Woodpecker ADH 5-410 User manual

TRANSLATION OF THE ORIGINAL VERSION
WOODPECKER
HOKUBEMA Maschinenbau GmbH
Graf-Stauffenberg-Kaserne, Binger Str. 28 | Halle 120
DE 72488 Sigmaringen | Tel. [phone]
E-Mail: [email protected] | Web: https://www.ichbinwoodpecker.de
Operating Manual
Combined Surface Planer & Thicknesser
WOODPECKER ADH 5-410
Machine Type:
ADH 5-410

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Table of Contents
1Introduction ................................................................................................................................................... 6
1.1 Legal Notice ............................................................................................................................................................ 6
1.2 Figures..................................................................................................................................................................... 6
2Symbols .......................................................................................................................................................... 6
2.1 General Symbols ..................................................................................................................................................... 6
2.2 Symbols in Safety Instructions ................................................................................................................................ 7
3General........................................................................................................................................................... 8
3.1 Target Group and Previous Experience................................................................................................................... 8
3.2 Requirements for the Operators............................................................................................................................. 8
3.3 Accident Prevention................................................................................................................................................ 8
3.4 General Safety Regulations..................................................................................................................................... 9
3.5 Standard Equipment ............................................................................................................................................. 10
3.6 Options, Accessories and Spare Knives................................................................................................................. 10
4Safety............................................................................................................................................................ 11
4.1 Basic Safety Instructions ....................................................................................................................................... 11
4.1.1 Application Area and Intended Use............................................................................................................. 11
4.1.2 Modifications and Conversions to the Machine.......................................................................................... 11
4.1.3 Residual Risks .............................................................................................................................................. 12
4.2 Observe the Environmental Protection Regulations............................................................................................. 13
4.2.1 Organisational Measures............................................................................................................................. 13
4.2.2 Personnel Selection and Qualification - Basic Duties .................................................................................. 13
4.2.3 Training of Personnel .................................................................................................................................. 14
4.3 Safety Instructions for Specific Phases of Operation ............................................................................................ 14
4.3.1 Normal Operation ....................................................................................................................................... 14
4.3.2 Special work within the Scope of Maintenance Work as well as Troubleshooting in the Workflow .......... 15
4.3.3 Safe Working Practices................................................................................................................................ 16
4.3.4 Construction-related Safety Devices ........................................................................................................... 16
4.4 Electrical Safety Devices........................................................................................................................................ 17
4.5 Hazardous Areas ................................................................................................................................................... 18
4.5.1 Danger Zones during Surface Planing.......................................................................................................... 18
4.5.2 Working Areas & Protective Measures ....................................................................................................... 18
4.5.3 Danger Zones during Thicknessing.............................................................................................................. 19
4.5.4 Working Areas & Protective Measures ....................................................................................................... 19
5Machine Data ............................................................................................................................................... 20
5.1 Technical Specifications ........................................................................................................................................ 20
5.2 Correspondence in the Case of Service................................................................................................................. 20
5.3 Emission Levels ..................................................................................................................................................... 21
5.3.1 Noise Information ....................................................................................................................................... 21
5.3.2 Noise Emission Values................................................................................................................................. 21
5.4 Workplace Requirements ..................................................................................................................................... 21
6Dimensions................................................................................................................................................... 22

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7Installation and Connection ......................................................................................................................... 23
7.1 Check Delivery Conditions .................................................................................................................................... 23
7.2 Transport .............................................................................................................................................................. 23
7.2.1 Unloading with a Forklift Truck ................................................................................................................... 23
7.2.2 Setting down with a Forklift Truck .............................................................................................................. 23
7.2.3 Unloading and setting down with Overhead Crane .................................................................................... 24
7.3 Machine Installation ............................................................................................................................................. 24
7.4 Temporary Storage ............................................................................................................................................... 25
7.5 Lashing on a Transport Vehicle ............................................................................................................................. 25
7.6 Connecting the Extraction Unit............................................................................................................................. 26
7.6.1 Automatic switching of the Extraction System (Option) ............................................................................. 26
7.6.2 Convert Chip Collector ................................................................................................................................ 26
7.7 Electrical Connections........................................................................................................................................... 27
7.7.1 Supply Cable and External Fuse Protection................................................................................................. 27
8Machine Overview ....................................................................................................................................... 28
8.1 Main Components 1.............................................................................................................................................. 28
8.2 Main Components 2.............................................................................................................................................. 29
9Machining Options ....................................................................................................................................... 30
9.1 Surface Planing ..................................................................................................................................................... 30
9.2 Jointing.................................................................................................................................................................. 30
9.3 Thickness Planing.................................................................................................................................................. 30
9.4 Workpiece Requirements ..................................................................................................................................... 31
9.4.1 Machining as a Surface Planer & Jointer..................................................................................................... 31
9.4.2 Machining as a Thickness Planer................................................................................................................. 31
10 Operating the Machine ................................................................................................................................ 32
10.1 Switching the Machine ON and OFF ..................................................................................................................... 32
10.1.1 Control Switches.......................................................................................................................................... 32
10.1.2 Switching ON............................................................................................................................................... 32
10.1.3 Switching OFF.............................................................................................................................................. 32
10.2 Operating Mode Surface Planing & Jointing ......................................................................................................... 33
10.2.1 Operating Elements for Surface Planing & Jointing..................................................................................... 33
10.2.2 Conversion from Thicknesser to Surface Planer & Jointer .......................................................................... 34
10.2.3 Surface planing and jointing: Preparation and Guidelines .......................................................................... 34
10.2.4 Surface Planing of Workpieces up to 65 mm Thickness.............................................................................. 35
10.2.5 Jointing of Workpieces up to 65 mm Thickness .......................................................................................... 36
10.2.6 Surface Planing of Workpieces over 65 mm Thickness ............................................................................... 36
10.2.7 Jointing of Workpieces over 65 mm Thickness ........................................................................................... 36
10.2.8 Surface Planing and Jointing of Small Cross Sections (e.g. Strips) ............................................................... 37
10.2.9 Surface Planing of short Workpieces........................................................................................................... 37
10.2.10 Jointing short Workpieces........................................................................................................................... 37
10.2.11 Surface Planing under Inclination or Bevelling............................................................................................ 37
10.2.12 Safety Accessories for small, short or narrow Workpieces ......................................................................... 38

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10.2.13 Adjusting the Parallelism of the Planing Tables........................................................................................... 38
10.3 Operating Mode Thickness Planing....................................................................................................................... 39
10.3.1 Operating Elements for Thickness Planing .................................................................................................. 39
10.3.2 Conversion from Surface Planer & Jointer to Thicknesser .......................................................................... 40
10.3.3 Thickness Planing Procedure....................................................................................................................... 40
10.3.4 Safe Working on the Thicknesser ................................................................................................................ 41
11 Changing the Planer Knives.......................................................................................................................... 42
11.1 Changing the Knives on Traditional Cutter Block.................................................................................................. 42
11.1.1 Cutter Block Setting Gauge ......................................................................................................................... 42
11.1.2 Magnetic Quick Adjusters 1533 (Option) .................................................................................................... 43
11.2 Changing the Knives on Spiral Cutter Block (Option)............................................................................................ 44
11.2.1 Procedure for Changing the Knives ............................................................................................................. 44
11.2.2 Advantages of the Spiral Cutter Block......................................................................................................... 44
11.2.3 Service Set for Spiral Cutter Blocks.............................................................................................................. 44
12 Optional Components .................................................................................................................................. 45
12.1 Bridge Guard SUVAMATIC..................................................................................................................................... 45
12.2 Mobile Base .......................................................................................................................................................... 45
12.3 Pushing Devices and Feeding Aids ........................................................................................................................ 45
13 Troubleshooting ........................................................................................................................................... 46
14 Maintenance and Inspection........................................................................................................................ 47
14.1 Cleaning ................................................................................................................................................................ 47
14.2 Lubrication............................................................................................................................................................ 47
14.3 Tensioning the V-Belts .......................................................................................................................................... 48
14.4 Maintaining the V-Belts ........................................................................................................................................ 48
14.5 Changing the V-Belts............................................................................................................................................. 48
14.6 Checking the Electronic Motor Brake ................................................................................................................... 48
14.7 Checking the Anti-Kickback Fingers ...................................................................................................................... 49
14.8 Checking the Function of the Emergency Stop Button ......................................................................................... 49
14.9 Checking the Safety Labels.................................................................................................................................... 49
14.10 Taking the Machine out of Operation / Storage ................................................................................................... 49
14.11 Average Situations / Emergencies ........................................................................................................................ 49
15 Electrical Circuit Diagram ............................................................................................................................. 50
16 Disassembly and Scrapping .......................................................................................................................... 51
17 Options and Accessories .............................................................................................................................. 52
17.1 Accessories for Traditional Cutter Blocks.............................................................................................................. 52
17.2 Spiral Cutter Block................................................................................................................................................. 52
17.2.1 Accessories for Spiral Cutter Block.............................................................................................................. 52
17.3 Optional Bridge Guard .......................................................................................................................................... 53
17.4 SI-TEC - Pushing Devices / Feeding Aids................................................................................................................ 53
17.5 Special Accessories ............................................................................................................................................... 53
EU - Declaration of Conformity ............................................................................................................................. 54

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List of Figures
Figure 1: ADH 5-410 in surface planing mode .......................................................................................................................................6
Figure 2: Danger zones during surface planing....................................................................................................................................18
Figure 3: Danger zones during thicknessing ........................................................................................................................................19
Figure 4: Name plate ...........................................................................................................................................................................20
Figure 5: Working areas.......................................................................................................................................................................21
Figure 6: Dimensions ........................................................................................................................................................................... 22
Figure 7: Unloading with a forklift truck.............................................................................................................................................. 23
Figure 8: Setting down with a forklift truck ......................................................................................................................................... 23
Figure 9: Unloading / setting down with crane.................................................................................................................................... 24
Figure 10: Remove transport straps .................................................................................................................................................... 24
Figure 11: Chip collector in "surface planing" position........................................................................................................................ 26
Figure 12: Chip collector in "thicknessing" position............................................................................................................................. 26
Figure 13: Main switch housing........................................................................................................................................................... 27
Figure 14: Machine overview - main components 1............................................................................................................................28
Figure 15: Machine overview - main components 2............................................................................................................................29
Figure 16: Surface Planing ................................................................................................................................................................... 30
Figure 17: Jointing ............................................................................................................................................................................... 30
Figure 18: Thickness planing................................................................................................................................................................ 30
Figure 19: Control switches ................................................................................................................................................................. 32
Figure 20: Operating elements during planing & jointing....................................................................................................................33
Figure 21: Locking springs for planing tables....................................................................................................................................... 34
Figure 22: Surface planing preparation ...............................................................................................................................................35
Figure 23: Planing up to 65 mm (1)...................................................................................................................................................... 35
Figure 24: Planing up to 65 mm (2)...................................................................................................................................................... 35
Figure 25: Planing up to 65 mm (3)...................................................................................................................................................... 35
Figure 26: Jointing preparation............................................................................................................................................................ 36
Figure 27: Jointing up to 65 mm .......................................................................................................................................................... 36
Figure 28: Planing over 65 mm............................................................................................................................................................ 36
Figure 29: Jointing over 65 mm (1)...................................................................................................................................................... 36
Figure 30: Jointing over 65 mm (2)...................................................................................................................................................... 36
Figure 31: Jointing small cross-sections...............................................................................................................................................37
Figure 32: Planing short workpieces....................................................................................................................................................37
Figure 33: Jointing short workpieces ................................................................................................................................................... 37
Figure 34: Inclined surface planing ...................................................................................................................................................... 37
Figure 35: Self-made auxiliary fence (example)...................................................................................................................................38
Figure 36: Adjustment screws on the outfeed table............................................................................................................................ 38
Figure 37: Adjustment screws on the infeed table .............................................................................................................................. 38
Figure 38: Operating elements for thickness planing ..........................................................................................................................39
Figure 39: Suction hose position in thickness planing mode ............................................................................................................... 40
Figure 40: Display for fine adjustment of the height ...........................................................................................................................40
Figure 41: Thickness planing................................................................................................................................................................ 41
Figure 42: Traditional cutter block....................................................................................................................................................... 42
Figure 43: Magnetic quick adjusters type 1533 ...................................................................................................................................43
Figure 44: Adjusting the cutter block................................................................................................................................................... 43
Figure 45: Indexable inserts of the spiral cutter block......................................................................................................................... 44
Figure 46: Service set for spiral cutter blocks ...................................................................................................................................... 44
Figure 47: Bridge guard SUVAMATIC................................................................................................................................................... 45
Figure 48: Mobile base ........................................................................................................................................................................ 45
Figure 49: Push stick............................................................................................................................................................................ 45
Figure 50: Push block........................................................................................................................................................................... 45
Figure 51: Push handle ........................................................................................................................................................................45
Figure 52: Infeed system ..................................................................................................................................................................... 45
Figure 53: Reversible infeed system .................................................................................................................................................... 45
Figure 54: Tightening V-belts...............................................................................................................................................................48
Figure 55: Electrical circuit diagram..................................................................................................................................................... 50

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1Introduction
The purpose of this operating manual is to acquaint the
user with the machine and enable him to use it to the full
extent of its intended capabilities. Additionally it contains
important information to operate the machine safely,
properly and economically.
Observance of the manual helps to avoid hazards, reduce
repair costs and downtimes and increase the reliability
and service life of the machine.
Furthermore, this operating manual serves to supple-
ment instructions based on national regulations for acci-
dent prevention and environmental protection.
Figure 1: ADH 5-410 in surface planing mode
Die This operating manual must always be available at the place of use of the machine. It
must be read and followed by every person who is assigned to work on the machine, e.g.
•during operation, including set-up, troubleshooting in the work process, removal of pro-
duction waste and maintenance,
•during maintenance (servicing, inspection, repair)
•and/or during transport.
Apart from the operating manual and the legally binding accident prevention provisions applicable in the coun-
try and place of use, the recognized technical regulations for safe and proper work must also be observed.
1.1 Legal Notice
WOODPECKER is a brand of Hokubema Maschinenbau GmbH. All contents of these operating instructions are
subject to the rights of use and copyright of HOKUBEMA Maschinenbau GmbH. Any reproduction, modification,
further use and publication in other electronic or printed media, as well as their online publication, requires the
prior written consent of HOKUBEMA Maschinenbau GmbH.
1.2 Figures
All photos, figures and graphics contained in this document are for illustration and better understanding only
and may differ from the current state of the product. Title photos and general views may also include optional
components and special accessories.
2Symbols
2.1 General Symbols
Symbol
Meaning

Indicates passages within this operating manual that must be particularly observed in order to
prevent malfunctions or damage to the machine.

Refers to chapters, sections, or figures within this document.

Refers to an external document or a third-party source.

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2.2 Symbols in Safety Instructions
Symbol
Safety Instruction
General danger symbol, which requires the highest attention!
Failure to observe may result in damage to the equipment, serious injury or even death.
Warning of possible danger from forklift traffic!
Non-observance may result in life-threatening injuries.
Warning indicates a possible hazard under suspended loads!
Non-observance may result in life-threatening injuries.
Warning indicates a possible fall hazard!
Non-observance of these instructions may result in serious injuries.
Warning indicates a possible cutting hazard!
Risk of personal injury and possibly additional damage to equipment.
Reference to the obligation to wear protective gloves!
Non-observance of these instructions may result in personal injury.
Reference to the obligation to wear hearing protection!
Non-observance of these instructions may result in personal injury.
Reference to the obligation to wear protective goggles!
Non-observance of these instructions may result in personal injury.
Reference to the obligation to wear a respiratory protection mask!
Non-observance of these instructions may cause breathing difficulties and lung damage.
Reference to the obligation to wear safety shoes!
Non-observance of these instructions may result in personal injury.
Possible dangerous crushing hazard in the area of stationary objects!
Risk of personal injury and possibly additional equipment damage.
Reference to a possible crushing hazard!
Non-observance increases the risk of injury to hands and fingers!
This symbol warns of the dangers of electric voltage!
Failure to observe may result in damage to the equipment, serious injury or even death.
Fire hazard! Do not smoke and do not ignite open fire.
Access for unauthorized persons prohibited!
Risk of personal injury and possibly additional equipment damage.
This safety notice indicates a possible dangerous pull-in hazard!
Wearing loose clothing, jewellery as well as long untied hair is prohibited!
Risk of personal injury and possibly additional damage to property.

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3General
This combined planer and thicknesser ADH 5-410 was produced according to the current state of the art and
put into operation as a complete machine. All legal and normative regulations were complied with.
•The machine has a surface planing width of 410 mm and a thickness planing width of 406 mm.
•The maximum chip removal during thickness planing is 4 mm and during surface planing 5 mm.
•The thickness planer capacity is in the range of 4 to 225 mm.
3.1 Target Group and Previous Experience
This operating manual is intended for the operating and maintenance personnel of the machine. The operating
personnel is to be determined by the operator and must further meet the following requirements:
•Basic technical knowledge (e.g. apprenticeship as carpenter, machine fitter, etc. and/or practice in operat-
ing woodworking machines)
•Reading and understanding these operating and maintenance instructions
In order to acquire the knowledge required to operate this machine, the operator must ensure the following
measures:
•Product training for every operator (also possible external personnel)
•Regular safety instruction
3.2 Requirements for the Operators
•The planer & thicknesser may only be operated by trained personnel who have also read this manual.
•Inspection, maintenance, cleaning and repair may only be performed by technical specialists
with product-specific training and mechanical and/or electrical training.
•Specialists with product-specific training are to be commissioned and held responsible for
planning and checking the work.
•The national protective regulations for employees must be observed .
•The operator is responsible for the safe use of the machine.
•The legal minimum age must be observed.
3.3 Accident Prevention
To avoid accidents, the following rules must be observed for operation:
•Prevent unauthorized persons from gaining access to the machine.
•Keep unauthorized persons away from the danger areas.
•Repeatedly inform present other persons about existing residual risks (see section 4.1.3).
•Conduct and record regular training & instruction for persons who must be in the area of the machine.
•New employees must be trained internally to work on a thickener and this training must be documented.

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3.4 General Safety Regulations
In general, the following safety regulations and obligations apply when handling the planer & thicknesser:
•A planer & thicknesser may only be operated in a technically perfect and clean condition.
•It is prohibited to remove, modify or bypass any protective, safety or monitoring equipment.
•It is forbidden to modify or alter the machine without the written approval of the manufacturer / supplier.
•Faults or damage must be reported to the operator immediately, eliminated without delay and repaired if
necessary.
•For repairs, only original spare parts may be used.
•All protective, safety and monitoring devices must be regularly checked and maintained by the operator.
•Only instructed, trained or qualified persons may work on this machine.
•Maintenance work must be carried out and documented in accordance with the maintenance instruc-
tions.
•After maintenance or repair, the machine may only be started with all protective devices fitted. A respon-
sible person must be defined for this purpose, who checks that the guards have been properly installed.
•For the operation of a thickness planer, the respective national safety regulations for employees as well as
the national safety and accident prevention regulations apply.

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3.5 Standard Equipment
•Powerful three-phase motor 5.5 kW (7.5 HP)
•Foldable bridge guard as cutter block cover
•Manual adjustment of the feed table during surface planing via scale
•Manual height adjustment of the thicknessing table via handwheel
(with scale, fine adjustment to 0.1 mm via analogue display)
•Traditional cutter block with four HSS knives
•Thickness planer with driven infeed and outfeed rollers
•Surface planing fence with tilt adjustment (90° ... 45°)
•Serrated table lips for noise reduction
•Electric, wear-free motor brake
•1 suction nozzle 120 mm Ø
•CE conform and GS tested
Included with V-bar cutter block:
•Planing knife setting gauge incl. matching open-end spanner
3.6 Options, Accessories and Spare Knives
•Switching contact for automatic switching of the extraction system
•Magnetic quick-setting devices for traditional cutter block
•Replacement knives for traditional cutter block
•Spiral cutterblock with 66 HM indexable inserts
(3 rows of 22 knives each) 15 x 15 x 2.5 mm
•Spare indexable inserts for spiral cutter block
•Service and cleaning kit for spiral cutter block
•Planer guard SUVAMATIC
•Mobile base with lifting rod
Included with spiral cutter block:
•10 pieces replacement carbide inserts
•10 pcs matching T20 screws
•Suitable torque spanner