Newman EPR, EPR-18, EPR-24 Service Manual

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SERVICE

MANUAL

EPR Series Electric Drive Double Roughing Planer

Equipped with Helical Carbide Cutterheads

Edition 1.4 Issued 9/12/2000

NEWMAN

QUALITY WOODWORKING MACHINERY

SINCE 1906

EPR-18 and EPR-24

Helical Carbide

Double Roughing Planer

Service and Parts Manual

Version 1.4

This Page Intentionally Left Blank

Table of Contents

1 GENERAL INFORMATION................................................................................................. 1

1.1 Warranty ......................................................................................................................... 1

1.2 Safety Practices............................................................................................................... 3

1.3 Basic Safety Procedures.................................................................................................. 5

1.3.1 Safe Operating Practices......................................................................................... 6

1.3.2 Lumber Jams........................................................................................................... 7

1.4 Receiving ........................................................................................................................ 8

1.4.1 Unloading................................................................................................................ 8

1.4.2 Checking Shipment................................................................................................. 8

1.4.3 Cleaning ..................................................................................................................8

1.4.4 Extended Storage .................................................................................................... 8

1.5 Installing The Planer..................................................................................................... 10

1.5.1 Foundation ............................................................................................................ 10

1.5.2 Accessory Equipment ........................................................................................... 17

1.5.3 Electrical ............................................................................................................... 19

1.5.3.1 Electrical Requirements.................................................................................... 19

1.5.3.2 Care Of Electrical Equipment........................................................................... 19

1.5.4 Compressed Air Requirements ............................................................................. 20

1.5.5 Dust Collection Requirements .............................................................................. 20

1.5.6 Start-Up Procedures.............................................................................................. 21

2 THEORY OF OPERATION................................................................................................. 22

2.1 Planer Description......................................................................................................... 22

2.2 Automatic Cut Control ............................................................................................. 23

2.3 Controls......................................................................................................................... 24

2.3.1 Operator’s console ................................................................................................ 24

2.3.2 Feeder Console (Optional).................................................................................... 27

2.4 Planer Adjustments ....................................................................................................... 28

2.4.1 Mechanical Adjustments....................................................................................... 28

3 PLANER MAINTENANCE................................................................................................. 34

3.1 Planer Lubrication......................................................................................................... 35

3.1.1 Lubrication Schedule ............................................................................................ 35

3.1.2 Lubrication Points................................................................................................. 36

3.2 Preventive Maintenance Schedule ................................................................................ 41

3.3 Machine Alignment Procedures.................................................................................... 42

3.3.1 Bedline Alignment Procedure............................................................................... 42

3.3.2 Leveling The Top Head Assembly ....................................................................... 46

3.3.3 Aligning The Pressure Bar.................................................................................... 49

3.3.4 Setting the Chipbreakers ....................................................................................... 54

3.4 Leveling the Bottom Cutterhead................................................................................... 56

3.4.1 Aligning The Anti-Lap Assembly ........................................................................ 58

3.4.2 Adjusting The Anti-Kickback Assembly.............................................................. 60

3.4.2.1 Adjusting Feedroll Reversing Time Delay ....................................................... 60

3.4.3 Zeroing The ProScale ........................................................................................... 61

3.5 Machine Wear And Maintenance Procedures............................................................... 63

3.5.1 Incline Table Insert Wear ...................................................................................64

3.5.1.1 Solid Incline Table Plates ……………………………………………………..64

3.5.1.2 A.C.C Equipped Incline Table Plates …………………………………………64

3.5.1.3 Removing The Incline Table Insert Plate ........................................................ 66

3.5.2 Automatic Cut Control™ Fingers ...................................................................... 67

3.5.3 Chipbreaker Wear and Replacement .................................................................. 69

3.5.3.1 Checking For Chipbreaker Toe Wear ............................................................. 69

3.5.3.2 To Remove Chipbreaker Toe Plates: .............................................................. 69

3.5.3.3 Removing The Chipbreaker ............................................................................ 71

3.5.4 Set Reference For Bedline Zero........................................................................ 73

3.5.5 Replacing the Top Head Raising Screw and Worm Gear .................................. 75

3.5.6 Cutterhead Bearings ......................................................................................... 78

3.5.6.1 General Information for Replacing Ball Bearings .......................................... 78

3.5.6.2 Top Cutterhead Bearing Replacement ............................................................ 79

3.5.6.3 Bottom Cutterhead Bearing Replacement ....................................................... 81

3.5.7 Pneumatic Feedroll Tires .................................................................................. 83

3.5.8 Pneumatic System ............................................................................................ 84

3.5.8.1 Locally Manufactured Pneumatic Hoses ......................................................... 87

4 PLANER OPERATION ............................................................................................. 89

4.1 Planer Safety ........................................................................................................ 89

4.1.1 Personal Safety Equipment .............................................................................. 89

4.1.2 Planer Safety Devices...................................................................................... 89

4.1.3 Maintaining Machine Guards .......................................................................... 89

4.1.4 Safety Practices ............................................................................................... 90

4.1.5 Safety Considerations While Clearing a Jam ................................................... 91

4.1.5.1 Avoiding Contact With A Rotating Cutterhead ............................................. 91

4.1.5.2 Avoiding Feed-Roll Pinch Points ................................................................. 91

4.1.5.3 Avoiding lumber ejection or 'kickback' ......................................................... 91

4.1.6 Clearing a Jam ................................................................................................ 92

4.2 Operating The Planer ........................................................................................... 93

4.2.1 Setting The Depth Of Cut ............................................................................. 93

4.2.1.1 Setting the Top Cutterhead ........................................................................... 93

4.2.1.2 Setting The Bottom Cutterhead Cut (With Automatic Cut Control™)........... 93

4.2.1.3 Setting The Bottom Cutterhead Cut (Without Automatic Cut Control™) ...... 94

4.2.2 Setting The Feedroll Height ........................................................................... 94

4.2.3 Setting the Anti-Lap ....................................................................................... 95

4.3 Planer Hints ........................................................................................................ 96

5 HELICAL CARBIDE CUTTERHEAD MAINTENANCE ........................................ 98

5.1 General Information ........................................................................................... 98

5.2 Maintenance Information ................................................................................... 98

5.3 Glossary ........................................................................................................... 100

5.4 Grinder Maintenance ........................................................................................ 105

5.4.1 Grinder General Information ........................................................................ 105

5.4.2 Grinder Setup and Alignment ....................................................................... 106

5.4.3 Installing and Aligning the Bottom Head Grinder Rail ................................. 108

5.5 Normal Jointing And ReGrinding Procedures .................................................. 111

5.5.1 General Information............................................................................................ 111

5.5.2 Jointing The Bottom Cutterhead......................................................................... 111

5.5.3 Jointing The Top Cutterhead .............................................................................. 113

5.5.4 Grinder Installation and Setup ............................................................................ 115

5.5.4.1 Preparation for Grinding................................................................................. 115

5.5.4.2 Setting the Grinding Angle ............................................................................. 115

5.5.5 Grinding The Cutterhead Knives ........................................................................ 118

5.5.5.1 Grinding the Bottom Cutterhead..................................................................... 118

5.5.5.2 Grinding the Top Cutterhead .......................................................................... 120

5.6 Installing New Knives................................................................................................. 123

5.6.1 Grinding New Knives ......................................................................................... 123

5.6.2 Installing New Knives......................................................................................... 124

5.7 Cutterhead Maintenance ............................................................................................. 126

5.7.1 Chipped Knives................................................................................................... 126

5.7.2 Replacing Broken Knives ................................................................................... 127

5.7.3 Refreshing the Clearance Angle ......................................................................... 127

5.7.4 Checking the Cutterhead Knife Height............................................................... 128

5.7.5 Calibrating an Impact Driver .............................................................................. 130

6 ILLUSTRATED PARTS BREAKDOWN......................................................................... 131

6.1 Ordering Repair Parts ................................................................................................. 131

7 APPENDIXES .................................................................................................................... 189

7.1 GPD-505 / P5 Parameters ........................................................................................... 189

7.2 P5+ Parameters ........................................................................................................... 191

7.3 Sew-Eurodrive Parts List For Epr-18 ......................................................................... 193

7.4 NORD Parts List for EPR-18...................................................................................... 196

7.5 Sew-Eurodrive Parts List For Epr-24 ......................................................................... 198

7.6 NORD Parts List for EPR-24...................................................................................... 201

7.7 Material Safety Data Sheets (Information Only)........................................................ 203

III

Table of Figures

Figure 1.5.1-A Foundation Plan: EPR-18 With Anti-Lap ............................................................ 11

Figure 1.5.1-B Foundation Plan: EPR-18 With Anti-Kickback ................................................... 12

Figure 1.5.1-C Foundation Plan: EPR-18 With Machine Enclosure............................................ 13

Figure 1.5.1-D Foundation Plan: EPR-24 With Anti-Lap ............................................................ 14

Figure 1.5.1-E Foundation Plan: EPR-24 With Anti-Kickback ................................................... 15

Figure 1.5.1-F Foundation Plan: EPR-24 With Machine Enclosure ............................................ 16

Figure 1.5.2-A Alignment of Infeed Conveyor ............................................................................ 17

Figure 1.5.2-B Alignment of Outfeed Conveyor .......................................................................... 18

Figure 1.5.2-C Alignment of Outfeed Pinch Roll......................................................................... 18

Figure 2.3.1-A Operator’s Console............................................................................................... 24

Figure 2.3.2-A Feeder Console..................................................................................................... 27

Figure 2.4.1-A Left Side Adjustments.......................................................................................... 28

Figure 2.4.1-B Bottom Infeed Rolls and Air Valve Panel............................................................ 29

Figure 2.4.1-C Pneumatic Pressure Bar Adjustments................................................................... 29

Figure 2.4.1-D Anti-Lap Adjustments.......................................................................................... 30

Figure 2.4.1-E Right Side Adjustments ........................................................................................ 31

Figure 2.4.1-F Top Head Limit Stops........................................................................................... 32

Figure 2.4.1-G Chipbreaker Adjustments..................................................................................... 32

Figure 3.1.2-A Left Side Lubrication Points #1 ........................................................................... 36

Figure 3.1.2-B Infeed Lubrication Points ..................................................................................... 37

Figure 3.1.2-C Chipbreaker Lubrication Points............................................................................ 37

Figure 3.1.2-D Bottom Head Jackscrew and Roll-Out Bearing .................................................. 38

Figure 3.1.2-E Eurodrive Gearbox................................................................................................ 38

Figure 3.1.2-F Right Side Lubrication.......................................................................................... 39

Figure 3.3.1-A Bedline Alignment Diagram ................................................................................ 42

Figure 3.3.2-A Top Head Leveling Adjustments.......................................................................... 46

Figure 3.3.2-B Pressure Bar Leveling Adjustments ..................................................................... 48

Figure 3.3.3-A Placement Of Straight Edges................................................................................ 50

Figure 3.3.3-B Relationship Of Pressure Bar To Straight Edges ................................................. 50

Figure 3.3.3-C Pressure Bar Alignment Adjustments .................................................................. 51

Figure 3.3.3-D Pressure Bar Actuator Adjustments ..................................................................... 53

Figure 3.3.4-A Chipbreaker Adjustments..................................................................................... 54

Figure 4-A Placement Of Straight Edges...................................................................................... 56

Figure 4-B Bottom Head Level And Height Adjustments............................................................ 57

Figure 4.1.1-A Anti-Lap Adjustments.......................................................................................... 59

Figure 4.1.1-B Anti-Lap Leaf Spring Adjustment........................................................................ 59

Figure 4.1.3-A ProScale Controls................................................................................................. 61

Figure 4.2.1-A Solid Incline Table Insert Wear ........................................................................... 65

Figure 4.2.1-B A.C.C Incline Table Insert Wear.......................................................................... 65

Figure 4.2.1-C Relationship of Incline Table Plate to A.C.C. Fingers......................................... 65

Figure 4.2.2-A Automatic Cut Control Wear ............................................................................... 67

Figure 4.2.3-A Chipbreaker Toe Plate Wear ................................................................................ 69

Figure 4.2.3.2-B Chipbreaker Cutaway ........................................................................................ 70

Figure 4.2.3-C Chipbreaker Assembly ......................................................................................... 71

Figure 4.2.4-A Setting Bedline Reference ................................................................................. 73

Figure 4.2.5-A Left Side Top Head Raising Gear Assembly ...................................................... 75

Figure 4.2.8-A Pneumatic Valve Panel ...................................................................................... 86

Figure 4.2.8.1-B Pneumatic Hose Layout .................................................................................. 87

Figure 4.2.8.1-C EPR Pneumatic Schematic .............................................................................. 88

Figure 5.2.3-A Handwheel Type Anti-Lap Properly Adjusted ................................................... 95

Figure 6.4.1-A Helical Carbide Grinder Assembly .................................................................. 105

Figure 6.4.2-A Removing LockNut And Washer ..................................................................... 106

Figure 6.4.2-B Grinder Vertical Slide ...................................................................................... 107

Figure 6.4.2-C Grinder Horizontal Slide .................................................................................. 107

Figure 6.4.3-A Bottom Head Yoke Cleaning ........................................................................... 108

Figure 6.4.3-B Bottom Head Grinder Rail Cleaning ................................................................ 109

Figure 6.4.3-C Rail Alignment – Horizontal Setup .................................................................. 109

Figure 6.4.3-D Rail Alignment - Vertical Setup ....................................................................... 110

Figure 6.5.2-A Setting The Bottom Head Jointer Stone ........................................................... 111

Figure 6.5.2-B Bottom Head Jointer Guard ............................................................................. 112

Figure 6.5.2-C Knife Joint ....................................................................................................... 112

Figure 6.5.4-A Grinding Angle Setup Mark ............................................................................ 116

Figure 6.5.4-B Finger In Top of Gullet .................................................................................... 116

Figure 6.5.5-A Weight on Bottom Cutterhead ......................................................................... 118

Figure 6.5.5-B Weight on Top Cutterhead ............................................................................... 119

Figure 6.5.5-C Finger Wheel Reference Marks ........................................................................ 119

Figure 6.6.2-A Setting Knife Bit Torque ........ …………………………………………………125

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1 GENERAL INFORMATION

1.1 Warranty

Except as otherwise specifically set forth herein, the Seller shall not be bound by representations, promises or inducements by its agents or employees. No course of prior dealings between the Seller and Purchaser and no usage of trade shall be relevant or admissible to, supplement, explain or vary any of the terms of this offer to purchase. No representations, understandings or agreements have been made or relied upon in the making of this offer to purchase other than those specifically set forth herein.

THE SELLER, ITS AGENTS OR EMPLOYEES, GIVE NO WARRANTY, EXPRESS OR IMPLIED, AS TO DESCRIPTION, QUALITY, MERCHANTABILITY, OR FITNESS FOR ANY PARTICULAR PURPOSE AND PRODUCTIVITY WITH RESPECT TO ANY ITEM HEREBY PURCHASED AND LISTED ON THE FACE HEREOF EXCEPT AS IS OTHERWISE PROVIDED BELOW. THE PURCHASER ACKNOWLEDGES THAT IT IS NOT RELYING ON THE SAID SELLERS SKILL OR JUDGMENT TO SELECT OR FURNISH EQUIPMENT OR GOODS SUITABLE FOR ANY PARTICULAR PURPOSE AND THAT THERE ARE NOT WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF AND EXCEPT AS OTHERWISE PROVIDED BELOW.

The seller warrants all machines and parts of its own manufacture to be free from defects in material and workmanship for a period of one (1) year from the date of shipment subject to the following:

(a) This warranty shall remain in effect only so long as said machines and parts are properly maintained and given normal care, and have not been the subject of misuse, negligence or accident, the instructions for installing or operating have not been disregarded or modified, the machines and parts have not been repaired or altered in any way by persons other than the Seller or by persons authorized by the Seller, and the machines are owned and operated at all times by the Purchaser.

(b) If said machines and parts are found to be defective and the warranties expressed herein are still in full force and effect, Seller will at its option, either ship new parts or repair the original parts, at no charge, to the Purchaser, said Parts to be shipped F.O.B. Seller's factory Greensboro, North Carolina.

(c) This warranty shall be null and void if a defect is not brought to the attention of the Seller within a reasonable time after discovery occurred, or with the exercise of reasonable diligence on the part of the Purchaser should have occurred, and the parts alleged to be defective are not returned carrying charges prepaid for Seller's inspection within thirty (30) days with pre-assigned Return Authorization number.

(d) Defects in electrical equipment, ball bearings and other components purchased by Seller as complete units for installation in Seller's machines are not warranted herein, but will be replaced or repaired by the Seller in accordance with the warranty or guarantee of the manufacturer or supplier of said devices. Warranty null if parts are not returned carrying charges prepaid for inspection within thirty (30) days with preassigned Return Authorization number.

(e) THE SELLER SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR

CONSEQUENTIAL DAMAGES INCURRED BY THE PURCHASER, INCLUDING, BUT NOT LIMITED TO, OPERATIONAL DELAYS OR DEFECTS IN PURCHASER'S PRODUCTS, PROXIMATELY RESULTING FROM ANY BREACH OF WARRANTY BY THE SELLER, EXCEPT AS OTHERWISE EXPRESSLY PROVIDED FOR HEREIN.

1.2 Safety Practices

A. Do not operate, adjust or attempt to maintain this machine until:

1. You have been authorized and properly instructed in the skill you are to perform.

2. You have read and understand these instructions.

B. Unless you have shut off all power and locked the switch:

• Never clear broken and/or jammed material from the planer while cutterheads, feed table rolls or planer rolls are turning.

• Never approach the planer or its' feed tables while wearing loose clothing or without required safety clothing: safety glasses, hard hat, safety shoes and additional items as your company requires.

C. The machines covered by this manual were designed and manufactured in accordance with

ANSI 01.1.

D. Throughout this manual, the following conventions will be observed:

In a numbered list of actions, items indented and marked with a ( • ) indicate additional

actions that should be performed during that step, or gives additional information about the step or information on equipment, tools, or fixtures used during that step.

A NOTE looks like the following example, and gives general information about a procedure

or setting. It denotes information that is more important than the general text.

NOTE

Denotes information that is more important than the general text. It gives

information that, if not followed, may result in damage to the equipment.

E. The following information conforms to the 1998 ANSI Z535.4 standard. The ISO "General

Danger" symbol is used in all Caution, Warning, and Danger information blocks in this manual.

A CAUTION looks like the following example and indicates a potentially hazardous

situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION

Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

A WARNING looks like the following example, and indicates a potentially hazardous

situation which, if not avoided, could result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

A DANGER warning looks like the following example, and indicates an imminently

hazardous situation which, if not avoided, will result in death or serious injury.

DANGER

INDICATES AN IMMINENTLY HAZARDOUS

SITUATION WHICH, IF NOT AVOIDED, WILL

RESULT IN DEATH OR SERIOUS INJURY.

1.3 Basic Safety Procedures

Virtually all automated machinery has the potential to cause personal injury. Although the EPR-Series planers are more properly classed as semi-automated, they are not an exception. When the planer is well maintained and safely operated, avoiding injury is easy. The basic safety procedures that apply to automated machines are easily applied to these planers. These procedures are defined as follows:

1. No Experience - No Touch! An untrained operator can probably learn to operate a planer in a few minutes, but they have a good chance of creating a safety hazard for themselves or their co-workers in a few hours. This is because a large part of safety is common sense and a very large part of common sense is knowledge and the ability to apply it. The untrained operator does not have experience and can unknowingly create an unsafe situation.

An individual with previous planer experience can learn to safely operate and perform

preventive maintenance on an EPR-Series Planer in two days or less. An individual with no previous planer experience can be expected to learn to safely operate and perform preventive maintenance in about a week. During this week, he should be closely supervised by an individual with at least six months experience on the planer.

2. Physical Safety Concerns: Beyond management concerns there are the concerns of physical safety. These include:

Eye Protection: Because the EPR-Series Planers are designed to allow easy access to the area under the top head, it is relatively easy for wood chips, splinters, and foreign material to exit the sides of the planer. The guards on the operator's side of the machine provide a measure of protection against larger objects, but smaller pieces can pass through them. For this reason, it is critical that the planer operator wear eye protection. It is also a very good idea to wear eye protection during the jointing process when there is no suction to guide small knife and jointer stone particles away from the exposed, spinning cutterheads.

Hearing Protection: The Helical Carbide Cutterhead, with which most EPR-Series planers are equipped, reduces the noise generated by the planing operation by 15-20 dB. High frequency noise is greatly reduced. It should be noted that damage to the ear by high levels of noise is cumulative, that is, new damage is added to the old damage. Individuals who already suffer from noise-related hearing loss should wear hearing protection to prevent further loss.

EPR-Series planers equipped with straight knife type cutterheads produce a noise volume that is comparable to the noise of a jet engine and may cause irreparable hearing loss if not guarded against. The use of padded, cup-type, hearing protection should be mandatory within 50 feet of the planer.

1.3.1 Safe Operating Practices

Besides knowing and following the basic safety rules and procedures that must be in force in any industrial area, the planer operator and maintenance technicians must also observe safe rules of planer operation. The experience of the planer operator cannot be replaced in this area.

Maintaining Machine Guards:

The EPR-Series Planers have two different widths, and they have the same pinch points, cutterheads, and other hazards that are built-in. Each machine has protective guards fitted to it at the factory. These guards are yellow (older machines) or orange (current machines) in color, and generally prevent easy access to pinch and crush points on the planer. Expanded metal guards are installed on both sides of the machine to protect the operators from simple human error. Solid guards are provided on the infeed and outfeed roll housings.

Machines that are fitted with the Planer Enclosure are not likely to allow accidental access to the planers’ moving parts since the enclosure covers the upper two thirds of the machine. If the enclosure is opened, the planer can still be operated. The planer should not be operated with the enclosure open unless required by a maintenance action.

The top cutterhead motor, bottom cutterhead motor, and feedroll drive motors all have metal shrouds covering the motor cooling fans. These shrouds should never be removed. They are painted the same color as the rest of the motor.

Guards should never be removed from the planer unless the planer is electrically locked out. Removing a guard in order to increase production by reducing time for maintenance or clearing actions is never a valid excuse. Removing a guard and not replacing it for any reason should always be considered a safety violation.

Electrical Hazards: The EPR-Series planers are electrically powered machines and require either 460 VAC or 230 VAC for operation. This voltage can be found in the main electrical panel enclosure, the machine junction box, and all four of the motor connection boxes. All of these enclosures except the motor connection boxes have High Voltage caution tags, and all of them are provided with a means of securing the access doors closed. The main enclosure also has an electrical interlock that holds the cabinet door closed as long as power is applied to the planer.

110 VAC is used for most of the control functions. This voltage can be found in the main electrical panel enclosure, the machine junction box, the operator’s console, and the feeder console (if provided).

All of these enclosures must be securely closed to prevent the possibility of electrical shock and burns, and to reduce the possibility of an electrical fire.

Cutterhead Brakes:

The cutterhead brakes on the EPR-Series planers were designed to

stop the cutterheads after the power is removed from the cutterhead motors. Since the cutterheads will freewheel for up to five minutes, they present a safety hazard. The cutterheads must have stopped rotating before performing maintenance on the planer, or before attempting to clear a jam (See Clearing a Jam in the Planer).

1.3.2 Lumber Jams

Clearing a Jam in the Planer: Jams are a fact of life around a planer, and they can occur at any time. Most accidents involving planers happen during the jam clearing process. The planer operator must pay special attention to his actions during the jam clearing process to prevent an accident.

The frequency with which jams occur is unpredictable. Poor, warped lumber; improper setup, loose feedrolls, and operating the planer too fast for marginal lumber can all cause jams.

For more information on lumber jams and how to clear them, see Section 4.1.5 and 4.1.6.

1.4 Receiving

Before accepting the machine from the transportation company, check for any possible damage in transit. Also, check the boxes in which loose parts are shipped to see if the boxes have been damaged in such a way that some part may have escaped the box. If damage is apparent, a notation describing the damage should be made on all copies of the waybill and the delivering agent required to sign all copies. After the extent of any damage has been determined, a claim should be filed with the transportation company. Taking photographs is also recommended.

1.4.1 Unloading

Reasonable care should be taken when removing the machine from the vehicle in which it has been shipped. Although the machine is sturdily constructed, certain parts may be damaged if the machine is subjected to rough treatment. The skids should be left on the machine until it has been moved to its permanent installation point.

1.4.2 Checking Shipment

Check the shipment against the packing lists. Tools, extra cutterhead equipment, etc. are packed in boxes. The 72” straight edge is fastened to the shipping platform. Separate the smaller parts as they are checked so there will be no possibility of their being discarded with the packing material. Notify Newman Machine Company, Inc. immediately if there is a shortage.

1.4.3 Cleaning

Before shipment all machined parts were coated with a rust preventative compound which may be removed by wiping with kerosene or varsol. Do not remove rust preventative until the day prior to the scheduled start up.

1.4.4 Extended Storage

1) Before shipment, each unpainted surface on the machine is coated with a rust preventative compound.

2) The bed plates, chipbreaker assemblies, lower feed rolls, roll raising shafts, high speed steel and green lumber cutterheads, head raising assemblies, pressure bar eccentric shaft, anti-lap shafts, anti-kickback shafts and fingers, guide rails, all three straight edges, and helical carbide knife bodies are machined steel or iron. These parts are highly subject to corrosion.

3) The rust preventative compound will dry out and begin losing its rust preventive properties in approximately two weeks. This compound is used to make it easier to clean off prior to machine start up.

4) If the machine is to be stored for an extended period of time (any length of time longer

than 14 days from the ship date), the following steps should be taken:

5) Coat all exposed metal surfaces with a heavy grease or rust preventative compound such

as COSMOLINE.

6) The bottom cutterhead should be rolled out of the machine and the yoke, support paddle,

and inside faces of the incline table and table after bottom head support coated with rust preventative.

7) If the machine is not going to be stored inside, drape a heavy tarp over the machine. The

tarp should be loose to allow air circulation and should be removed periodically to check for condensation buildup.

8) Do not remove the wooden skids until time for final installation. The shipping platform

may be removed at any time.

9) Do not store the electrical enclosure, detached control console, remote feeder console, or

electrical conduits outside. Store these items and the loose parts in a dry place. Remove the poly wrap from the cabinets to prevent condensation. A tarp may be loosely draped over these items if desired.

10) Additionally, both grinder rails and grinder slide assembly should be coated with a

lithium-based grease.

11) The machine components should be checked for condensation buildup and corrosion at

least once a week. Corrosion should be removed as soon as it is discovered. While performing the weekly condensation check, rotate both cutterheads three to four rotations (by hand) to prevent damage to the bearings.

1.5 Installing The Planer

Some consideration should be given to the location of the planer prior to installation. Most installations where the planer is replacing another unit go smoothly, the exception being that there is not enough room for the bottom cutterhead to be rolled out.

1.5.1 Foundation

The foundation should be per the foundation diagram for the model of machine that was purchased, i.e. EPR-18 (FIGURE. 1.7.1-A, B, C) or EPR-24 (Figure. 1.7.1-D, E, F). The machine should sit on the concrete or steel foundation with an underlay material (see below) between the machine base and foundation. The underlay material will prevent direct contact of the machine with the concrete or steel foundation and thereby absorb vibration.

Particular attention should be paid to having enough room on the left side of the machine to roll the bottom cutterhead out for grinding and jointing. If this area is normally a pedestrian or handling equipment traffic area, movable safety barriers should be provided for use when grinding or jointing.

On machines equipped with a machine enclosure, special attention must be paid to the area directly above the planer, as the two enclosure halves swing up when opened. Enough space should be left around the machine to allow the operator to open the enclosure.

Level the machine from infeed to outfeed and side to side using a spirit level on the incline table insert. Leveling should be done by driving thin hardwood wedges under the base. Place them close together and do not leave any portion of the frame unsupported so it will not be distorted when the bolts are tightened.

RECOMMENDED UNDERLAY MATERIALS

Unisorb vibration material - EB 1/2 coated both sides. Obtain from: Machinery Installation Systems, Jackson Michigan (517-764-6060)

Masterflow 713 grout (non-shrinking). Obtain from: Master Builders, Cleveland, Ohio (216-831-5500)

Clear hardwood board, approximately 1 inch thick, planed on both sides.

NOTE

INSTALL ANTI-LAP DEVICE AFTER PLANER IS INSTALLED, BUT

BEFORE THE INFEED CONVEYOR IS INSTALLED.

Figure 1.5.1-A Foundation Plan: EPR-18 With Anti-Lap

Figure 1.5.1-B Foundation Plan: EPR-18 With Anti-Kickback

Figure 1.5.1-C Foundation Plan: EPR-18 With Machine Enclosure

Figure 1.5.1-D Foundation Plan: EPR-24 With Anti-Lap

Figure 1.5.1-E Foundation Plan: EPR-24 With Anti-Kickback

Figure 1.5.1-F Foundation Plan: EPR-24 With Machine Enclosure

1.5.2 Accessory Equipment

Accessory lumber handling equipment, such as conveyors and pinch-rolls, need to be properly setup during their installation. The accessory equipment centerline must be in line with the planer centerline, and with the equipment at the other end of the planer. The bedline of the planer will determine the height of the accessory equipment. After the planer has been set in place, install the accessory equipment using Figure 1.7.2A, 1.7.2-B, or 1.7.2-C, as required by the type of equipment. For planning purposes, the bedline of the planer is 34 inches from the floor, not including the vibration dampening material. On machines equipped with a machine enclosure the outfeed lumber handling equipment must be placed not less than 9 inches from the planer’s frame at the outfeed end. Installations using an outfeed chain table should install the equipment according to the manufacturer’s instructions. The chain table should be placed 2-3 inches from the planer outfeed or the outfeed pinch-roll. There should not be any obstructions within 6 inches of the chain table that may obstruct the lumber as it moves down the chain. If the planer has the anti-kickback option, the outfeed conveyor or table should be installed in accordance with Figure. 1.7.2-B. As shipped from the factory, the planer’s incline table is set to 3/32” below the bottom cutterhead, and the top head yoke has been lowered onto a shipping block that rests on the incline table and table after bottom head. The top head yoke must be raised to 6 inches, the block removed, and the incline table raised to 0 (see section 2.4.1 and 3.3.1). This will be bedline for all installation measurements.

STRAIGHT EDGE

ANTI-LAP LOWER GATE

TABLE AFTER BOTTOM HEAD

BOTTOM OUTFEED ROLL

BOTTOM INFEED ROLLS

INCLINE TABLE & A.C.C.

BOTTOM CUTTERHEAD LOWERED 5 TURNS OF HANDCRANK

CONVEYOR ROLL SHOULD BE 1/4" TO 3/8" LOWER THAN STRAIGHT EDGE. BELT SHOULD NOT TOUCH STRAIGHT EDGE EXCEPT FOR THE LAST 3 INCHES. THE INFEED END OF THE CONVEYOR (END FURTHEREST FROM PLANER) SHOULD BE RAISED 1.5" HIGHER THAN END CLOSEST TO PLANER

Figure 1.5.2-A Alignment of Infeed Conveyor

STRAIGHT EDGE

CONVEYOR ROLL 1/4" TO 1/2" BELOW STRAIGHT EDGE

CONVEYOR BELT SHOULD NOT CONTACT STRAIGHT EDGE UNTIL APPROXIMATLY 6" FROM END

END FRAME

TABLE AFTER BOTTOM HEAD

BOTTOM OUTFEED ROLL

BOTTOM CUTTERHEAD LOWERED 5 TURNS OF HANDCRANK

BOTTOM INFEED ROLLS

INCLINE TABLE & A.C.C.

Figure 1.5.2-B Alignment of Outfeed Conveyor

STRAIGHT EDGE

BRING PINCH ROLL UP TO TOUCH BOTTOM OF STRAIGHT EDGE

OUTFEED FRAME

INCLINE TABLE & A.C.C.

BOTTOM CUTTERHEAD LOWERED 5 TURNS OF HANDCRANK

TABLE AFTER BOTTOM HEAD

BOTTOM OUTFEED ROLL

Figure 1.5.2-C Alignment of Outfeed Pinch Roll

BOTTOM INFEED ROLLS

1.5.3 Electrical

1.5.3.1 Electrical Requirements

The plant electrical connection to the planer is the customer’s responsibility. Connection to the planer’s main electrical panel is made through the top left-hand corner of the cabinet. The customer must provide a means of disconnecting the electrical power from the planer and locking it out.

Power requirements for the EPR-series planers are:

EPR-18 VOLTAGE 460 VAC 3 PHASE 60 HZ

F.L.A. 100A FUSE 125A BREAKER 150A VOLTAGE 380 VAC 3 PHASE 50 HZ F.L.A. 123A FUSE 175A BREAKER 200A VOLTAGE 230 VAC 3 PHASE 60 HZ F.L.A. 123A FUSE 250A BREAKER 300A

EPR-24 VOLTAGE 460 VAC 3 PHASE 60 HZ

F.L.A. 166A FUSE 200A BREAKER 250A VOLTAGE 380 VAC 3 PHASE 50 HZ F.L.A. 185A FUSE 200A BREAKER 400A VOLTAGE 230 VAC 3 PHASE 60 HZ F.L.A. 314A FUSE 400A BREAKER 500A

These specifications are for standard horsepower premium efficiency motors. They are subject to change if a different horsepower or motor efficiency rating is specified by the customer. The specifications for each individual machine are on a data plate on the front of the main electrical panel enclosure.

1.5.3.2 Care Of Electrical Equipment

An electrical schematic diagram is supplied with each machine when shipped from the factory. On a standard machine, a copy of the diagram will be found in a pocket provided on the

inside of the main electrical panel cabinet door. The serial number of the machine is required when ordering extra copies of the electrical diagram.

The magnetic starters are wired so that if either the top or bottom cutterhead motor stops due to an overload, the other cutterhead motor will also stop. When either of the cutterhead motor starters drops out due to overload, both feedroll motors will also drop out.

Before the planer can be started again, the overload relays in the magnetic starter must be manually reset. Allow time (about one or two minutes) for the overloads to cool before pressing the reset buttons. Do not restart the planer, however, until the trouble has been determined and corrected.

The electrical motors should be cleaned regularly with compressed air in order to keep all air ducts open. Clogged ventilating ducts prevent the flow of air, resulting in a temperature rise higher than that indicated on the nameplate of the motor. When a motor is required to run at elevated temperatures its life is greatly reduced.

1.5.4 Compressed Air Requirements

The planer requires connection to the plant’s compressed air system, and requires 80 P.S.I. to 110 P.S.I. The planer’s air connection is located on the upper right corner of the air valve panel, which is located underneath the infeed rolls. (Section 3.5.8)

System air should be dehydrated, and should not be allowed to drop below 80 P.S.I. Pressure levels below this affect the upper roll raising mechanisms. If system pressure drops below 60 P.S.I., there may not be enough pressure to raise the feedrolls.

1.5.5 Dust Collection Requirements

The planer’s two cutterheads are equipped with separate dust collection chutes. The top head chute has a 10” diameter opening. The bottom head chute has an 8 3/4” diameter opening for connection to 9” pipe.

A minimum suction head of 4” to 5” of water should be maintained in each branch pipe leading away from each hood or chute. A suction head test can be made by placing one end of a rubber tube over a small hole in the branch pipe near the hood or chute and connecting the other end of the tube to a U-shaped water gauge and noting the difference in water level between the two sides of the gauge. All the branch pipes should be open and unobstructed while the test is being made.

The EPR-Series machines require 6400 C.F.M. (Cubic Feet per Minute) total. The top hood requires 3545 C.F.M., and the bottom hood requires 2855 C.F.M. The air velocity should be at least 6500 feet-per-minute per cutterhead, measured at the pipe-to-hood junction.

The area of the main exhaust duct should be equal to or slightly larger than the sum of the areas of the branch pipes.

Elbows or turns in the pipe should have a radius in the throat at least equal to or greater than one and one half times the diameter of the pipe. Branch pipes should never enter the main

pipe at right angles, but should be connected at an angle of from 30o to 45o. Branch pipes should not enter the main pipe from the bottom but from the sides or top. Two branch pipes should not enter directly opposite each other.

Pipes should be kept free of obstructions and the area of the pipe should never be reduced after it leaves the hood or chute.

1.5.6 Start-Up Procedures

The EPR-Series of Double Roughing Planers are electrically powered machines with an electrically driven infeed/outfeed system. All magnetic motor starters and motor controllers are located in a remote electrical control enclosure. The remote enclosure is designed for floor mounting remote from the machine.

All internal electrical wiring and pneumatic plumbing is fitted and tested at the factory. All adjustments for the proper speed of the motors are made prior to shipment. The terminals to which the outside electrical leads are to be connected are located near the top of the electrical control enclosure.

Before starting the machine for the first time make sure that:

1. All alignment has been performed in accordance with the procedures outlined in section 3.3.1.

2. Lubrication and adjustments have been made as indicated in sections 3.1 and 3.3.1.

3. Each cutterhead motor turns freely with no drag.

4. All foreign objects have been removed from the planer and feed-tables, including alignment tools.

5. Voltage and phase of all electrical motors are the same as those of the supply line.

6. All guards have been properly fastened to the planer, and the dust collector chutes are installed and hooked up.

7. Compressed air is hooked up and pressures set according to section 3.5.8.

When ready to start, turn the main power line switch to ON. Next, start each cutterhead individually with the start buttons located on the main console. If the cutterheads do not start, make sure that current is coming to the machine before looking for trouble elsewhere. Cutterheads should rotate so that knives will cut against the feed. If a three phase motor runs backwards, it may be corrected by reversing any two leads.

2 THEORY OF OPERATION

2.1 Planer Description

The EPR-Series Planers are electrically driven double roughing planers. The planer accepts lumber at its’ infeed, lines it up with the cutterheads, and feeds the lumber through the cutterhead section. The cutterheads remove material from the top and bottom surface of the board simultaneously. Because of the design of the planer (and depending on lumber grade), the board will exit the planer planed to a typical tolerance of less than .015”. Feed speeds vary from 40 feet per minute at the low end to 150 feet per minute for an EPR-18, and from 60 to 250 feet per minute for the EPR-24. Various mechanical adjustments can be made to allow for wear and different species of wood. These adjustments also determine dimension tolerance. The operating controls are electrical, with the feedrolls being driven through a reduction gearbox by electric motors. The motors are controlled by variable frequency controllers. The cutterhead brakes, chipbreaker release, roll raising mechanism, and pressure bar release are pneumatically operated by solenoid valves. The pressure bar, chipbreakers, and Automatic Cut Control fingers are mechanically tensioned by springs. The upper feedrolls consist of 3 or 4 pneumatic tires. The tires are shaft mounted, with removable hub extensions. Feedroll traction is developed as a result of weight. The roll is held down by gravity when in the ‘RUN’ position and given an extra 40 P.S.I. of pressure on the down side of the roll raising cylinder when in the ‘DOWN’ position. (This increases traction when in ‘REVERSE’ or when running badly warped lumber.) The top head assembly serves as the attach point for 3 operating groups: the top cutterhead assembly; the chipbreaker assembly; and the pressure bar assembly. The chipbreaker assembly consists of 6 or 8 individually adjustable sections. Each section is spring loaded so it will give under pressure from wood passing underneath. The chipbreaker presses the lumber into the incline table, providing a solid anvil for the top cutterhead to work against. The chipbreaker acts as the chip break-off point for the top cutterhead. The pressure bar holds the board down solidly against the table after bottom head. It also acts as the anvil for the bottom cutterhead. The pressure bar is positioned so that its’ leading edge is the same height above the incline table as the top cutterhead cutting circle. The incline table positions the wood for the cutting action of the bottom cutterhead and serves as the chip break-off point for the bottom cutterhead. (For this purpose, the Automatic Cut Control fingers are the actual chip break-off point.) The height of the incline table in relation to the top of the bottom cutterhead cutting circle determines the maximum amount of cut available on the bottom head. The bottom cutterhead cutting circle is positioned higher than the table after bottom head. The table after bottom head holds the wood up as it passes from the cutterhead section to the outfeed roll section and acts as the second hold down device for the top cutterhead.

2.2 Automatic Cut Control

The A.C.C. (Automatic Cut Control) is a sectional, mechanical device designed and developed by Newman*Whitney to offset the fixed bottom head cut found on conventional knife planers, and to provide more equal cut distribution between the top and bottom cutterheads.

The varying bottom head on the A.C.C. equipped EPR-Series planer provides for shared distribution of cut between the top and bottom cutterheads up to the maximum cut set for the bottom cutterhead. On boards that are at or below target thickness the A.C.C. equipped planer will not cut the board at all. This results in increased lumber yield for the user.

The A.C.C. consists of sections that are 3-11/16" wide, mounted on a shaft allowing each section to pivot individually. Each section has dual steel springs that apply approximately 50 pounds of force to each section. This force positions the sections approximately 5/16" above the flat surface of the incline table bedplate. By positioning these fingers in this manner, they apply upward pressure against boards, forcing them against the upper pressure bar.

Target size for lumber is set by raising or lowering the top cutterhead according to the desired thickness. Once the target thickness has been set, the A.C.C. will prevent boards from being cut less than target size. This is accomplished by the A.C.C. fingers holding the board against the pressure bar at the bottom head and allowing the bottom head to cut to finish the board to the target thickness. By increasing or decreasing the depth of cut on the bottom cutterhead one can provide for more equal stock removal.

Remember, because the A.C.C. is applying upward force against the pressure bar, any board that is scant or below target size will not depress the A.C.C. sections enough to take a cut on the bottom cutterhead. For example, if you have a heavy 3/32" cut registered for the bottom cutterhead, it will not remove 3/32" from every board unless there is sufficient stock for complete depression of the A.C.C. sections.

2.3 Controls

The operator’s console is connected to the main electrical panel by a 30 foot conduit. This panel contains all of the operator’s electrical controls. (Section 2.3.1) The main electrical panel is connected to the planer by two 18 foot conduits. The remote or feeder console (Optional) is connected to the operator’s console by a 25 foot conduit. This panel contains duplicates of some of the operator’s console’s controls. (Section 2.3.1) For the purposes of this manual, mechanical controls are grouped and described with the mechanical adjustments. (Section 2.4.1.)

2.3.1 Operator’s console

Figure 2.3.1-A Operator’s Console

Operator’s Console Function Table

1. FEED SPEED INDICATOR - Shows the feed speed of the upper feedrolls in feet per minute. It is active in both forward and reverse.

2. TOP HEAD - Illuminated momentary pushbutton. Starts the top cutterhead motor, and indicates that the starter is in the run mode. (It is overridden or released by the ‘UP/RUN/DOWN’ switch in ‘UP’ and both EMERGENCY STOP buttons.)

3. BOTTOM HEAD - Illuminated momentary pushbutton. Starts the bottom cutterhead motor and indicates that the starter is in the run mode. (It is overridden or released by the ‘UP/RUN/DOWN’ switch in ‘UP’ and both EMERGENCY STOP buttons.)

4. FEED START - Illuminated momentary pushbutton. Starts the upper feedroll motors, and indicates that the starter is in the run mode. It will not engage unless both cutterhead motors are running. (It is overridden or released by the ‘UP/RUN/DOWN’ switch in ‘UP’ and both EMERGENCY STOP buttons.)

5. FEED SPEED CONTROL - Potentiometer that controls speed of the feedrolls. Varies feed speed from the minimum set speed to the maximum forward speed the machine is capable of. It is not active in reverse mode.

6. STOP FEED - Pushbutton. Stops the feedroll motors. Does not affect the cutterhead motors.

7. TOP HEAD UP - Momentary pushbutton. Activates the top head power hoist motor to raise the top head assembly. It is overridden by an upper limit switch at 6 inches above bedline, and a crank handle proximity sensor on the top head raising shaft.

8. FWD/REV - 2 position rotary switch. Controls the feed system.

FWD - Enables feed system to run in the forward direction. REV - Enables feed system to run in the reverse direction. Activates solenoid valve to

apply 40 P.S.I. to the down side of the roll raising cylinders to increase traction.

9. UP/RUN/DWN - 3 position rotary switch. Controls upper feedroll raising mechanism.

UP - Raises the upper feedrolls to the full open position. Disables both cutterhead

starters and the feedroll motors starters. It will not function if the brake timers are functioning.

- Upper feedrolls are in the normal run position.

RUN DWN - Activates solenoid valve to apply 40 P.S.I. to the down side of the roll raising

cylinders to increase traction.

10. TOP HEAD DOWN - Momentary pushbutton. Activates the top head power hoist motor to lower the top head assembly. It is overridden by a lower limit switch at 1/2 inch above bedline and a crank handle proximity sensor on the top head raising shaft.

11. CHIPBREAKER RELEASE - Push button switch on machines that do not have the air operated pressure bar release. Activates a solenoid valve to operate the chipbreaker release.

12. PRESSURE BAR RELEASE / CHIPBREAKER RELEASE - 3 position switch, spring loaded to center off position. Only on machines equipped with air operated pressure bar release.

PRESSURE BAR RELEASE - Activates a solenoid valve to operate the pressure bar

release.

CHIPBREAKER RELEASE - Activates a solenoid valve to operate the chipbreaker

release.

13. MAIN/FEEDER - 2 position rotary switch. Only present on machines with remote feeder console option.

MAIN - All controls on the operator’s console are active. Only ‘E-STOP’ on feeder

console is active.

FEEDER - FEED START; FEED STOP; FWD/ REV; PRESSURE BAR

RELEASE/CHIPBREAKER RELEASE or CHIPBREAKER RELEASE functions are transferred to the feeder console. All other controls on the main panel remain active.

14. EMERGENCY STOP - Two position, push-pull type, internally illuminated palm switch. When pushed in, it stops the top cutterhead motor, bottom cutterhead motor, and both feedroll motors, and activates the brake timers. When pulled out, the RED internal light is on, and the cutterhead motor starters, feedroll frequency controllers, and conveyor frequency controllers (if installed) are enabled to allow the motors to be started.

• The top head power hoist, pressure bar release, chipbreaker release, and upper feedroll positioning functions are still active when the EMERGENCY STOP button is pressed in.

Use of the EMERGENCY STOP is not the same as the Lock Out-Tag Out procedure. Follow local procedures to make the machine safe for maintenance purposes.

CAUTION

2.3.2 Feeder Console (Optional)

START FEED REV - FWD

PRESSURE BAR RELEASE

STOP FEED

RED

CHIPBREAKER RELEASE

EMERG. STOP

RED

BLANK

Figure 2.3.2-A Feeder Console

Feeder Console Function Table

1. FEED START - Illuminated momentary pushbutton. Starts the upper feedroll motors and indicates that the starter is in the run mode. It will not engage unless both cutterhead motors are running. (It is overridden or released by the ‘UP/RUN/DOWN’ switch in ‘UP’ and both EMERGENCY STOP buttons.)

2. STOP FEED - Pushbutton. Stops the feedroll motors. Does not affect the cutterhead motors.

3. FWD/ REV - 2 position rotary switch. Controls the feed system.

FWD - Enables feed system to run in the forward direction. REV - Enables feed system to run in the reverse direction. Activates solenoid valve to

apply 40 P.S.I. to the down side of the roll raising cylinders to increase traction.

4. CHIPBREAKER RELEASE - Push button switch on machines that do not have the air operated pressure bar release. Activates a solenoid valve to operate the chipbreaker release.

OR PRESSURE BAR RELEASE / CHIPBREAKER RELEASE - 3 position switch, spring loaded to center off position. Only on machines equipped with air operated pressure bar release.

PRESSURE BAR RELEASE

- Activates a solenoid valve to operate the pressure bar

release.

CHIPBREAKER RELEASE

- Activates a solenoid valve to operate the chipbreaker

release.

5. EMERGENCY STOP - Momentary pushbutton switch with red palm button. Stops top cutterhead motor, bottom cutterhead motor, and both feedroll motors, and activates the brake timers.

2.4 Planer Adjustments

2.4.1 Mechanical Adjustments

Fig. 2.4.1-C

Figure 2.4.1-A Left Side Adjustments

Figure 2.4.1-B Bottom Infeed Rolls and Air Valve Panel

LENGTH OF STROKE

MANUAL RELEASE

(YELLOW BUTTON)

VERTICAL ADJUSTMENT

Figure 2.4.1-C Pneumatic Pressure Bar Adjustments

17 18

Figure 2.4.1-D Anti-Lap Adjustments

Figure 2.4.1-E Right Side Adjustments

32 - DOWN TRAVEL LIMIT

32 - UP TRAVEL LIMIT

Figure 2.4.1-F Top Head Limit Stops

Figure 2.4.1-G Chipbreaker Adjustments

Mechanical Adjustments Table

1. Top Head Lock - Locks and unlocks top head yoke. Clockwise rotation locks yoke.

Counter clockwise rotation unlocks yoke.

2. Top Head Raising Screw Lock, (Left Hand) - locks top head raising screw in position.

Used to level top head to incline table.

3. Incline Table Scale. (Bottom Head Depth Of Cut.)

4. Vertical Adjustment For Incline Table.

5. Vertical Adjustment For Top Cutterhead.

6. Tension Adjustment For Top Head Power Hoist Chain.

7. Vertical Adjustment For Bottom Cutterhead.

8. Vertical Adjustment For Lower Outfeed Roll. (Left Hand)

9. Bottom Head Lock - Locks and unlocks bottom head yoke.

10. Pressure Bar Spring Tension Adjustments

11. Lower Infeed Roll Vertical Adjustment, Left Side, Typical Four Places.

12. Lower Infeed Roll Vertical Adjustment, Right Side, Typical Four Places.

13. Upper Feedroll Down Pressure Adjustment

14. System Pressure Adjustment

15. Pneumatic System ON/OFF Valve

16. Anti-Lap Lower Fence Vertical Adjustment, (Typical Both Sides)

17. Anti-Lap Upper Gate Adjustment Handwheel

18. Anti-Lap Upper Gate Lock

19. Anti-Lap Leaf Spring Tension Adjustment, (Typical Both Sides.)

20. Anti-Lap Lower Gate Vertical Adjustment, (Typical Both Sides.)

22. Top Head Raising Screw Lock, (Right Hand) - Locks top head raising screw in position.

Used to level top head to incline table.

23. Outfeed Roll Down Stop Adjustment.

24. Lower Outfeed Roll Scraper Adjustment

25. Vertical Adjustment For Lower Outfeed Roll. (Right Hand)

26. Outfeed Roll Raising Flow Control, Up Side.

27. Outfeed Roll Raising Flow Control, Down Side.

28. Bottom Head Yoke Slide Stop.

29. Infeed Roll Raising Flow Control, Up Side.

30. Infeed Roll Raising Flow Control, Down Side.

31. Infeed Roll Down Stop Adjustment.

32. Power Hoist Up And Down Limit Switch Adjustments.

33. Chipbreaker Height Adjustment, Typical All Sections

34. Chipbreaker Spring Tension Adjustment, Typical All Sections

3 PLANER MAINTENANCE

This section is intended to give the planer operator and maintenance man the knowledge to perform effective preventative maintenance.

Lubrication, suggested preventative maintenance schedule, and alignment procedures are in sections 3.1, 3.2, and 3.3.

Separate sections on wear and replacement for major components are in section 3.4.

Preventative maintenance is maintenance done on a schedule. The purpose of preventative maintenance is to maintain equipment in such a manner as to greatly reduce the possibility of a breakdown.

Preventative maintenance includes inspection, lubrication, adjustment, cleaning, and replacement of worn parts before they cause a problem.

Preventative maintenance reduces operating cost by reducing down time. If preventative maintenance is performed outside of normal operating hours, then even more production time is available.

If the replacement of worn parts can be scheduled, then a costly and time-consuming breakdown may be prevented.

3.1 Planer Lubrication

3.1.1 Lubrication Schedule

Lubrication is a necessity for increased machine life. Proper lubrication will increase the life of the bearings, various gear assemblies, and slide wear parts and decrease the number of repairs. The following intervals and lubricants (or their equivalents) are recommended.

Planer Lubrication Schedule

ITEM LUBRICANT SCHEDULE

Cutterhead Bearings Lubriplate EMB Grease Every 40 hours of

operation

Roll Bearings Lubriplate EMB Grease

or equivalent

Incline Table Slide-Ways Lubriplate EMB Grease

or equivalent

Chipbreaker Joints Lubriplate EMB Grease

or equivalent

Pressure Bar Shaft Lubriplate EMB Grease

or equivalent

Bottom Head Locks Lubriplate EMB Grease

or equivalent

Electric Motor Bearings Lubriplate EMB Grease

or equivalent

Pneumatic Lubricator Texaco Spindura Oil 10

or equivalent

Reduction Gearbox Texaco Meropa 220 or

equivalent

Top Head Power Hoist

Gearmotor

Texaco Meropa 220 or

equivalent

Every 160 hours or 4

weeks

Every 160 hours or 4

weeks

Every 160 hours or 4

weeks

Every 160 hours or 4

weeks

Every 160 hours or 4

weeks

Every 1000 hours or 125

days

As Required By Weekly

Inspection

As Required By Monthly

Inspection

As Required By Monthly

Inspection

Bottom Head Slide Bar Light Machine Oil When Bottom Cutterhead

is Ground.

Top Head Raising

Gear Assembly

Lubriplate EMB Grease

or equivalent

Annually

3.1.2 Lubrication Points

2 3

Figure 3.1.2-A Left Side Lubrication Points #1

9 8

Figure 3.1.2-B Infeed Lubrication Points

DETAIL

17 - CHIPBREAKER LUBRICATION

Figure 3.1.2-C Chipbreaker Lubrication Points

Figure 3.1.2-D Bottom Head Jackscrew and Roll-Out Bearing

Figure 3.1.2-E Eurodrive Gearbox

Figure 3.1.2-F Right Side Lubrication

Planer Lubrication Points Table

1. Top cutterhead bearing.

2. Infeed roll bearing.

3. Infeed roll pivot shaft bearing.

4. Top head raising shaft bearing.

5. Upper incline table slide.

6. Top head power hoist drive chain.

7. Top head hoist gearmotor.

8. Top head raising gear assembly.

9. Bottom head raising jackscrew.

10. Bottom head lock.

11. Outfeed roll bearing.

12. Outfeed roll pivot shaft bearing.

13. Bottom cutterhead bearing.

14. Lower incline table slide.

15. Incline table raising worm gear.

16. Air system oil dispenser.

17. Chipbreaker rotating joint.

18. Bottom head roll-out bearing.

19. Feedroll reduction gearbox (typical two places).

20. Cutterhead electric motor bearing. (Not shown. Two points on each motor.)

21. Bottom head slide bar.

3.2 Preventive Maintenance Schedule

Clean area around top

head

Remove dust, chips, and shavings

Any time the top cutterhead is raised,

Clean planer interior

Remove dust, chips, and shavings

At end of eac

h shift.

Clean planer exterior

Remove dust, chips, and shavings

At end of each shift.

Clean area underneath Automatic

Remove dust, chips, and shavings

At end of each shift.

Check tire wear

Visually inspect all roll tires for

At least once each shift.

Check tire pressure

Using the inflator gauge, check the

Before each shift.

Machine Alignment

Check bedline; bottom infeed and

After grinding or jointing the knives.

Machine Alignment:

Check cutterhead level to table after

Any time the bottom cutterhead has

Machine wear

Check bedplates; chipbreaker toe

Machines with Helical Carbide

This schedule is recommended by the Newman Machine Company Engineering. It does not include the cutterhead knives. Lubrication of the machine is covered in a separate schedule.

ITEM ACTION SCHEDULE

raising screws

Cut Control fingers

Note 1

General

Note 2

Bottom cutterhead

Note 2

with compressed air.

with compressed air. Remove large pieces by hand.

with compressed air.

with compressed air. Manually operate fingers if required to clean.

worn areas.

pressure in all feedroll tires.

outfeed roll height; top cutterhead alignment; pressure bar alignment; chipbreaker height; bottom cutterhead level and height

bottom head; cutterhead height above table after

plates; Automatic Cut Control fingers; steel rolls

before it is lowered.

been rolled out and back into the machine.

cutterheads: After grinding and jointing the knives. Machines with High Speed Steel cutterheads: At least once every ninety days.

Notes:

1. Heavy wear on any one tire can indicate low pressure in that tire. Heavy wear can also

cause the planer to have feed problems.

2. Feed problems are often caused by poor machine alignment. Alignment should be checked

any time feed problem causes are not readily apparent.

3.3 Machine Alignment Procedures

3.3.1 Bedline Alignment Procedure

Figure 3.3.1-A Bedline Alignment Diagram

The table after bottom head is used as the reference point for making all height and alignment adjustments. Refer to Figure 3.3.1-A.

CAUTION

Remove the main electrical power from the planer after

Step 1. Restore main electrical power only after the

maintenance action is complete.

1. Stop the planer, and lock out the cutterheads and feed system. Unlock and raise the top

cutterhead to approximately 6 inches. Raise the upper feedrolls and brace them in the raised position.

• Planers equipped with Anti-Lap – Raise the anti-lap upper gate to maximum to allow the long straight edge to be inserted into the machine.

• Planers equipped with Anti-Kickback – Raise the fingers and chock them in the raised position using a wooden block under the cylinder arm.

2. Unlock and lower the bottom head three full turns of the hand crank.

3. Blow out the bed of the machine using compressed air. Clean the table after bottom head and incline table using a good solvent.

4. Lower bottom outfeed roll below table after bottom head.

5. Lower 1st and 2nd bottom infeed rolls below bedline.

6. Insert the long straight edge long-end first into the machine from the outfeed end. Position the straight edge on the left side of the planer bed. The cutout on the bottom of the straight edge will fit over the A.C.C. fingers. Use caution when inserting the straight edge so that the knives will not be damaged.

7. Raise the incline table to 0 on the incline table scale (Adjustment 8).

8. Using a 0.0015” feeler gauge to check, adjust the incline table up or down until the straight edge rests flat on the incline table.

• Moderate down pressure may be required on the outfeed end of the straight edge

to ensure that it is resting flat.

9. Check the table after bottom head for alignment. The leading edge of the table should be

0.0015” tight to the straight edge for at least one inch.

10. Repeat steps 7 and 8 on the other side of the machine.

11. Check the first infeed roll. It should be 0.0015” tight to the straight edge. If it is not, use the square head screws at the end of the roll to adjust the roll height up or down (Adjustment 19).

• Check the leading edge of the incline table insert (the plate closest to the bottom

cutterhead). The straight edge should be 0.004” above the insert.

• If it is not, use the square head screws at the end of the roll to adjust the roll

height up or down.

12. Check the 2nd infeed roll. It should be 0.0015” tight to the straight edge. If it is not, use the square head screws at the end of the roll to adjust the roll height up or down (Adjustment 19).

13. Check the 3rd infeed roll. It should be 0.0015” tight to the straight edge. If it is not, use the square head screws at the end of the roll to adjust the roll height up or down (Adjustment 19).

14. Check the 4th infeed roll. It should be 0.0015” tight to the straight edge. If it is not, use the square head screws at the end of the roll to adjust the roll height up or down (Adjustment 19).

15. Repeat steps 10 through 13 on the right side of the machine. Re-check left side.

16. Raise the bottom outfeed roll until it contacts and raises the straight edge. The straight edge should be 0.008” above the leading edge of the table after bottom head (adjustments 9 & 13).

17. Remove the long straight edge from the machine.

18. Using the top head setting block, check the top cutterhead for level to the bedline.

• Place the setup block under the operator’s side of the top cutterhead so that its

length is perpendicular to the cutterhead.

• Rotate the top cutterhead by hand in a clockwise direction. Slowly lower the top

cutterhead until the tips of the knives brush across the top of the block.

• Repeat this step on the other side of the machine. If the top cutterhead is not

level, adjust the operator’s side of the cutterhead until level. See section 3.3.2.

19. The front edge of the top head pressure bar must be even with the bottommost projection of the knives in the top cutterhead. Using the top head setting block, check the height of the leading edge of the pressure bar. The block should have the same amount of drag on its top that the knives produce.

20. If the block does not touch the pressure bar, or will not go underneath the pressure bar, adjust the height of the pressure bar. See section 3.3.3.

• A vertical adjustment handwheel is provided for machines with a manual pressure

bar release. See section 3.3.3.

• A vertical adjustment setscrew is provided for machines with an air operated

pressure bar release. See section 3.3.3.

21. The leading edge of the pressure bar should be approximately 0.007” lower than the back edge. Insert the two short straight edges. (See section 3.3.5, steps 4 and 5.) Using a

0.006” and a 0.008” feeler gauge, check the distance between the top of the straight edges and the rear of the pressure bar. If the 0.006” gauge will slide in and the 0.008” will not slide in, then the tilt is correct.

• Three leveling screws and three jackscrews are provided for this adjustment on

EPR-18 and EPR-24 machines. See section 3.3.3.

22. Check for the tip of the top head chipbreakers 1/16” below the top cutterhead cutting circle. Raise the top cutterhead yoke two turns of the hand crank (this is 1/16”). Slide the setup block underneath the chipbreaker toes. There should be moderate resistance.

Check each chipbreaker assembly. The resistance as the block is pushed under the toes should be the same for all chipbreakers.

• See section 3.3.4 for adjustment.

• Pay attention to excessive loss motion in pins and links so as to always have

spring tension when chipbreaker yields.

23. The bottom cutterhead should be level with the table after bottom head.

• If this test shows the bottom head is not level, use the procedure in section 3.4.

24. Place both short straight edges on table after bottom head, with cutout up, and the end extending over the bottom cutterhead.

25. Raise the bottom cutterhead to 0.003” - 0.005” above the table after bottom head by using a feeler gauge between the straight edge and the table after bottom head.

26. The top infeed and outfeed rolls should have down stop adjust nuts (Adjustment 17) set for proper feeding without undue strain on tire and rim due to natural pull-under pivot effect.

Bedline alignment is now complete.

3.3.2 Leveling The Top Head Assembly

1. Stop the planer and lock out the cutterheads and feed system. Unlock and raise the top cutterhead to approximately 6 inches. Raise the upper feedrolls and brace them in the raised position.

CAUTION

Remove the main electrical power from the planer after

Step 1. Restore main electrical power only after the

maintenance action is complete.

Figure 3.3.2-A Top Head Leveling Adjustments

2. Remove the safety guard from the right side of the machine and raise the guard on the left side of the machine to gain access to the interior of the planer.

3. Blow out the bed of the machine using compressed air. Clean the table after bottom head and incline table using a good solvent.

4. Place the wooden top head setting block underneath the top head assembly so that the block is lengthwise to the cutterhead and chipbreakers. The block should be in between the cutterhead and chipbreakers.

• Slowly lower the top head assembly until the block will not slide underneath the cutterhead.

• Slowly raise the top head assembly until the block will slide underneath the cutterhead.

• This eliminates the backlash of the top head raising mechanism so that the top head is

resting solidly on the raising screws.

5. Rotate the block until it is perpendicular to the body of the cutterhead.

• Slowly rotate the top cutterhead clockwise by hand. Slowly raise the top head until the knives just touch or ‘tap’ the top of the block. If the knives hit the block hard enough to move it towards the pressure bar, the top head is too low.

6. Repeat steps 5 and 6 on the opposite side of the machine.

• If the feel of the taps on the block is the same on both sides of the head, then the top head is level and parallel to the incline table. No further action is required.

• If the feel of the taps on the block is not the same on both sides, proceed with step 7.

NOTE

ALWAYS ADJUST THE LEVEL OF THE TOP CUTTERHEAD FROM THE

OPERATOR’S SIDE OF THE MACHINE.

The raising screw lock on the motor side raising screw has a set screw to prevent

rotation of the screw. The set screw should not be moved except to replace the

raising gear assembly.

7. Use the setup block to set the height on the motor side of the cutterhead.

8. On the operators’ side of the machine, insert the block under the top head. Loosen the two setscrews that clamp the raising screw in place in the top head yoke. (Figures 3.3.2 A & B)

9. Locate the hole near the top of the top head raising screw. Insert a 6” #2 Phillips screwdriver into the hole. Using the screwdriver, adjust the head up as required. Continue to check the cutterhead for position by checking for the feel of the taps on top of the block.

10. When the cutterhead height is adjusted properly, move the block to the other side of the machine, and check the cutterhead height.

11. If the height is correct, tighten the raising screw lock setscrews.

• If the high side of the cutterhead is still too high, tighten the low side lock setscrews before readjusting the height. Otherwise the raising screw will rotate, causing the unlocked side to be even lower than it originally was.

12. Make sure that all tools have been removed from the machine prior to returning it to operation.

TO CHECK THE ALIGNMENT OF THE PRESSURE BAR TO THE TOP CUTTERHEAD:

This procedure is a continuation from step 12 of leveling the top cutterhead.

13. Gently pull the block towards the outfeed of the planer. It should just barely start to go underneath the toe of the pressure bar. Check both sides of the pressure bar.

14. Loosen the center hex head cap screws located near the top of the pressure bar until they are finger loose. Adjust the two outer hex head cap screws until you have the same height on both sides of the pressure bar. This is determined by how tight the pressure bar feels on top of the block. When this is accomplished, tighten the center cap screws finger-tight, and tighten their jam nuts. Carefully tighten the outer jam nuts. Check to see that the height has not changed.

15. Set the tension of the pressure bar springs using the 1/2” square head setscrews. A setscrew is located in the bottom of the pressure bar slide on each side of the pressure bar. (Figures 3.3.2 A & B)

• Loosen the jam nut.

• Tighten the setscrew until it is as far in as it will go.

• Back the setscrew out 3/4 to one full turn.

• Tighten the jam nut.

16. Repeat for the setscrew on the opposite side of the pressure bar.

17. Reinstall the guards on the machine and insure that all tools are accounted for.

Figure 3.3.2-B Pressure Bar Leveling Adjustments

3.3.3 Aligning The Pressure Bar

The following instructions are intended to enable the maintenance personnel to adjust and set the pressure bar on an EPR Series Double Roughing Planer. The illustrations are simplified pictures of specific portions of the planer mechanism and are intended only to clarify the adjustment points mentioned.

Safety is an important consideration during this procedure. Ensure that power is applied to the planer only when large movements of the top head are required.

This procedure requires that you have at hand the following items:

15/16" wrench 9/16” wrench 7/8" wrench 5/32" Allen wrench 3/4" wrench Feeler gauge set 1/2" wrench Top head setting block 5/8" wrench (2) Short parallel straight edges

1. Stop the planer and lock out the cutterheads and feed system. Unlock and raise the top

cutterhead to approximately 6 inches. Raise the upper feedrolls and brace them in the raised position. Clean the incline table and table after bottom head using compressed air and a solvent to remove chips and sap build-up.

CAUTION

Remove the main electrical power from the planer after

Step 1. Restore main electrical power only after the

maintenance action is complete.

2. The planer's bedline must first be obtained using the procedure given in section 3.3.1. This

is to ensure that the top head assembly is parallel to the bedplates.

3. Place the two short straight edges in the planer, one on each side of the bed, so that the

thicker end rests on the incline table. Using the hand crank, lower the incline table until both of the straight edges are resting flat on the incline table, and touching just the leading edge of the table after bottom head. (Figure 3.3.3.A).

NOTE LOWER THE TOP HEAD VERY SLOWLY. THE CARBIDE KNIVES IN THE CUTTERHEAD FRACTURE EASILY. EXCESSIVE PRESSURE ON

THE KNIFE FROM THE STRAIGHT EDGE CAN BREAK KNIVES.

Figure 3.3.3-A Placement Of Straight Edges

4. Run the top head down using the hand crank until the front edge of the pressure bar just touches the front top side of the straight edge, and the rear side of the pressure bar is .008" above the straight edge (Figure 3.3.3.B).

Figure 3.3.3-B Relationship Of Pressure Bar To Straight Edges

5. If the pressure bar plate has been removed from the pressure bar slide, perform the following adjustments. Otherwise, do not adjust the pressure bar tension screws (Figure

3.3.3.C). They have been set at the factory and will not require adjustment for several years.

6. If the pressure bar plate has been removed from the pressure bar slide, tighten the pressure bar tension screws until a moderate pressure is felt on the wrench. The lock-washer will not be completely compressed by the screw head. This allows the lock-washer to act as a spring.

7. Loosen the center square head setscrew on the pressure bar so that it is finger loose (Figure

4.3.3.C). Obtain the .008" clearance at the rear of the pressure bar by adjusting the two outside square head setscrews on the pressure bar. When the .008" is achieved, tighten the center setscrew finger tight and then tighten the jam nut. Carefully tighten the jam nuts on the two outside setscrews. Check to see that the .008" clearance has not been lost.

8. Run the top head up until the top head setting block can be placed underneath the top cutterhead. Lower the top head slowly until the knives are touching the top of the block. (This can be determined by slowly turning the cutterhead counterclockwise and lowering the top head until the knives "tap" the top of the block.) Use the block to check both sides for the same height.

9. If the pressure bar does not have the same height at both ends: Loosen the center hex head cap screw located near the top of the pressure bar assembly (Figure 4.3.3.C) until it is finger loose. Adjust the two outer hex head cap screws until you have the same height on both sides of the head. This is determined by the feel of the taps on the setting block. When this is accomplished, tighten the center cap screw finger tight, and then tighten the jam nut. Carefully tighten the outer jam nuts. Check to see that the height has not changed.

Figure 3.3.3-C Pressure Bar Alignment Adjustments

10. The amount of downward pressure exerted by the pressure bar on the wood can be controlled by adjusting the setscrews on the pneumatic actuator or the manual actuator. If your machine has an air-operated pressure bar, refer to paragraph 10.a and figure 3.3.3.D (a). If your machine has a manual pressure bar, refer to paragraph 10.b and figure 3.3.3.D (b).

10(a) The amount of pressure exerted is controlled by the left-hand screw. The right hand screw

controls the length of the stroke of the pressure bar from the full down position (normal operating position) to the full up position (pressure bar released).

• Turning the left screw CLOCKWISE will decrease the amount of pressure exerted.

• Turning the left screw COUNTERCLOCKWISE will increase the amount of pressure

exerted.

• Turning the right screw CLOCKWISE will decrease the length of the stroke.

• Turning the right screw COUNTERCLOCKWISE will increase the length of the

stroke.

• This adjustment will not need to be made unless the actuator is replaced.

10(b) The amount of pressure exerted is controlled by the hand screw. The length of the stroke cannot be adjusted separately.

• Turning the pressure bar hand screw clockwise will lower the pressure bar and increase the pressure exerted on the wood.

• Turning the pressure bar hand screw counterclockwise will raise the pressure bar and decrease the pressure exerted on the wood.

11. Adjusting the downward pressure of the pressure bar is the last step of setting the pressure bar. The machine must be running lumber to set the pressure. Once the pressure bar is set to give a good cut, carefully tighten the jam nut on the screw.

12. Ensure that all tools are accounted for. Run the machine and inspect the lumber to determine whether the pressure bar is high or low. Adjust the pressure bar accordingly.

Figure 3.3.3-D Pressure Bar Actuator Adjustments

If the pressure bar plate or pressure bar slide has been removed, make the following adjustments. Otherwise, these screws have been set at the factory and will not require adjustment.

• Adjust the two pressure bar spring tension setscrews (Figure 3.3.3.C) to the full up

position (until the spring is fully compressed and the screw does not turn). Adjust both setscrews down one (1) complete revolution and lock the jam nut.

3.3.4 Setting the Chipbreakers

1. Stop the planer and lock out the cutterheads and feed system. Unlock and raise the top

2. Using the top head setup block, check to see that the top cutterhead is level to the incline

table. (See section 3.3.1.)

3. Raise the top cutterhead two full turns of the hand-crank.

4. Push the setup block underneath one of the outside chipbreaker toes. A moderate amount

of force should be required.

• If the block does not touch the toe or there is no spring tension evident, the chipbreaker is

too high and must be lowered.

• If the block will not go under the toe, the chipbreaker is too low and must be raised.

• The adjustment for the chipbreaker height is the two 3/4” nuts on top of the spring rod

(Figure 3.3.4.A).

Toeplate Height Adjustment

Shaft Retaining Bolts

Chipbreaker Spring Tension

Adjus tment

Spring Rod Retaining Screw

Figure 3.3.4-A Chipbreaker Adjustments

5. Loosen the two nuts on top of the spring rod.

• If the height of the chipbreaker must be increased, run the lower nut down the spring a small amount and check the toe of the chipbreaker.

• If the height of the chipbreaker must be decreased, run the lower nut up the spring a small amount and check the toe of the chipbreaker.

6. When the force on the top head setup block feels appropriate, lock the jam nut down on the adjustment nut.

7. If slack in the movement of the chipbreaker is evident, adjust the tension of the chipbreaker. The tension adjustment is the two 3/4” nuts below the spring.

• Loosen the jam nut below the tensioning nut.

8. Adjust the tensioning nut upward (increase tension), and check the chipbreaker toe height. When toe height is correct, and there is tension evident, tighten the jam nut against the tensioning nut.

9. Repeat this procedure on each chipbreaker in turn. All of the chipbreakers should require the same amount of force as the first one checked.

3.4 Leveling the Bottom Cutterhead

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Disconnect and lock out main power.

CAUTION

Remove the main electrical power from the planer after

Step 1. Restore main electrical power only after the

maintenance action is complete.

2. Blow out the bed of the machine using compressed air. Clean the table after bottom head and incline table using a good solvent.

3. Unlock the bottom cutterhead, leaving the lock at a snug position so that the cutterhead will not wobble.

4. Position the incline table for a readout of 3/32”.

5. Place both short straight edges into machine with wider ends on incline table insert plate, approximately three inches from lumber guide rails.

• Place 3 strips of paper (1” x 4”) under one of the straight edges: one on the leading edge of the table after bottom head; one at the cutterhead side of the incline table; and one under the infeed end of the straight edge.

Figure 3.3.4-A Placement Of Straight Edges

• Raise or lower the incline table until pulling gently on each strip of paper can move the straight edge. Remove the paper.

6. Slowly rotate the bottom cutterhead counter-clockwise by hand until at least one knife has passed underneath each straight edge.

• If neither straight edge moves, raise the bottom cutterhead 1/2 turn of the hand crank and rotate the cutterhead again.

• If the straight edges move so far that they contact the Automatic Cut Control fingers, lower the bottom cutterhead 5 turns of the handcrank, and then raise it 4 turns.

7. If the straight edges are not moved the same amount by the knives, loosen the set collar setscrew on the bottom cutterhead-raising shaft. Slide the sleeve to the right until the shaft is disconnected from the left-hand actuator. TAKE CARE NOT TO LOSE THE TWO 1/8” KEYS.

• Raise the low side of the bottom cutterhead one or two turns and check the movement of the straight edges. When the two straight edges move the same distance, replace the key(s) in the shaft sleeve and reconnect the shaft.

8. Lower the bottom cutterhead five turns of the hand crank, then raise it five turns. Check to see that the movement of the straight edges is the same. If the movement is not the same, repeat step 7.

9. Tighten the set collar setscrew. Check to ensure that the bottom cutterhead is 0.003” to

0.005” above the table after bottom head. Remove the straight edges. Replace any guards that were removed. Lock the bottom cutterhead securely.

Bottom Head

Suppo rt Bar

Duff-Norton

Actuator

Set Collar

Bottom Head

Roll-Out Gear

Hand Crank

Adapte r

Figure 3.3.4-B Bottom Head Level And Height Adjustments

Sleeve-Type

Coupling

Bottom Head Jackscrew

Cross Shaft

3.4.1 Aligning The Anti-Lap Assembly

1. Raise the top head to 6". Raise the upper feed rolls and brace them in the raised position. Clean the incline table and table after bottom head using compressed air and a solvent to remove chips and sap build-up.

CAUTION

Remove the main electrical power from the planer after

Step 1. Restore main electrical power only after the

maintenance action is complete.

2. Raise the incline table to zero (Fig 2.4.1-A, #4).

3. Raise the anti-lap upper gate to the full open position.

4. Using the long straight edge, check bed-line alignment. (See section 3.3.1.)

5. Turn the straight edge notch side up. Move the straight edge towards the infeed of the machine, until one end is resting on the incline table insert. The straight edge should extend through the anti-lap.

6. Using a ¼” Allen wrench as a gauge, check the bottom anti-lap guide for clearance.

• Check both sides of the guide for a loose ¼” clearance.

7. Use the following procedure if adjustment is needed.

• Loosen the two 1¼” bolts at either end of the guide.

• Raise or lower the guide using the ¼” square head setscrews located at either end of the

guide.

• Tighten the bolts, and check guide clearance again. If it is satisfactory, tighten the setscrew jam nuts.

8. Using a ¼” Allen wrench, check the bottom gage weldment for clearance.

• Check both sides of the gage for a loose ¼” clearance.

9. Use the following procedure if adjustment is needed.

• Loosen the jam nuts on the ½” square head setscrews at either end of the weldment.

• Raise or lower the weldment using the ½” setscrews. When clearance is satisfactory,

tighten the jam nuts.

10. Remove the straight edge from the planer.

11. Lower the upper gate to the closed position. Check the tension of the leaf springs on both sides of the anti-lap.

12. The leaf springs should require the same amount of force to raise them 1 inch by hand.

• To increase leaf spring tension, tighten the ¾” bolt that holds the leaf spring to the anti- lap bottom gage.

• To decrease leaf spring tension, loosen the ¾” bolt that holds the leaf spring to the anti- lap bottom gage.

13. Ensure that the jam nut on the ¾” bolt is tightened.

14. Ensure no tools are left in the planer or on the infeed conveyor.

Procedure complete.

Upper Gate Adjustment Handle

Upper Gate Adjustment Handwheel

Upper Gate Adjustment

Bottom Gate Adjustment

Figure 3.4.1-A Anti-Lap Adjustments

Spring Tension Adjustment

Lower Gate Adjustment

Figure 3.4.1-B Anti-Lap Leaf Spring Adjustment

3.4.2 Adjusting The Anti-Kickback Assembly

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Raise upper feedrolls and brace them in the raised position. Lock out cutterhead and feed starters at the main control panel.

2. Clean the anti-kickback table, anti-kickback finger assembly, and infeed roll area using compressed air to remove chips.

CAUTION

Care should be taken to observe pinch points during this procedure. Machine assemblies will be moving rapidly.

Ensure that stop lock-button is in the stop/locked position.

3.4.2.1 Adjusting Feedroll Reversing Time Delay

1. Remove main power from the planer, and clean the main electrical enclosure off with compressed air. Open the main electrical enclosure. Restore main power.

2. Start the cutterhead motors and feedroll motors. Select “FWD” on main control panel.

• When the feed switch is set to “REV” there should be a five-second delay between the time the anti-kickback fingers are raised and the time that the feed system goes into

WARNING

This procedure is performed while the planer is operating. Care

should be taken that lumber is not in the feed path. Machine

parts may move unexpectedly.

reverse.

3. Select “REV” on the main control panel. Time the reversing sequence.

4. Adjust the reversing timer relay for a five-second interval. Check the adjustment by selecting “FWD” and letting the feed system come up to speed and then select “REV”.

5. When delay is set, stop the planer. Close the main electrical cabinet.

End of procedure.

3.4.3 Zeroing The ProScale

The ProScale is an electronic measuring instrument that is used to measure the distance from bedline zero to the bottom of the top cutterhead cutting circle. The ProScale can display this distance in sixteenths (1/16), thirty-seconds (1/32), sixty-fourths (1/64), millimeters, or thousandths of an inch.

The ProScale should not need maintenance other than changing the battery. The ProScale will not lose accuracy until adjustments are made to the height or level of the top cutterhead or the top cutterhead knives are ground and jointed. For the most consistent accuracy, the ProScale should be re-zeroed at these times.

For error codes or more information on the ProScale, refer to the ProScale manual.

ON/OFF MODE

-0

Figure 3.4.3-A ProScale Controls

1. Press the MODE button until the display is in thousandths of an inch. (This is the

measurement system used by most dial calipers. If the measuring device uses another scale, set the ProScale to that scale.)

2. Unlock the top cutterhead and raise or lower it to the desired thickness. (If there is a large

difference between the ProScale and the manual height indicator, use the manual height indicator.) Press the “0” button. Lock the top cutterhead.

3. Run a board through the planer, and measure the thickness of the board. This is the true

height of the top cutterhead. Use the Set Plus (+) or Set Minus (-) button to increment the ProScale display until it agrees with the actual measurement.

NOTE

When installing a new Proscale, if negative values read, jumper JP3 in the display module must be changed. Move the jumper from Pin A/Common (Proscale factory setting) to Pin B/Common. This will give positive values.

Refer to page 49 in the Proscale ABS (Model 901-1510-010) manual.

The ProScale is set for zero, and will now read accurately.

3.5 Machine Wear And Maintenance Procedures

Various parts of the machine wear faster than others, in particular the bedplates and holddown devices. The hold-down devices are equipped with replaceable wear plates. The following sections deal with determining the amount of wear and how to replace these parts. Wood that is wet or has a large amount of dust and grit accumulation on the surface causes metal surfaces to wear faster than kiln dried wood. A new, properly adjusted planer will typically hold a tolerance of 0.015”. As operations continue, the bedplates and wear plates are worn and the cutterhead knives become dull and are sharpened. This wear has the effect of moving the bedplates and hold-down devices apart, and the planers' ability to hold a tolerance decreases. Various adjustments will allow the operator and maintenance personnel to correct for this wear until the bedplate or wear surface has completely worn out.

3.5.1 Incline Table Insert Wear

The incline table serves as the foundation for the top cutterhead. As the top cutterhead removes wood from the top side of the board, it presses the board downward. The incline table provides an even, stable surface for the cutterhead to work against. Over a period of several years, the lumber wears the surface of the incline table plate away. Commonly, this wear is greater in one area of the plate, resulting in an uneven surface. This shows up as the lumber having been planed unevenly from side to side, or it may show up as a feed problem. If the top cutterhead is level to the incline table at both ends, then a worn area on the incline table insert may be the problem.

3.5.1.1 Solid Incline Table Plates

On planers that do not have the Automatic Cut Control option, the incline table plate is a hardened steel plate. (See Figure. 3.4.1-A.) When the surface has been worn approximately halfway to the back edge of the plate (zone B), it is time to resurface or replace the plate. When the surface has been worn almost to the back edge of the plate (zone C), it is time to replace the plate. When any portion of the plate has been worn 1/16” or more lower than the portion of the plate protected by the guide rails, the plate must be replaced. This is most easily observed in zone A. A straight edge 1/2" shorter than the bed-width of the planer will be required to check this.

3.5.1.2 A.C.C. Equipped Incline Table Plates

On planers that have the A.C.C. option, the incline table insert is a hardened steel plate that has been machined on the bottom to accept the A.C.C. option. (See Figure. 3.4.1-B.) When the insert is worn into the area of zone B, it is time to replace the plate. The plate will last through the replacement of at least two sets of A.C.C. toes. When any portion of the plate has been worn 1/16” or more lower than the portion of the plate protected by the guide rails, the plate must be replaced. This is most easily observed in zone A. Wear can be checked easily when this plate is removed to work on the Automatic Cut Control. The 72” straight edge can be used for this. In general, this plate cannot be resurfaced. Resurfacing requires grinding the surface of the plate flat with its lowest point, and then adding a layer of chrome equal to the total thickness of material removed during grinding. Shimming an insert that has been ground flat to bring it above the Automatic Cut Control toes is not practical because of the increased room for sawdust and wood chips in the area above the toes’ tailpiece.

If the surface is lower than the top of the A.C.C. finger, the lumber will tend to hang or jam when it hits the finger. (See Figure. 3.4.1-C.) For more information on the A.C.C., refer to the section titled “Automatic Cut Control”.

SOLID INCLINE TABLE INSERT

FEED DIRECTION

GUIDE RAIL AREA

INCLINE TABLE PLATE

GUIDE RAIL AREA

Figure 3.5.1-A Solid Incline Table Insert Wear

AUTOMATIC CUT CONTROL TOES

0.010"

A.C.C. TOE SHOWN IN FULL DOWN POSITION

FEED DIRECTION

GUIDE RAIL AREA

INCLINE TABLE INSERT

INCLINE TABLE PLATE

GUIDE RAIL AREA

Figure 3.5.1-B A.C.C Incline Table Insert Wear

INCLINE TABLE PLATE

INCLINE TABLE

Figure 3.5.1-C Relationship of Incline Table Plate to A.C.C. Fingers

3.5.1.3 Removing The Incline Table Insert Plate

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Raise upper feedrolls and brace them in the raised position. Disconnect and lock out main power.

2. Remove the lumber guide rails. Use care to avoid damaging the cutterhead knives.

3. Remove two center 3/8” socket head cap screws from incline table insert plate.

4. Install two 1/2” x 4” square head screws with a nut and a flat washer. These screws are to release the Automatic Cut Control spring tension in a controlled manner.

5. Remove the other six socket head cap screws.

6. Release the spring tension using the nuts on the square head screws. The plate will rise approximately 1 inch before all tension is released.

7. Remove square head screws. Remove incline table insert plate.

• Take care that the A.C.C. springs are not lost. There are two springs per section.

8. Installation is the reverse of removal.

• When reinstalling the socket head cap screws, use a small amount of blue LOC-TITE™ on each screw.

• Use care when lining springs up with their retainer holes in the plate. The plate can pinch fingers when the last spring is placed into its hole.

3.5.2 Automatic Cut Control Fingers

The Automatic Cut Control fingers are made of hardened steel. As wood passes over them, the contact area is worn away. New fingers will project approximately 5/16” above a new incline table insert. When they have worn down to approximately 1/8”, they should be replaced The fingers should be replaced before they develop a sharp edge. A sharp edge will tend to dig into the wood when reverse feed is selected, making it difficult to reverse the wood out if it jams. The ability of the Automatic Cut Control to distribute the cut between the top and bottom heads will also decrease.

5/16"

1/8"

Figure 3.5.2-A Automatic Cut Control Wear

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Raise

upper feedrolls and brace them in the raised position. Disconnect and lock out main power.

2. Remove incline table insert plate using the procedure in section 3.4.1.3.

CAUTION

If the A.C.C. fingers have been worn down to a sharp edge, it is

recommended that heavy gloves be worn when handling the A.C.C.

assembly.

3. Unlock and roll out the bottom cutterhead. The A.C.C. assembly will tend to fall into the

cutterhead area when the screws are removed.

4. Remove the two 1/4” socket head cap screws in each support arm, and remove the A.C.C.

assembly from the planer.

5. Loosen the setscrews in the lower side of each support arm.

6. Remove the arms and fingers from the shaft.

• The arms and fingers should slide off the shaft. If they do not, the use of a press is recommended.

• If a press is not available, care should be taken to not damage the ends of the shaft. A 3/4” diameter brass rod and a non-marring hammer should be used to drive the shaft out of the fingers and arms.

7. Clean and inspect the support arms and pivot shaft.

• If cracks are found in a support arm, replace the arm.

• If the pivot shaft is cracked, bent, or worn to the point that a new finger has play in that

area, replace the shaft.

8. Reassemble the A.C.C. assembly with new parts.

• Do not use oil or grease for lubrication. Liberal use of an anti-seize compound is recommended.

• When reinstalling the setscrews, use a small amount of blue LOC-TITE™ on each screw.

9. Ensure the flat area on either end of the pivot shaft is next to the setscrews in the outer support arms.

• Do not tighten the setscrews in the outer support arms until the assembly is bolted into the machine.

10. Reinstall the A.C.C. assembly into the machine. Apply a small amount of blue LOCTITE™ to the socket head cap screws before tightening them down. Apply a small amount of blue LOC-TITE™ to the outer arm setscrews and tighten the setscrews.

11. Ensure that all setscrews and socket head cap screws are tight.

12. Reinstall the incline table insert plate using the procedure in section 3.4.1.3.

13. Roll bottom cutterhead back in, level the bottom cutterhead, and lock it in place.

Procedure Complete.

3.5.3 Chipbreaker Wear and Replacement

Each chipbreaker section has a hardened steel toe plate. The toe plate wears more rapidly with air-dried or dusty wood than with kiln-dried wood. When the toe plate has worn down to a sharp edge (3.4.3.A), it will tend to dig into lumber when reverse feed is selected. Because of the increased height of the toe plate above the incline table, the wood will start to show surface defects if the wear is not compensated for. The toe plate can wear off approximately 1/8” of its thickness on either end. The chipbreaker can be adjusted approximately 3/16” in height. A quick check for wear should be done whenever the chipbreaker height is adjusted.

Figure 3.5.3-A Chipbreaker Toe Plate Wear

3.5.3.1 Checking For Chipbreaker Toe Wear

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Raise upper feedrolls and brace them in the raised position. Disconnect and lock out main power.

2. Using a flashlight, visually inspect the lower edges of the chipbreaker toe plates.

3. The outermost toe plates generally wear at a slower rate than the inner toe plates due to less contact with the wood. Compare the amount of wear on the outer plates to the amount of wear on the inner plates.

4. Toe plates that have developed a sharp edge must be turned around or replaced at this time.

3.5.3.2 To Remove Chipbreaker Toe Plates:

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Raise upper feedrolls and brace them in the raised position. Disconnect and lock out main power. Disconnect and remove top head dust collector hood.

2. Remove two 3/8” socket head cap screws from inside chipbreaker shoe (3.4.3.B)

3. Remove toe plate. Inspect alignment roll pins. If the pins are in good condition, reuse them.

• If toe plate has only been used on one end, reinstall so that unused end is next to cutterhead.

• If toe plate is worn on both ends, replace with a new plate.

4. Insert pins into toe plate from the upper surface. Do not drive pins all the way through the toe plate.

5. Using the 3/8” socket head cap screws, pull the plate up tight to the chipbreaker shoe. Tighten the screws securely.

6. Ensure that the alignment pins do not protrude through the toe plate.

7. After all toe plates have been replaced, align the chipbreaker with the top cutterhead.

Figure 3.5.3.2-B Chipbreaker Cutaway

3.5.3.3 Removing The Chipbreaker

Toeplate Height Adjustment

Shaft Retaining Bolts

Chipbreaker Spring Tension Adjustment

Spring Rod Retaining Screw

Figure 3.5.3-C Chipbreaker Assembly

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Raise upper feedrolls and brace them in the raised position. Disconnect and lock out main power. Place a piece of cardboard inside of planer infeed section to catch any small parts that may be dropped.

2. Remove the pivot shaft retaining bolts from the right-hand chipbreaker support.

3. Remove the jam nuts from the right-hand end of the top head lock shaft. (These nuts have left-hand threads.)

4. Remove the pin from the lock collar on the left-hand end of the top head lock shaft. Loosen the lock collar setscrew.

5. Unscrew the lock shaft until the shaft can be removed from the left-hand side of the machine.

• Retain the lock collar and thrust bearing as the shaft is removed.

6. Remove the chipbreaker release shaft and lock collars.

7. Manually adjust the top head assembly up or down until the lower pivot shaft can be removed. Retain the spacers from both ends of the shaft.

• Use a 3/4” diameter rod, at least 12” longer than the planer is wide, to drive the shaft

out.

8. Manually adjust the top head assembly so that the upper pivot shaft may be removed. As

the shaft is removed, the chipbreaker release levers will come out. Retain the release levers and the spacers from the shaft.

CAUTION

The chipbreaker sections weigh 23 pounds each and may have very

sharp edges due to wear.

9. Manually raise the top head assembly to six inches.

• Do Not Loosen The Tension Adjustment Nuts Below The Spring.

10. Remove the upper adjustment jam nut from the top of the spring rod.

11. While supporting the chipbreaker section, remove the adjustment nut. Lower the chipbreaker section and remove it from the machine. Take care that the spring and spring washers do not fall off the spring rod.

12. Repeat step 10 for each chipbreaker section.

Disassemble the chipbreaker sections. The lower pivot link pin that the spring rod attaches to has a NyLoc setscrew in the end that holds the spring rod in place. Thoroughly clean the chipbreaker shoe, both links, spring rod, spring, and spring washers. Inspect the chipbreaker shoe and links for cracks. Remove and replace broken grease fittings. Discard bent spring rods and replace with new ones. When replacing the toe plates, use new roll pins (1/4” x 1 1/4”) and new socket head cap screws. Replace socket head cap screws when turning the toe plates around.

NOTE

If the socket head cap screws or the roll pins are replaced, they will extend below

the toe plate. They must be ground flat to avoid damage to the wood surface.

13. Assembly of the chipbreaker sections is the reverse of disassembly. Make sure that the

flat surface ground into the end of the spring rod faces the link pin setscrew.

• When reinstalling the chipbreaker sections, start with the lower pivot shaft. This will help support the chip breaker section while installing the upper shaft and release lever.

• After all the sections are installed, but before the top head lock shaft is installed, grease the chipbreaker assembly.

• Repack the top head lock thrust bearing with grease before re-installing it.

14. Align the chipbreakers with the top cutterhead cutting circle using the procedure in section

3.3.4.

3.5.4 Set Reference For Bedline Zero

If the table after bottom head plate has been resurfaced, it will be lower than the original setup, and the bedline zero reference point will be changed. Use the following procedure to reestablish the zero reference point for bed-line.

Figure 3.5.4-A Setting Bedline Reference

NOTE

This procedure will result in inaccurate indications if the incline table insert plate

is not flat. The incline table plate should be replaced at the same time as the table

after bottom head plate.

NOTE

Do not use jackscrews to level out wear in table after bottom head plate. This will

warp the plate and may result in feed problems and dimension defects.

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Raise upper feedrolls and brace them in the raised position. Disconnect and lock out main power.

2. Remove lumber guide rails. Clean incline table plate using compressed air and a good solvent.

3. Raise incline table to “0” as indicated on the incline table scale.

4. Place the long straight edge in the planer on the left-hand side, in the area that was protected by the guide rail.

5. Lower the outfeed roll and infeed rolls below bedline as indicated by the straight edge. Roll the bottom cutterhead out of the machine to gain access to the jackscrews.

• The straight edge may need to be held down at the outfeed end so that the straight edge will be flat on the incline table insert plate.

• The straight edge must be 0.0015” flat to the incline table plate. (Zone A.)

6. Adjust the incline table up or down until the straight edge is 0.0015” tight in Zone B.

7. Adjust the left-hand jackscrew to raise the table after bottom head plate. Zone B must be

0.0015” tight to the straight edge, and Zone C should be approximately 0.003” to 0.004” lower than the straight edge. Check Zone A. If the incline table plate is not 0.0015” tight, adjust the incline table accordingly.

8. Move the straight edge to the right side of the machine. Adjust the right-hand jackscrew until Zone A is 0.0015”, Zone B is 0.0015”, and Zone C is approximately the same measurement that was found on the left side of the planer. Do not adjust the incline table.

NOTE

If the incline table plate was replaced, perform step #9 and #10.

If the incline table plate was not replaced, perform step #10 only.

9. Move the straight edge to the center of the machine. Adjust the jackscrew until Zone A is

0.0015”, Zone B is 0.0015”, and Zone C is approximately the same measurement that was found on the left side of the planer. Do not adjust the incline table.

10. Check all zones again. If measurements are correct, LOC-TITE the jack screws one at a time, lock the jam nuts, and check each zone again.

Perform a complete alignment of the planer.

3.5.5 Replacing the Top Head Raising Screw and Worm Gear

Figure 3.5.5-A Left Side Top Head Raising Gear Assembly

Over the period of a year, very fine wood dust will enter the top head raising mechanism gear cavity. On an annual basis, the cavity should be cleaned out and filled with fresh grease. This will prolong the life of the brass worm gear. If the top head power hoist motor thermal overloads trip, the head ‘sways’ from side to side when moving, the top head becomes very hard to move manually, or one side of the head moves before the other side or will not maintain its level when moving between settings, it is usually an indication of heavy wear on the brass worm gear or something jamming the rotation of the worm gear.

NOTE

The brass worm gear and raising screw are fitted at the factory. When replacing

the worm gear it will be necessary to fit the worm gear and thrust bearing to the

gear cavity.

NOTE Removal of the raising screw requires the top head assembly to be raised to the top of the supports. The top head yoke and the top head motor must be

supported before raising the top head assembly to this point by using a crane

or forklift.

WARNING

The top head assembl

, including the motor, weighs in excess of on

ton. The balance point for the assembly is near the right hand

cutterhead bearing. Do not use rope to support the assembly.

2. Remove top head lock shaft, jam nuts, thrust bearing, and lock collar.

3. Remove top head raising limit switch (if installed).

4. Disconnect chipbreaker cylinder piston from chipbreaker shaft.

5. Disconnect air line from pressure bar actuator (if installed).

6. Disconnect air line from top head brake.

7. Remove the ProScale sensor from the top head yoke.

8. Remove the top dust collector hood.

9. Remove the top head power hoist proximity sensor and mount, chain guard, chain, and sprocket from the top head raising shaft (if installed).

10. Disconnect the top head motor electrical connection from the junction box. Using a crane or a forklift, support the motor. Remove the three bolts that secure the top head motor mount to the top head yoke. Pull the motor straight out from the yoke for at least one inch to clear the alignment pins. Set the motor out of the way.

11. Manually raise the top head assembly three inches. Support the top head assembly by: Using two eight foot, heavy-duty nylon straps wrapped around the top head assembly to form cradles.

Using two lengths of ½” chain wrapped around the top head assembly to form cradles. To avoid damage to the cutterhead knives and the pressure bar plate, place two boards between the chain and the pressure bar plate, and the chain and the top cutterhead.

NOTE

The motor side lock has a set screw that is accessed from inside the planer. It

must be loosened prior to attempting to remove the top head assembly.

12. Unlock both top head raising screw locks. Using a crane or forklift, raise the top head assembly until it is almost off of the top head supports. If the lifting device can be locked in this position, do so. If the lifting device cannot be locked, completely remove the top head assembly. Set the assembly down on a pallet, keeping tension on the chains or straps.

13. Remove both gear cavity covers and remove excess grease.

14. Remove cotter pin from castle nut on right-hand end of shaft. Remove castle nut. Remove shaft through the left-hand side of the planer. Remove steel worm gears.

15. Unscrew the raising screws from the brass worm gear.

16. Clean both gear cavities thoroughly.

17. The brass worm gear and thrust bearing must be fitted to the gear cavity. Using a piece of sandpaper or a belt sander, remove a very small amount of material from the top surface of the worm gear. Repeat until the worm gear and thrust bearing slide into the cavity. The maximum clearance allowed on top of the worm gear is 0.005”.

18. Before assembling screw into gear, coat the screw with grease. Pack the thrust bearing with fresh grease.

19. Ensure that the set screw hole in the motor side screw is facing into the machine. Use a spirit level or other measuring device, across the top of both screws, to ensure that the screws are level. Adjust the operator’s side screw to make the two screws level.

20. Reassemble the raising mechanism. Make sure that it turns freely. Pack both cavities with fresh grease, and replace the covers.

NOTE

If the top head assembly was removed, care must be taken that none of the sliding

surfaces are damaged during installation.

21. Lower the top head assembly onto the raising screws. Care must be taken that the stub shafts on top of the screws are not damaged. Ensure that the set screw in the motor side lock is in the hole. Lock the top head raising screw locks.

22. Manually lower the top head to two inches. Manually raise the top head to four inches. Check for slack in the mechanism and smoothness of operation.

23. Reinstall the top head power hoist proximity sensor and mount, chain guard, chain, and sprocket on the top head raising shaft.

24. Reapply electrical power to the planer. Run the top head down to two inches, then return it to four inches. Observe correct operation of top head raising mechanism. Remove and lock out electrical power.

25. Reinstall the top head lock shaft, jam nuts, thrust bearing, and lock collar.

26. Level the top head assembly (Section 3.3.2).

27. Reinstall the top head raising limit switch.

28. Reinstall the chipbreaker cylinder piston on the chipbreaker shaft.

29. Reinstall the ProScale sensor on the top head yoke (Appendix B, Section 1).

30. Re-connect the air line to the pressure bar actuator and top head brake.

31. Reinstall the top head dust collector hood and re-connect the compressed air line.

Reapply electrical power to the planer. Operate the planer and check for proper operation of all actuators and mechanical devices.

3.5.6 Cutterhead Bearings

All cutterhead spindles are equipped with specially manufactured precision ball bearings. Replacement bearings should be of the same type and may be ordered from Newman Machine Company, Inc. For long bearing life it is important that the lubrication instructions are followed as outlined in Section 3.1.

The life of ball bearings will be reduced unless they are kept clean; therefore, every effort should be made to keep dirt out of the bearing housings. If a compressed air hose is used to clean the machine, care should be taken that the stream of air is not directed in such a way that it can blow along the spindles and into the bearing housings. Compressed air can penetrate virtually any seal and it can carry dirt and/or moisture, which is harmful to bearings.

The bearing housings should never need cleaning until a new bearing is installed or unless it is definitely known that dirt has penetrated the bearing housing. Normally, the regular addition of grease will have sufficient flushing action to work out the old grease and prevent solidifying.

Keep the supply of grease in a clean place in a tightly covered container. Always clean grease fittings before filling.

3.5.6.1 General Information for Replacing Ball Bearings

1. Because high precision bearings are used to help maintain the balance of the cutterhead,

it is preferable to replace both bearings at the same time. Spare lock nuts and washers should be ordered at the same time as the bearings since these can be damaged during removal.

2. Before attempting to replace ball bearings prepare a clean place to work. A bench or

similar support should be nearby and reasonably sheltered from the dust usually found in the air of a woodworking plant. Cover the top of the bench with clean paper.

3. Preheat the bearings for at least 20 minutes prior to installation. This will cause the

bearing to expand, allowing it to slip easily onto the machined bearing seat on the cutterhead shaft. The bearing heater should be close to the machine so that the bearings will not cool off.

4. Blow all dirt off the machine and, using clean rags, wipe the parts that are to be handled.

5. Inspect all surfaces of the housing and spindle for burrs that might come in contact with

the bearing. Since burrs can cock the race of a bearing enough to cause heating and wear, remove any burrs with a file or scraper; then wash again.

6. Upon replacing with a new bearing, fill the housing half full of grease, making sure that

the grease contacts the ball retainer. The grooves in the hole through which the spindle passes should be completely filled with grease as these act as seals.

7. It is always preferable to use bearing pullers or bearing drivers when removing or

installing bearings. However, these tools are not always available or may not be applicable to a particular situation.

8. When it becomes necessary to install a new bearing without the benefit of an arbor press

or bearing driver, installation can be performed with a hammer, but several precautions should be taken. Use care when placing a bearing in a housing or on a shaft, making sure it is started straight and square. Apply all force on the tight fitting ring. Never pound directly on a bearing with hammer; rather use a piece of brass between the bearing and the hammer. When driving the bearing use short, quick taps rather than a few heavy blows. Drive alternately on one side of the bearing and then the other to keep the bearing from cocking. Care should be taken not to strike the bearing shield or ball separator.

3.5.6.2 Top Cutterhead Bearing Replacement

1. Stop planer and lock out cutterheads. Disconnect the compressed air connection. Bleed

pressure off the planer’s pneumatic system. Unlock and raise top cutterhead to four inches. Place two 4”x 4” x 4” wooden blocks underneath the cutterhead, approximately 2” from the ends of the knives. Lower the top cutterhead until the knives contact the blocks. The blocks will support the cutterhead when the bearings are removed and will allow the cutterhead to slide as needed during the replacement procedure. Disconnect and lock out main power.

2. Remove the top dust collector hood. Blow off the machine using compressed air, paying

particular attention to the top head assembly.

NOTE

The balance point for the motor and motor mount is approximately halfway

between the eyebolt and the motor mount. Use a sling to cradle the motor to

prevent sudden shifts of position when the motor is no longer mechanically

supported.

3. Disconnect the top head motor electrical connection from the planer junction box. Using

a crane or a forklift, support the motor. Remove the three bolts that secure the top head motor mount to the top head yoke. Pull the motor straight out from the yoke for at least one inch to clear the alignment pins. Set the motor out of the way. Remove the coupling half from the cutterhead shaft.

• Measure the distance between the coupling half and the bearing housing to properly relocate the coupling half when re-installing.

4. Remove the brake disc cover, brake caliper, and brake disc.

5. Remove the bearing housing.

• Two threaded (1/2-13) holes are provided to use as jack points to pull the housing from the yoke. Jack bolts should be at least 5 inches long and be completely threaded.

• As the bearing housing is removed, the cutterhead will tend to pull out of the opposite bearing housing.

6. Clean grease and dirt from the bearing and cutterhead shaft. Clean the interior of the bearing housing.

7. Remove the bearing lock nut and lock washer. Use a set of bearing pullers to remove the bearing.

NOTE

Do not attempt to heat the bearing to remove it from the shaft. This may warp

the cutterhead shaft, causing the cutterhead to be unbalanced.

8. Clean the shaft and bearing seat, paying particular attention to the threads.

9. Inspect the cutterhead shaft, threads, bearing lock nut, and bearing lock washer for damage. Repair or replace as required.

10. Install the new bearing. Install the lock washer and lock nut, ensuring that one of the tangs on the washer lines up with a slot on the nut. After the nut is tight, bend the tang down into the slot.

11. Using the grease gun and Lubriplate EMB grease, pack the bearing full of grease.

12. Install the bearing housing. The bolts that secure the bearing housing are 5/8”-11 x 1 3/4”. Longer bolts with a nut may be used to pull the housing far enough into the yoke to install the regular bolts.

13. Repeat steps 5 through 12 for the other bearing.

14. Install the brake disc, brake caliper, and brake disc cover. Ensure that the disc is centered in the caliper.

15. Install coupling half on cutterhead shaft. Inside face of coupling collar should be 5/8” from bearing housing.

16. Reinstall cutterhead motor. Spray the ends of the coupling sleeve with a silicone lubricant. Insert coupling sleeve into coupling halves as motor is being installed.

• There should be a small amount of play in the coupling sleeve, parallel to the

cutterhead, not to exceed 1/8”.

• Re-connect cutterhead motor connections to the planer junction box. Ensure proper

polarity is maintained.

17. Raise the top cutterhead assembly and remove blocks. Ensure that all tools, parts, and packaging are removed from the planer and accessory equipment.

18. Using the grease gun and Lubriplate EMB grease, fill the bearing housings until grease starts to flow out of the housing around the cutterhead shaft.

19. Re-connect main electrical power. Start the cutterhead motor. Check the motor for proper rotation. Viewed from the left side of the planer the cutterhead will rotate in a counterclockwise direction.

20. Run the cutterhead under no-load conditions for 45 minutes to one hour. Check for excessive heat in the bearing housings, unusual vibrations, or unusual noise. Any of these conditions can indicate either that a bad bearing has been installed, or that a bearing has been installed incorrectly. Determine which bearing is bad and take corrective action.

21. Perform a complete alignment.

Procedure Complete.

3.5.6.3 Bottom Cutterhead Bearing Replacement

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to 6 inches. Disconnect and lock out main power. Disconnect the compressed air connection. Bleed pressure off the planer’s pneumatic system.

2. Remove the brake disc cover, brake caliper, and brake disc.

3. Unlock the bottom cutterhead and roll it out of the planer. Ensure that the support legs are extended (EPR-24 only).

4. Remove the bottom cutterhead coupling guard.

5. Unbolt the bottom cutterhead motor. Slide the motor away from the cutterhead and remove the coupling sleeve. Using a forklift or crane, remove the motor and set it on a clean pallet, two pieces of 2” x 4”, or heavy cardboard. This is to protect the motor mounting pads from damage. Save and mark any shim stock for location. It will be reused during installation.

6. Remove the coupling half from the cutterhead shaft.

• Measure the distance between the coupling half and the bearing housing to properly

relocate the coupling half when re-installing.

7. Cut two wooden wedges, approximately 1” x 2” x 6”. Place one under the cutterhead spindle next to the bearing housing and the other between the cutterhead spindle and the infeed side of the yoke. These wedges will support the cutterhead shaft when the bearing housing is removed.

8. Remove the bearing housing. Use either a heavy, soft face hammer; a brass rod and hammer; or a wooden block and hammer to drive the housing off the shaft.

9. As the bearing housing is removed, the cutterhead will tend to pull out of the opposite bearing housing.

10. Clean grease and dirt from the bearing and cutterhead shaft. Clean the interior of the bearing housing.

11. Remove the bearing lock nut and lock washer. Use a set of bearing pullers to remove the bearing.

NOTE

Do not attempt to heat the bearing to remove it from the shaft. This may warp

the cutterhead shaft, causing the cutterhead to be unbalanced.

12. Clean the shaft and bearing seat, paying particular attention to the threads.

13. Inspect the cutterhead shaft, threads, bearing lock nut, and bearing lock washer for damage. Repair or replace as required.

14. Install the new bearing. Install the lock washer and lock nut, ensuring that one of the tangs on the washer lines up with a slot on the nut. After the nut is tight, bend the tang down into the slot.

15. Using the grease gun and Lubriplate EMB grease, pack the bearing full of grease.

16. Install the bearing housing. The bolts that secure the bearing housing are 5/8”-11 x 13/4”. Longer bolts with a nut may be used to pull the housing far enough into the yoke to install the regular bolts.

17. The cutterhead shaft may no longer be aligned with the center of the bearing housing and may need to be positioned to allow the housing to slide over it. Place a 1” thick block of wood on the outfeed lip of the yoke. This will prevent damage to or misalignment of the jointer rail.

18. Repeat steps 7 through 15 for the other bearing.

19. Install the brake disc, brake caliper, and brake disc cover. Ensure that the disc is centered in the caliper.

20. Install the coupling half on cutterhead shaft. The inside face of the coupling half should be even with the end of the shaft.

21. Clean the bottom of the motor mounting pads, and reinstall the cutterhead motor. Re-use the shim stock, if any.

• The motor shaft must be aligned with the cutterhead shaft. The maximum tolerance

allowed is plus or minus 0.010” in any direction. This may be checked by mounting a dial indicator on one coupling half and measuring the difference in position of the other coupling half as the cutterhead is rotated by hand.

• There should be a small amount of play parallel to the cutterhead, not to exceed 1/8”,

in the coupling sleeve.

22. Ensure that all tools, parts, and packaging are removed from the planer and accessory equipment.

23. Using the grease gun and Lubriplate EMB grease, fill the bearing housings until grease starts to flow out of the housing around the cutterhead shaft.

24. Reinstall the bottom cutterhead coupling guard.

25. Roll the bottom cutterhead back into the planer and lock it in place.

26. Re-connect main electrical power. Start the cutterhead motor. Check the motor for proper rotation. Viewed from the left side of the planer the cutterhead will rotate in a clockwise direction.

27. Run the cutterhead under no-load conditions for 45 minutes to one hour. Check for excessive heat in the bearing housings, unusual vibrations, or unusual noise. Any of these conditions can indicate either that a bad bearing has been installed, or that a bearing has been installed incorrectly. Determine which bearing is bad and take corrective action.

28. Perform a bedline alignment.

Procedure Complete.

3.5.7 Pneumatic Feedroll Tires

Pressure in the top roll pneumatic tires should always be maintained at 50 to 60 P.S.I. This is important for long tire life. The distance between the bottom of the tires and the top of the infeed and outfeed rolls should be set according to the thickness of the stock being run.

If the tires spin on the lumber when in operation, it indicates the tires are set too high. Immediately lower the tires until there is no spin under any condition. If the tires stall, it strongly suggests a board is jammed and the machine should be purged by reversing the feed or by manual means if reversing fails. Failure to follow these simple "spin-stall" hints will result in needless wear on the tires, reducing expected tire life.

To check tire pressure, or to inflate a tire, valve extension tubes connect the inner tires to valve stems in the outside rims. On EPR-24s the second tire from the right hand end of the roll connects to a stem on the end tires’ rim. The second tire from the left-hand end connects to a stem on the left-hand end tires’ rim.

If a tire is damaged or punctured, it should be replaced immediately. To remove wheels in order to replace tires:

1. Stop planer and lock out cutterheads. Unlock and raise top cutterhead to six inches. Raise upper feedrolls and brace them in the raised position. Disconnect and lock out main power.

2. Loosen the bearing setscrews.

3. Remove the bolts attaching the roll yoke end plate.

4. Remove the end plate with bearing.

The tires and wheels can now be removed by taking the lugs off as you would on a truck. Be careful of the valve extension tubes.

3.5.8 Pneumatic System

The Pneumatic systems on the EPR-Series Planers are simple and easy to maintain. Extra contacts on control switches or relays control the pneumatic systems. 80 to 110 P.S.I. of air pressure is required for proper operation of the systems. If plant air pressure falls below 60 P.S.I., the feedroll raising mechanism may not work and the cutterhead brakes may not stop the cutterheads on shutdown.

The pneumatic valve panel is located on the infeed end of the machine. It contains the main air connection and shut-off valve, moisture separator, lubricator, upper feedroll valve, brake valve, chipbreaker valve, and anti-kickback valve (optional). The pressure bar release valve is mounted on the top cutterhead brake guard.

1. Pressure regulators are provided to set system pressures. The master pressure regulator

regulates pressure to all of the sub-systems. It should be set at 80 P.S.I. during the planer start-up.

The master regulator is combined with the moisture separator. The level of water can be seen through a port on the cover. This should be emptied when the bowl is half full.

CAUTION

If any part of the pneumatic system is to be disconnected, ensure

that the shut-off valve has been closed and pressure has been bled

from the system.

The feedroll down pressure regulator should be set at 40 P.S.I. during planer start-up. This regulator is active when the feed system is put into reverse or “DOWN” is selected on the main control panel. Turning the regulator control knob clockwise will increase pressure. Turning the knob counterclockwise will decrease pressure.

2. The lubricator should be checked weekly for oil level. When the oil level is down to ¼, the

bowl should be refilled with 10 weight, non-detergent oil.

To refill the bowl, shut-off system pressure at the planer shut-off valve and allow pressure to bleed off. Remove the bowl and fill with oil to the mark.

Since airflow through the system is not constant, setting the drip rate may require several tries over a period of several hours. Use a small screwdriver to adjust the drip rate using the screw located on top of the lubricator body one turn at a time. Turning the screw counterclockwise will increase the drip rate, and turning the screw clockwise will decrease the drip

rate. If the drip rate is set high enough to soak the planer frame below the valve block, the rate is set too high and must be decreased.

3. Depending on the options installed either at the factory or on site, the planer may have as

many as five solenoid operated valves installed. (Refer to Figure 3.4.9-B.) The valves are not adjustable. The pressure bar release valve may be manually operated by pressing the yellow override switch.

4. A manifold block is installed on the right side of the frame, near the infeed roll raising

cylinder. Air lines from the feedroll raising valve are split at this manifold and directed to the lower (raise) end and upper (down) end of the two roll raising cylinders. A check valve and muffler are installed on the down-side line to exhaust static air pressure as the rolls are raised.

5. The two roll raising cylinders have flow controls at each port. The chipbreaker cylinder,

pressure bar rotary actuator, brake calipers, and anti-kickback cylinder (optional) do not have flow controls.

NOTE

Some early versions of the EPR do have flow controls for the chipbreaker. If the

machine has a flow control, it will be located at the air cylinder.

Figure 3.5.8-A Pneumatic Valve Panel

3.5.8.1 Locally Manufactured Pneumatic Hoses

DESCRIPTION DIAMETER LENGTH QTY 1 Top Head Brake ¼ 68” 1 2 Air Actuated Pressure Bar Valve Supply ¼ 108” 1 3 Pressure Bar Valve to Actuator ¼ 12” 2 4 Bottom Head Brake ¼ 135” 1 5 Top Head Chipbreaker 3/8 125” 1 6 Roll Raising Cylinder – Up Pressure Supply 3/8 50” 1 7 Roll Raising Cylinder – Down Pressure Supply 3/8 35” 1 8 Manifold to Infeed Cylinder – Bottom 3/8 15” 1 9 Manifold to Infeed Cylinder – Top 3/8 20” 1

10 Manifold to Outfeed Cylinder – Bottom 3/8 50” 1 11 Manifold to Outfeed Cylinder – Top 3/8 65” 1 12 Anti-kickback Cylinder 3/8 105” 1

Figure 3.5.8.1-B Pneumatic Hose Layout

Figure 3.5.8.1-C EPR Pneumatic Schematic

4 PLANER OPERATION

4.1 Planer Safety

4.1.1 Personal Safety Equipment

Personal safety equipment includes eye protection, hearing protection, and safety shoes at a minimum. Some companies may expand this to include heavy gloves, safety helmets, and for some employees may prescribe other equipment, also. Know the safety requirements for your plant. Inspect your personal safety equipment frequently and replace it before it becomes unusable.

4.1.2 Planer Safety Devices

Cutterhead Brakes: The cutterhead brakes on the EPR Series Planers were designed to stop the cutterheads after the power is removed from the cutterhead motors. Since the cutterheads can freewheel for up to five minutes, they present a safety hazard. The cutterheads must have stopped rotating before performing maintenance on the planer, or before attempting to clear a jam. EPR Series planers are equipped with timer-controlled, air-operated brakes. These brakes are factory-set and will stop both cutterheads within 30 seconds. As a safety feature, the pneumatically powered feedrolls will not raise until the brake timer times out.

An electrically controlled pneumatic cylinder raises the upper feedrolls. When the rolls lower, they can pinch or crush the operators’ hand or arm between the upper and lower rolls. Removing electrical power or compressed air from the machine will allow the feedrolls to lower unless they are braced in the raised position.

4.1.3 Maintaining Machine Guards

The EPR Series Planers have pinch points, sharp cutterheads, and crushing hazards that are built-in. Guards are provided at various points on the machine to prevent accidental access to these hazards and should never be removed from the planer unless the planer is electrically locked out. Removing a guard in order to increase production by reducing time for maintenance or clearing actions is never a valid excuse. Removing a guard and not replacing it for any reason should always be considered a safety violation.

Expanded metal guards are installed on both sides of the machine to protect the operators from simple human error. Solid metal guards are also installed at the infeed and outfeed of the machine, in such a way as to prevent access to the feedroll tires.

Guards are installed over the bottom cutterhead motor coupling, top cutterhead motor coupling, and top head power hoist drive chain. A guard is also installed on the right side of the machine at the table after bottom head. A bar-type guard is attached to the top cutterhead motor to warn of the crushing action of the upper feedrolls. Safety stands are provided on the right-hand side of both upper feedroll housings to brace the feedrolls in the raised position.

The top cutterhead motor, bottom cutterhead motor, and gearmotor electric motors all have metal shrouds covering the motor cooling fans. These shrouds should never be removed. They are painted the same color as the rest of the motor.

4.1.4 Safety Practices

Unusual Noise: Whenever the planer is started, wait a moment after starting each motor to listen. When all the motors are started, wait a moment longer and listen to the sound of the planer before lumber feeding is started. You may detect unusual noises that can indicate a malfunction. While not a completely reliable trouble-shooting method, it does serve as an additional check on the operating condition of the planer.

Unusual Events: Always pay attention to the way the planer operates. Even though all of Newman's machines are built to exacting standards, each machine will have it's own set of quirks. Familiarity with your planer can be an asset to the maintenance effort, thus increasing the safety of the planer. Odd noises, strange vibrations, increased frequency of jams, difficulty in feeding lumber, decreasing feed-roll power, or decreased cutterhead performance all indicate a problem. Trust your feeling that "something isn't right", because that feeling is frequently correct. It is the responsibility of the planer operator to determine if a problem exists and to have it corrected. Remember that a properly maintained machine is safer to operate.

Warning Signs: Always notice and heed the warning signs placed in various locations on the planer. These signs are there to call attention to hazards that cannot be guarded against except by being alert and careful.

4.1.5 Safety Considerations While Clearing a Jam

4.1.5.1 Avoiding Contact With A Rotating Cutterhead

DO NOT reach into the cutterhead areas until you have visually cutterhead has stopped rotating. There is frequently no audible indication that the cutterhead is still spinning. If lighting is insufficient to see clearly into cutterhead areas, use a flashlight or trouble light to give adequate light.

4.1.5.2 Avoiding Feed-Roll Pinch Points

DO NOT attempt to reach into the feedroll areas while the feed system is still in operation. On all EPR-Series Planers, stopping the cutterheads by using the STOP switch or E-STOP switch also stops the feed system. (It is possible in some installations that the

planer STOP switches do not control the customer provided accessory lumber handling equipment. This is a safety hazard and should be corrected immediately).

4.1.5.3 Avoiding lumber ejection or 'kickback'

DO NOT attempt to raise the feedrolls or the top head until the cutterheads have stopped and the feed system is shut down. The cutterheads rotate in the direction opposite to the normal direction of feed and without the pressure of the feed-rolls and top head assembly could throw lumber out of the planer with enough force to severely injure a person.

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