Wadkin ULTRACARE FSP 180 Instruction Manual Download Page 31

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Summary of Contents for ULTRACARE FSP 180

Page 1: ...lif1 1 ULTRACARE La 3 At the Cutting Edge of Industry FSP 180 220 THROUGH FEED FOUR SIDE PLANING MACHINE INSTRUCTION MANUAL No 2022 3...

Page 2: ...lations 1992 and Amendment No 2063 COMPANY Wadkin Ultracare Limited Franks Road Hilltop Industrial Park Bardon Leicestershire LE67 1TT RESPONSIBLE PERSON Mr J P Smith Director MACHINE DESCRIPTION TYPE...

Page 3: ...tructed and in accordance with good practice Read instruction manual before installing operating or maintaining machine Manufactured by Wadkin UltraCare Franks Road Hilltop Industrial Park Bardon Leic...

Page 4: ...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...

Page 5: ...ing The machine shall not be operated unless the safe guardings are in position and are functional 3 Cutters blades are the correct type suitable fcir the machine and working conditions rotate in the...

Page 6: ...r 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 operator hazard Do not attempt to repair or rectify t...

Page 7: ...sed 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 suitabl...

Page 8: ...vant personal protective equipment 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...

Page 9: ...capacities Output of motors Standard supplied tooling SECTION 2 INSTALLATION Lifting and Transportation Unloading Moving Unpacking Cleaning Installation Data Major dimensions and weight Foundations S...

Page 10: ...nce adjustment 3 8 Setting fence side head cutterblock 3 8 Near side head adjustment Top head beam adjustment Setting through feed rollers Final adjustments Manual 3 9 Powered 3 1 O Manual 3 10 Powere...

Page 11: ...fence lnfeed gate assembly Bottom head adjustment Fence side head adjustment Near side head Manual adjustment Near side head Powered adjustment Near side head hood Side head belt tension Top head hoo...

Page 12: ...pitch the better the quality of surface finish FIG 1 From experience a good quality surface finish has knife marks at a pitch of 1 5 to 2mm Reducing the pitch improves the surface finish but increase...

Page 13: ...of knife marks the feed speed may be increased in direct relationship to the number of knives in the cutterblock Cuttermark pitch Feed speed in mm per min Block rpm x No of cutters For example 12 x 1...

Page 14: ...ft in the machine traction stops as the trailing end leaves 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 unf...

Page 15: ...er at the infeed end of the machine and automatically fed one at a time from the bottom of the stack at a rate to ensure butt up A slipping device prevents the hopper feed trying to override the machi...

Page 16: ...etween The four position head has the added capability of use as a fence side head The universal head gives greater flexibility for splitting and moulding on a conventional machine and special pressur...

Page 17: ...eneral 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 individua...

Page 18: ...rolls pneumatic or spring Sharpness of cutters Yield of chipbreakers Tightness of side guide onto timber Oil level of bed lubrication pump Position of feedrolls on workpiece Ripples appear on surface...

Page 19: ...edge to table fence is critical to obtain perfect straightening Sharpness of cutters Feed rollers and top side pressures should not be used before first bottom head Is the amount of cut set at the in...

Page 20: ...ed rolls per station Spindle diameter all heads Max cutting circle diameter all heads Min cutting circle diameter all heads Output of Motors Feed motor Bottom head Fence and near side head shared driv...

Page 21: ...ed feed rolls per station Spindle diameter all heads Max cutting circie diameter all heads Min cutting circle diameter all heads Output of Motors Feed motor Bottom head Fence and near side head shared...

Page 22: ...must not exceed 90 Remove shackles before opening hood Moving In the process of moving avoid jolting or vibrating the machine If the ground is flat the machine can be positioned on wooden plinths and...

Page 23: ...ion The electrical connection and schematic diagram are found in the electrical control cubicle of the machine All that is required is to connect the power supply to the disconnect isolator switch at...

Page 24: ...for feed roll pressures An air compressor rated at approximately 2 cu dm sec 4 elm is recommended for pneumatics Exhaust Dust Extraction Connections The size of the connections are given on the Found...

Page 25: ...o pieces of timber were butt feed throu The figures quoted in the noise emission chart are emission levels and not necessarily safe working levels Whilst there is a correlation between emission levels...

Page 26: ...in the use of woodworking machines issued by the Department of Employment and available from Her Majesty s Stationary Office Also BSI Code of Practice Safeguarding Woodworking Machines Part 1 BS 6854...

Page 27: ...the correct type and rotate in correct direction of cut are sharp and securely fastened Remove or fasten loose clothing confine long hair and remove jewellery etc Ensure sufficient working space is pr...

Page 28: ...the rollers may be made independently to suit the finished workpiece A typical panel mounted control station at the infeed end of the machine may contain the following features Stop Start Push button...

Page 29: ...ot to allow the cutterblock to fall onto the spindle shoulder while removing or refitting This can cause damage to spindle bearings and subsequent vibration This is especially applicable to vertical s...

Page 30: ...be opened whilst the illuminated button is pushed With the hood open the feed and spindle motors are inoperative 4 Closing the hood re engages the interlock and the heads may be started if the master...

Page 31: ...ck in position FIG 3 INFEED TABLE AND FENCE ADJUSTMENT Setting Cut to Fence Side Head by lnfeed Fence Adjustment Fig 3 Adjustment of the infeed fence sets the cut depth on the fence side head The maxi...

Page 32: ...g when there is no gap between the cutterblock knives and the fence To set adjust cutterblock manual 1 Isolate power at master stop or at mains and open hood 2 3 With a clean bed and fence place a dat...

Page 33: ...d side guide stop machine using master stop 3 Open the hood 4 5 6 7 8 Slacken off the side guide screw 7 and using the test piece between fence 9 and guide 8 set the guide to exert a very light pressu...

Page 34: ...lock until the knives are just touching the block Note Removal of the front cover 3 will allow a clear view 4 5 6 Check siko reading is correct to datum block If the indicator 4 should need adjusting...

Page 35: ...s collar and then rotate this collar to obtain a reading that corresponds to the finished timber height Tighten grubscrew 6 7 To set the top head spring pressure 5 open the hood and slacken off the tw...

Page 36: ...ved and re spaced to suit timber requirements The setscrew 5 may need to be unscrewed if extra rollers or spacers are to be fitted 7 6 Refit C washer 6 and tighten setscrew 5 5 FIG 9 FLANGE MOUNTED FE...

Page 37: ...Faults In Grinding and Setting FAULT Nicks in the edges of the cutters especially carbide Cause Generally caused by removing too much melal when re grinding This results in undue stresses and subseque...

Page 38: ...lubricant if the spindle bearings are replaced There is no requirement for periodic lubrication of the feedrolls motor driven speed units Regular maintenance cleaning and lubrication will pay dividend...

Page 39: ...e top face and one location peg on each side a Near Side Head Leadscrew and Slideways 1 Position the head to its maximum setting 2 Apply grease along the length of both slides 2 3 Adjust the head to i...

Page 40: ...nthly Remove rear cover see previous NOTE Lubricate universal drive shaft couplings 7 and variable speed couplings when fitted with Wadkin grade L6 grease 7 0 FIG 4 DRIVE SHAFT WBRICATION Grease motor...

Page 41: ...oned via a gas spring but it s condition should still be checked at the snme intervals Check Adjustment for Top and Bottom Heads 1 Isolate power at master stop 2 3 Remove rear drive cover Check belt t...

Page 42: ...ded that the machine be cleaned thoroughly once a week especially when working on hardwood or highly resinous material to prevent choking of ventilator airways and build up of deposits on working part...

Page 43: ...t as a powder and must be removed before applying further adhesive Preparation Prior to Fitting Bearings Before fitting a new bearing the protective lubricant must be meticulously removed with petrole...

Page 44: ...w three hexagon socket capscrews 10 securing hood base Lift clear and remove base Unscrew and remove the two locknuts 11 and bronze bush 12 holding the worm adjusting shaft in position 5 7 10 FIG 7 FE...

Page 45: ...the spindle can be extracted d Top Head i Remove drive belt ii Unscrew and remove the two holding grubscrews 8 using a 6mm alien key iii Extract spindle from front of machine 5 6 7 8 9 10 11 Slide pu...

Page 46: ...sure that bearings fit up to location shoulders on the spindle Refit key 21 pulley 19 and spigot 20 Apply loctite 241 to threads of screw 18 and tighten to 82 Nm 60 lbft Fit new bearing 28 and barrel...

Page 47: ...st position Remove clevis pin 4 and move spring assembly 5 clear Remove E retaining dips from the pivot shaft 6 of the throughfeed roll swing 7 Supporting the swing 7 tap the pivot shaft 6 out Pulling...

Page 48: ...into swing Ensure outer race fits tight up to shoulder FIG 13 BEARING CHANGE TO SHAFT MOUNTED FEEDROLLS 7 8 9 b 1 2 3 Fit front bearing 5 onto shaft 3 using octile 641 on inner race Check bearing fit...

Page 49: ...s If necessary replace worn or damaged items 8 9 10 Apply bearing loctite 641 to inner race of front bearing 14 and fit to shaft 11 Ensure bearing locates up to shaft shoulder Refit spacer 8 and mount...

Page 50: ...m front of machine 3 4 Place the supplied lever tool as shown Fig 12 the hole in the tool fitting over the idle belt roller pivot Applying force on the lever push the idle roller 6 back against the ga...

Page 51: ...til clear Note If the table is supported only by a rope sling then when removing this pivot shaft 3 a second person should support the table at the bottom head point taking suitable care to prevent in...

Page 52: ...d plates not only along its length but also across its width Tighten locking grubscrews when set and replace cap 13 Replace infeed fence and cutterblock Replacement of Variable Speed Friction Dive Rin...

Page 53: ...ort the other gearboxes and drive unit Each gearbox is held in place by four capscrews 12 which must be removed FIG 21 REPLACING FRICTION RING 8 Pull the unit backwards to separate the two halves of t...

Page 54: ...he housing measure the depth at point A The depth must be between 5 2mm and 5 4mm Differences may be compensated for by adding shims 18 as illustrated providing the wear is not localised to the form o...

Page 55: ...is also important that the cutters are evenly ground and set to run true in the cutterblock the assembled cutterblock should be statically balanced before fitting to the spindle In the case of high sp...

Page 56: ...iagnosis a The motor does not run freely b There is a short circuit in the wiring mains c The motor windings or winding are is earthed Remedial Action a Check that the motor is free running b Check th...

Page 57: ...ish as speed of rotation decreases Remedial Action a Establish mechanical or electrical origin b Check symptoms Deduce by elimination to locate position and nature of fault FAULT The Air Break Magneti...

Page 58: ...1 73 0 58 Remedial Action a Replace with correctly rated relay FAULT A spindle stops but the motor still runs Diagnosis a The drive belts are loose broken or have come off Remedial Action a Re tensio...

Page 59: ...150 150 Extra EP 150 13 or Heavy cs 150 Energol Vitrea Vactral Nurray Service URSA P20 HP 68 68 Oil 68 51 or Heavy CS68 Medium Energrease Alvania Mobilplex Beacon Gulfcrown Regal LS3 Grease Grease 3 G...

Page 60: ...OUT FEEDROLL BETWEEN SIDE HEADS FEEOROLL AFTER TOP HEAD FEEDROLL AFTER BOTTOM HEAD FEEDROLL BEFORE TOP HEAD PRE5SU E ARE MY APPRO IMATE VALLES ANO MAY NEED ADJUSTING TO SUIT WORK MATERIAL CONOfflet IS...

Page 61: ...TEPHENS REF WADKIN REF GA 1851 B85x30 GT 10 K3005507 GA 1852 1775 x 55GG10 K3005510 GA 18 51 84Sx30 GT10 K30 05 513 SPINDLE DRIVES MOTCfl PUU Y BELT WADKIN REF STEPHENS REF WADKIN REF GA 4898 B45x30 G...

Page 62: ...e Head Belt Tensioning 11 Top Head Hood and Chipbreaker 180 12 Top Head and Beam Vertical Adjustment Manual 13 Top Head and Beam Vertical Adjustment Powered 14 Rise and Fall Gearbox for Beam and Top H...

Page 63: ...ILLUSTRATED PARTS LIST w N FIG 1 BEDPLATES FENCES AND BEDROLL 5 2 0 _ C 11 JllbJ 0 0 1 w I J Z__ N 1...

Page 64: ...ate with driven bedroll Idle bedroll Driven bed roll see separate section Outfeed fence with idle bedroll Outfeed fence with driven bedroll Hexagon socket capscrew M12 x 25mm long Tension pin Smm dia...

Page 65: ...Wadkln IL LU ST RA_T_ED_P_AR Ts_u_sT 111 N N w w N N FIG 2 INFEED TABLE U1 0...

Page 66: ...n for table Pivot pin for adjusting lever Lever block Positioning stud for table Spring Spring tension stud Pivot pin for table Pivot link for table Mounting bracket for adjusting lever Plain washer M...

Page 67: ...Wadkln ILLUSTRATED PARTS LIST Ill en 0 FIG 3 INFEEO FENCE 5 6 1 11 If If w 01 r...

Page 68: ...1 12 13 14 Description lnfeed fence Hand lever Fence pivot link Pivot link pin Pivot pin Washer Pointer bracket Scale Hexagon nut M12 Plain washer M12 Drive screw Stud M12 x 55mm long Hexagon socket c...

Page 69: ...ILLUSTRATED PARTS LIST 2 6 7 1 FIG 4 INFEED GATE 5 8 10 3...

Page 70: ...2 3 4 5 6 7 8 9 10 Description lnfeed gate Support plate for hinge Hexagon nut M6 Hexagon socket capscrew M4 x 16mm long Socket head button screw MS x 1Smm long Tension pin M6 x 20mm long Hinge Limit...

Page 71: ...Wadkln ILLUSTRATED PARTS LIST Ill I FIG 5 BOTTOM HEAD ADJUSTMENT 5 10...

Page 72: ...arrel support bracket Clamping nut Spindle assembly Eccentric pin assembly Bronze headed bush 22mm O D x 16mm l D x 12mm long Stud M12 x 80mm long Hexagon setscrew M12 x 40mm long Taper washer M12 Bro...

Page 73: ...ILLUSTRATED PARTS LIST 3 FIG 6 FENCE SIDE HEAD ADJUSTMENT 5 12...

Page 74: ...Worm shaft Barrel support bracket Clamping nut Spindle assembly Bronze headed bush 18mm O D x 12mm l D x 20mm long Special locking nut M12 x 1 0p Stud M12 x somm long Hexagon selscrew M12 x 40mm long...

Page 75: ...O m l i i o 0 TJ O s o s n c z rn ILLUSTRATED PARTS LIST FIG 7 NEAR SIDE HEAD MANUAL ADJUSTMENT 5 14...

Page 76: ...er ref AS2035 Collar 32mm O D x 20mm f D x 14mm Tension pin dia 6mm x 32mm long Brass pad Stud MS x 45mm long Plastic hand wheel Nyloc hexagon socket screw MS x 16mm long Hexagon socket capscrew MS x...

Page 77: ...ILLUSTRATED PARTS LIST FIG 8 NEAR SIDE HEAD POWERED ADJUSTMENT 5 16 J I 0 N N w 1 1 N...

Page 78: ...ed motor unit Limit switch Siko dial indicator Hexagon socket capscrew MB x 50mm long Tension pin 6mm dia x 32mm long Key 5mm x 5mm x 32mm fang Hexagon socket grubscrew M6 x Bmm long Hexagon head sets...

Page 79: ...ILLUSTRATED PARTS LIST Ip p 3iir i MI 1 8 7 9 10 r 1 1 12 23 24 4 FIG 9 NEAR SIDE HEAD HOOD 5 18...

Page 80: ...uast hood Chamfered washer MB Wing nut MB Self locking nut M16 Plain washer M16 Siud M16 x 110mm long Bronze bush 20mm O D x 16mm l D x 16mm long Stud M1ox 40mm long Lock nutM10 Plain washer M1O Self...

Page 81: ...Wadkln ILLUSTRATED PARTS LIST Ill 18 19 4 11 17 16 6 14 FIG 10 SIDE HEAD BELT TENSIONING 5 20 w 90 w i 11 10 w S U l z w 7 8 3 9...

Page 82: ...r link Tensioner pivot bracket External circlip dia 25mm Bearing SFK ref 6305 2RS Bearing SFK rel 6206 2RS Stud MB x35mm long Sett locking nut MB Hexagon socket countersunk screw MB x 25mm long Hexago...

Page 83: ...Wadkin ILLUSTRATED PARTS LIST Ill 5 e J FIG 11 TOP HEAD HOOD AND CHIPBREAKER 180 5 22...

Page 84: ...Top head hood Front cover Washer Bearing bush Coil spring Pivot shaft Top head pressure Hexagon socket capscrew MS x 12mm long Hexagon head setscrew M12 x 25mm long Plain washer M12 Tension pin dia 6...

Page 85: ...Wadkin ILLUSTRATED PARTS LIST Ill N I I FIG 12 TOP HEAD AND BEAM VERTICAL ADJUSTMENT MANUAL 5 24...

Page 86: ...ll nut 1 6 Gearbox assembly 1 7 Bracket carrying cross shaft 1 8 Clamping block 1 9 Bronze bush 25mm O D 20mm l D x 15mm long 2 10 Siko digital counter 1 11 Elesa crank handle 1 12 Elsea axial retaini...

Page 87: ...Wadkin ILLUSTRATED PARTS LIST Ill i 6 ch El 11 FIG 13 TOP HEAD AND BEAM VERTICAL ADJUSTMENT POWERED 5 26 5 2 19 4 3 15 21 18 22...

Page 88: ...0mm l D x 15mm long 2 9 Bronze bush 25mm O D x 20mm VD x 20mm long 2 10 Locknut M20 x 1 5p 2 11 INA Thick thrust washer ref WS81104 2 12 INA Thrust bearing ref AXK2035 2 13 INA Thin thrust washer ref...

Page 89: ...Wadkin ILLUSTRATED PARTS LIST Ill 1 Q 1 N I FIG 14 RISE AND FALL GEARBOX FOR BEAM AND TOP HEAD 5 28 0...

Page 90: ...Rise and fall leadscrew SFK bearing ref 6204 RS Internal circlip dia 47mm Hexagon socket capscrew M12 x 30mm long Key 6mm x6mm x20mm long Hexagon socket grubscrew M6 xBmm long Bronze bush 25mm O D x 2...

Page 91: ...Wadkln ILLUSTRATED PARTS UST Ill Ul FIG 15 SPINDLE ASSEMBLY 5 30...

Page 92: ...barrel front bearing Nut for spindle front bearing Locking collar assembly Locking nut Spindle Bearing SFK 6009 Bearing SFK 6306 Pulley spigot Hexagon head setscrew M12 x 40mm long Bearing disc spring...

Page 93: ...ILLUSTRATED PARTS LIST l FIG 16 SHAFT MOUNTED THROUGH FEED ROLL 5 32...

Page 94: ...x 20mm long Key 10mm x Smm x 150mm long External circlip 30mm dia Hexagon socket grubscrew MB x 25mm Jong Hexagon nut M6 Hexagon head setscrew M10 x 16mm long Special Schrader single acting cylinder...

Page 95: ...ILLUSTRATED PARTS LIST I w 1 FIG 17 FLANGE MOUNTED THROUGH FEED ROLL 5 34...

Page 96: ...mplete with location peg used w Mn second feedroll required 1 E Retainer 2 Bearing SFK 6206 2RS 2 Key Bmm x mm x 20mm long External circlip 30mm dia Hexagon socket grubscrew MB x 25mm long 1 Hexagon n...

Page 97: ...ILLUSTRATED PARTS LIST 20 8 6 2 FIG 18 DRIVEN OUTFEED BEDROLLER 5 36...

Page 98: ...ed bed plate Fence after fence side head Cover for outfeed bedroll Nut M12 Plain washer M12 Locknut M12 Terry Compression spring ref D13810 Bronze headed bush Key 8mm x mm x 20mm long Key 10mm x Bmm x...

Page 99: ...Wadkin ILLUSTRATED PARTS LIST Ill U1 FIG 19 TOP HEAD HOOD AND CHIPBREAKER 220 5 38...

Page 100: ...ing Pivot shaft Top head pressure Chipbreaker shoe Front bearing bush Hexagon socket capscrew MB x 12mm long Hexagon head setscrew M12 x 25mm long Plain washer M12 Tension pin dia 6mm x 40mm long Hexa...

Page 101: ...ILLUSTRATED PARTS LIST 11 r 0 1 _ I 11 1 E9 EE3 10 10 1 10 2 4 6 0 3 FIG 20 GEARBOXES AND DRIVE SHAFTS SINGLE SPEED 5 40...

Page 102: ...0 1 Connecting rod Gearbox and motor assembly Rotex coupling ref 19ALUD Adaptor Rotex coupling spider Elbe universal shaft Feed roll swing Key Bmm x 7mm x 40mm long gearbox drive Star fastner for univ...

Page 103: ...ILLUSTRATED PARTS LIST c J Ja L 15 12 13 14 12 13 14 17 17 5 6 8 9 10 11 2 4 FIG 21 GEARBOXES ANO DRIVE SHAFTS VARIABLE SPEED 5 42...

Page 104: ...and dial Rotex coupling ref 19ALUD Rotex coupling spider Adaptor Pointer bracket Mounting bracket for speed control Universal joint Hexagon socket grubscrew M6 x 6mm long Elbe universal shaft Key Bmm...

Page 105: ...ILLUSTRATED PARTS LIST 9 11 2 FIG 22 DRIVE TO OUTFEEO BEDROLL...

Page 106: ...ive shaft Gearbox support bracket Beam Top feed roll gearbox Fenner timing pulley ref 27L075 Fenner timing belt ref 187L075 Taper lock bush 14mm bore ref 1108 Star lock fastner Key 8mm x 7mm x 40mm lo...

Page 107: ...STRATED PARTS LIST ____ 2 3 6 bar J 2 67 P 5 1 5 FEEOROLL BEFORE BOTTOM HEAD FiG 23 PNEUMATICS 5 46 FEEDROLL BETWEEN SIDE HEADS FEEDROLL AFTER TOP HEAD FEEDROLL AFTER BOTTOM HEAD FEEOROLL BEFORE TOP H...

Page 108: ...regulator ref ROS 200 RNKD Pressure gauge Schreder 3 2 spool valve ref 843003 1 OOA Schrader facia actuator ref 33000 1 OOOUAXS Schrader single acting cylinder ref IXB 4726C No Off 1 1 5 Items 3 and...

Page 109: ..._ _L 12 1 _t 11 _______________ 1ML 14 1 j BRAKE COIL STOP START 1 21 1 o_i_ 22 r2 I r o BOTTOM HEAD INDICATOR LIGHT BRAKE OFF FENCE NEAR HEAD INDICATOR LIGHT 2ML 24 I I BRAKE OFF BRAKE COIL STCI STAR...

Page 110: ...A...

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