS
with serrated back
With carbide or stellite tip,
with serrated back
DoubleBack tip
with carrier plate
DOKW0044
1234
5 – 8 mm
10 mm
DOKW0032
DOKW0083

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 2-7
PowerLock
Removal:
1. Release clamping screws (1).
2. Pull out profiled cutters.
Installation:
1. Remove dirt and resin on clamping ledges and
serrated back.
2. Insert clamping ledge and profiled cutter.
3. Mount setting device (2) on tool and axially press
against shoulder.
4. Axially position clamping ledge and profiled cutter
against setting device and tension middle clamping
screw with half the specified torque.
5. When all cutters have been fixed in this way, remove
setting device and tension all clamping screws to
30 – 33 Nm, working from the inside outwards.
6. Check that cutters are correctly seated in the
serration.
7. Note the maximum cutter adjustment (a).
a = 4 spaces (6.4 mm)
Never tension the complete cutter groove in
one operation, otherwise the tool could
become deformed.
Do not use damaged Allen keys or keys on
which the hexagon head has become round,
as this may result in damage to the clamping
screws.
1
DOKW0045
2
DOKW0046
a
DOKW0084

2-8 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
PowerLock
2.2.7 DoubleBack
Two-part cutter comprising a tip (1) and carrier plate (2).
Carrier plate and tip are positively connected via a
serration (3). Due to its special back serration (4) the
carrier plate (2) can only be fitted in the tool in one
position and is held securely. Carrier plate and tip are
clamped in the tool by means of pressure screws (5)
acting on a clamping ledge (6).
The mark (7) indicates the maximum adjustment (a) of
the tip in relation to the carrier plate. The bottom of the
tip must not be displaced beyond this mark for safety
reasons, otherwise the stability of the entire system will
be jeopardized.
2.2.8 Grinding DoubleBack cutters
The carrier plates must first be profiled without the tips.
Blind lugs (8) must be fitted in order to grind the carrier
plates. They are only ground once. The lowest point in
the profile is ground as close to the tool body as
possible. Use a tracing pin dia. 3 mm and grinding
wheel 4 mm wide for grinding. This ensures that the
profile in the carrier plate is slightly wider than the profile
in the tip.
Remove the blind lug after grinding the carrier plate and
install the tip in the bottom serration. Use a diamond
wheel to grind the carbide tips.
The diameter of the tracing pin must correspond with the
width of the grinding wheel. After profiling, the tip must
not protrude more than max. 5 mm in relation to the
carrier plate. If the carrier plate is reached when the tip
is resharpened, the tip must be moved forwards one
space. The tip must be replaced and a new one fitted
when the maximum adjustment has been reached.
DOKW0028
1
2
3
4
56
DOKW0029
7
a
DOKW0082
8

Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG Weinig Tools 2-9
PowerLock
Profile depth, projection, max. cutting circle:
The following table for a profile cutterhead with diameter
90 mm illustrates the relationship between profile
cutterhead, fitted cutter height, resultant profile depth
and maximum permissible cutting circle diameter.
2.2.9 Grinding
The blanks are profiled in accordance with a profile
template and ground in the profile cutterhead on a
Weinig grinder for profiled cutters.
2.2.10 Technical data
– Tool body of high-strength steel
– Optionally fitted with 2 or 4:
HSS (5/8 mm blank)
Stellite / carbide (6/10 mm blank)
– Blank weight max. 50 g per 10 mm blank length
– Positive clamping of the profiled cutters with serrated
back, serration 1/16" x 60°
– Hardened clamping elements with ground clamping
area
– Cutting angle: 12° or 20°
– Diameter of tool body: 90 mm
– Max. speed n = 12,000 rpm
up to tool length 240 mm
– Max. speed n = 8,000 rpm
for tool length over 240 mm
(see legend on tool)
Subject to change without notice!
Cutter height
[mm]
Max. permissible
cutting circle dia.
[mm]
Max. possible
profile depth
[mm]
50 130 approx. 11
60 150 approx. 20
70 170 approx. 35

2-10 Weinig Tools Tech. Dok. / WNW 850 02 / 02.2005.A / © MICHAEL WEINIG AG
PowerLock
2.3 Weinig PowerLock 539
2.3.1 General
The Weinig PowerLock 539 is a heavy-duty cutter.
All the relevant safety regulations and the instructions in
this operating manual must be closely followed in order
to ensure safe use and handling of this tool.
Please read these instructions through carefully before
using the tool.
2.3.2 Intended use
The profile cutterhead is only approved for mechanical
feed systems and is used for the following purposes:
Planing and profiling work on solid wood (hard and soft
wood) and wood substitutes.
Applications: see technical data.
2.3.3 Special safety instructions for tool 539
• Check that the profiled cutters are correctly seated in
the serration.
• Insert all cutters in the serration in the same position
(distance from bottom of groove).
• Leitz DoubleBack system:
• The corresponding clamping ledge must be selected
in accordance with the thickness of the profiled
cutters (5, 6, 8 or 10 mm).
• Blind lugs must be fitted to prevent the clamping
ledges from bending when using profiled cutters
which are more than 20 mm shorter than the
clamping ledges.
Chapter 1 Safety must be read through
carefully and observed before using the
tool.
Max. blank height 60 mm for Z = 2
Max. blank height 70 mm for Z = 4
539
DOKW0047