This document is an instruction manual for Weinig Tools, specifically focusing on various cutterheads used in Weinig planers and moulders. The manual covers both PowerLock and Normal clamping systems, as well as Hydraulic clamping systems, detailing their mechanical design, intended use, installation, removal, and maintenance.

General Safety Instructions

The manual emphasizes the importance of safety when handling Weinig tools. Tools have sharp cutting edges and must be handled with care, always wearing protective gloves. Work should always be away from the cutting edge when loosening clamping screws. Protective gloves are also essential when packing, unpacking, or handling tools. Tools must be transported in suitable packaging and stored safely.

Tools and Machine Safety

Several critical safety instructions are provided regarding the tools and their interaction with the machine:

The maximum speed specified on the tool must never be exceeded.
All tools described are approved only for machines with mechanical feed.
Damaged or dull tools must never be used.
Ensure the correct direction of rotation for the tools.
The machine must not start inadvertently during tool or cutter changes.
Tools must be fitted and secured according to the machine manufacturer's instructions.
Before switching on, ensure tools are correctly clamped.
The machine should only be switched on when statutory guards are in position.
Tools must never be fitted with cutters on one side only (asymmetrically) to avoid imbalance. All cutters, clamping ledges, and blind lugs must be fitted without exception, and all cutters and blanks must be of the same weight. Cutters should be distributed symmetrically when not using a full complement.
Clamping areas must be clean, and parts must be fitted correctly during cutter changes.
Cutters and tools must be fitted flush, with no protruding edges.
Tools heated during cleaning must be allowed to cool before installation to prevent loosening or reduction of the tool clamp due to shrinkage.
Only original cutters and replacement parts should be used.

Hydraulic Tools Specific Safety

For hydraulic tools, additional safety measures are outlined:

Hydraulic tools must only be clamped on the mounting arbor or spindle.
The clamping pressure (300 bar) on the hydro cutterhead and, if applicable, on the outboard bearing, must be checked daily using a high-pressure grease gun before machine startup.
A safety collar must be used on the spindle.
Safety collars must not clamp the tool axially; clamping should occur via hydraulic sleeves (300 bar).
The permissible clamping length must be considered when clamping hydraulic tools on spindles without an outboard bearing.

PowerLock System

The PowerLock system features tools with a tapered mount, clamped via a hollow conical shank interface (HSK) using hydro-mechanical or electro-mechanical tool clamps. The clamping force is generated by a spring assembly.

Weinig PowerLock 536 (Heavy-Duty Cutter)

Function Description: Planer head with reversible cutters for 2-fold use, designed for low-noise, vibration-free operation. Used for planing and edge-jointing on solid wood (hard and soft) and wood substitutes.
Mechanical Design: Solid steel body, robust construction. Consists of a body, clamping ledge, clamping screws, and reversible cutters (2 cutting edges). Right or left clamping ledges are used depending on tool rotation.
Installation/Removal: Cutters are removed by releasing clamping screws and ledges with a striker. Installation involves cleaning, inserting ledges and cutters, mounting a setting device, axially positioning, securing the front clamping screw, removing the setting device, and tensioning clamping ledges to 25 Nm from both sides.
Important Note: Never tension the complete cutter groove in one operation to avoid tool deformation. Do not use damaged Allen keys.
Technical Specifications:
- Tool body: High-strength steel.
- Cutters: Two straight reversible, HSS or carbide options.
- Clamping: Positive, form-fitting with hardened clamping ledges.
- Cutting angle: 12° / 27°.
- Cutter cutting circle dia.: 93 mm.
- Max. speed: 12,000 rpm (up to 240 mm tool length), 8,000 rpm (over 240 mm tool length).

Weinig PowerLock 538 (Profile Cutterhead)

Function Description: Profile cutterhead with profiled cutters, suitable for planing and profiling on solid wood and wood substitutes.
Mechanical Design: Solid steel body, robust construction for low-noise, vibration-free operation. Components include body, clamping ledge, clamping screw, and profiled cutter (Solid, Tipped, or DoubleBack tip with carrier plate). Clamping ledges are marked by cutter thickness.
Installation/Removal: Cutters are removed by releasing clamping screws and pulling out. Installation involves cleaning, inserting ledges and cutters, mounting a setting device, axially positioning, tensioning the middle clamping screw (half torque), removing the setting device, and tensioning all clamping screws to 30-33 Nm from inside outwards.
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Check cutter seating and maximum adjustment (a = 4 spaces / 6.4 mm).
DoubleBack System: Two-part cutter (tip and carrier plate) connected by serration. Carrier plate is held securely in one position. Max adjustment (a) of the tip relative to the carrier plate is indicated by a mark; exceeding this jeopardizes stability.
Grinding DoubleBack Cutters: Carrier plates are profiled first without tips, using blind lugs. Lowest point of profile is ground close to the tool body. A tracing pin (3 mm dia) and grinding wheel (4 mm wide) are used. After grinding, the tip should not protrude more than 5 mm. Tips are moved forward one space or replaced when max adjustment is reached.
Technical Specifications:
- Tool body: High-strength steel.
- Cutters: Two or four profiled, HSS (5/8 mm blank), Stellite/carbide (6/10 mm blank) options.
- Blank weight: Max. 50 g per 10 mm blank length.
- Clamping: Positive, form-fitting with serrated back (1/16" x 60°), hardened clamping elements.
- Cutting angle: 12° or 20°.
- Diameter of tool body: 90 mm.
- Max. speed: 12,000 rpm (up to 240 mm tool length), 8,000 rpm (over 240 mm tool length).
- Profile depth, projection, max. cutting circle table provided for 90 mm diameter cutterhead.

Weinig PowerLock 539 (Profile Cutterhead)

Function Description: Heavy-duty profile cutterhead for planing and profiling on solid wood and wood substitutes.
Safety Instructions: Similar to 538, emphasizing correct seating of profiled cutters, inserting all cutters in the same position, and specific blank heights for Z=2 (60 mm) and Z=4 (70 mm) for Leitz DoubleBack system. Corresponding clamping ledges must be selected based on cutter thickness. Blind lugs must be fitted if profiled cutters are more than 20 mm shorter than clamping ledges to prevent bending.
Mechanical Design: Similar to 538, with body, clamping ledge, clamping screw, and profiled cutter (Solid, Tipped, or DoubleBack tip with carrier plate). Clamping ledges are marked by cutter thickness.
Installation/Removal: Similar to 538, with clamping screws tensioned to 30-33 Nm.
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Check cutter seating and maximum adjustment (a = 4 spaces / 6.4 mm).
DoubleBack System & Grinding: Identical to PowerLock 538.
Technical Specifications:
- Tool body: High-strength steel.
- Cutters: Two or four profiled, HSS (5/8 mm blank), Stellite/carbide (6/10 mm blank) options.
- Blank weight: Max. 50 g per 10 mm blank length.
- Clamping: Positive, form-fitting with serrated back (1/16" x 60°), hardened clamping elements.
- Cutting angle: 12° or 20°.
- Diameter of tool body: 90 mm.
- Max. speed: 12,000 rpm (up to 240 mm tool length), 8,000 rpm (over 240 mm tool length).
- Profile depth, projection, max. cutting circle table provided for 90 mm diameter cutterhead.

Normal Clamping System

Tools are secured on the spindle with a spindle nut, safety collar, and spacer ring.

Hydraulic Spindle Nut (Optional)

Function Description: Tools are clamped on the spindle using hydraulic pressure.
Usage Features: Pressure cylinder must be fully retracted before screwing the hydraulic clamping nut onto the spindle.
Retracting Pressure Cylinder: Back off clamping screw, insert Allen key (7) in hole (8) on nut circumference, screw adjusting pin (6) in until pressure cylinder (2) is fully retracted, then unscrew adjusting pin.
Clamping Tools: Back off clamping screw, drive out locking pin, screw hydraulic spindle nut down tight (then back off slightly to press in locking pin), turn in clamping screw until indicator pin protrudes.
Releasing Tools: Back off clamping screw, drive out locking pin, unscrew hydraulic spindle nut.

Weinig Centrolock 530 (Heavy-Duty Cutter)

Function Description: Planer head with reversible cutters for 2-fold use, designed for low-noise, vibration-free operation. Used for planing and edge-jointing on solid wood and wood substitutes.
Mechanical Design: Solid steel or aluminum body, robust construction. Consists of body, clamping ledge, clamping screws, and reversible cutter (2 cutting edges).
Installation/Removal: Cutters are removed by backing off clamping screw, releasing clamping ledge with striker, and pulling out cutter. Installation involves cleaning, fitting ledges and cutters, and clamping from both sides with clamping screw.
Important Note: Use two angled Allen keys to tighten clamping screws simultaneously to 25 Nm. Never tension the complete cutter groove in one operation. Do not use damaged Allen keys.
Technical Specifications:
- Tool body: High-strength steel or aluminum.
- Cutters: Two or four straight reversible, HSS or carbide options.
- Clamping: Positive, form-fitting with hardened clamping ledges.
- Cutting angle: 12° / 27° / 35°.
- Cutter cutting circle dia.: 125 or 140 mm.
- Max. speed: 9,000 rpm.

Weinig Centrolock 533 (Profile Cutterhead)

Function Description: Heavy-duty profile cutterhead for planing and profiling on solid wood and wood substitutes.
Safety Instructions: Similar to PowerLock 539, emphasizing correct seating of profiled cutters, inserting all cutters in the same position, and specific blank heights for Z=2 (60 mm) and Z=4 (70 mm) for Leitz DoubleBack system. Corresponding clamping ledges must be selected based on cutter thickness. Blind lugs must be fitted if profiled cutters are more than 20 mm shorter than clamping ledges to prevent bending.
Mechanical Design: Similar to PowerLock 539, with body, clamping ledge, clamping screw, and profiled cutter (Solid, Tipped, or DoubleBack tip with carrier plate). Clamping ledges are marked by cutter thickness.
Installation/Removal: Similar to PowerLock 539, with clamping screws tensioned to 25 Nm.
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Check cutter seating and maximum adjustment (a = 4 spaces / 6.4 mm).
DoubleBack System & Grinding: Identical to PowerLock 538.
Technical Specifications:
- Tool body: High-strength steel.
- Cutters: Two or four profiled, HSS (8 mm blank), Stellite/carbide (10 mm blank) options.
- Blank weight: Max. 50 g per 10 mm blank length.
- Clamping: Positive, form-fitting with serrated back (1/16" x 60°), hardened clamping elements.
- Cutting angle: 12° or 20°.
- Diameter of tool body: 122/137 mm.
- Max. speed: See legend on tool.
- Profile depth, projection, max. cutting circle table provided for 122/137 mm diameter cutterhead.

Weinig Cutterhead 500 / 510

Function Description: Heavy-duty cutterhead for planing and edge-jointing on solid wood and wood substitutes.
Mechanical Design: Solid steel or aluminum body, robust construction for low-noise, vibration-free operation. Consists of body, clamping ledge, clamping screws, and planing knife (Solid or Tipped).
Safety Instructions: Note markings for minimum cutter clamping length. Cutters can only be adjusted with corresponding setting devices. Planing knives have compression springs; care must be taken when undoing the last clamping screw as the knife may spring up. Press against the knife with hard wood when undoing the last screw.
Installation/Removal: Removal involves cleaning clamping screws, undoing them from outside inwards, pressing against knife with hard wood, and removing cutter and clamping ledge. Installation involves cleaning, fitting clamping ledges, pressing cutter against springs, clamping with middle screw, adjusting with setting device, and tightening clamping screws from middle outwards to 25-26 Nm (M10) or 30-33 Nm (M12).
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys.
Grinding: Cutters are ground either outside the cutterhead or on a suitable Weinig grinder.
Technical Specifications:
- Tool body: High-strength steel or aluminum.
- Cutters: Two or four straight, HSS, stellite or carbide options.
- Dimensions: 3 x 30 mm.
- Clamping: Non-positive (frictional) with hardened clamping ledges.
- Cutting angle: 12° / 27°.
- Cutter cutting circle dia.: 125 or 140 mm.
- Max. speed: 9,000 rpm.

Weinig Profile Cutterhead 503 / 513

Function Description: Heavy-duty profile cutterhead for planing and profiling on solid wood and wood substitutes.
Safety Instructions: Similar to Centrolock 533, emphasizing at least two clamping screws, selecting appropriate clamping ledges for slim cutters, removing unused screws, correct seating, minimum clamping length markings, correct part fitting, inserting all cutters in same position, and Leitz DoubleBack system specifications.
Mechanical Design: Solid steel body, robust construction. Consists of body, clamping ledge, clamping screw, and profiled cutter (Solid, Tipped, or DoubleBack tip with carrier plate). Clamping ledges are marked by cutter thickness.
Installation/Removal: Removal involves cleaning clamping screws, undoing them from outside inwards, pushing clamping ledge out, and removing cutters. Installation involves cleaning, fitting cutters in serration, sliding in clamping ledge, axially aligning and tightening middle clamping screw (half torque), checking seating, tightening screws from center outwards to 25-26 Nm (M10) or 30-33 Nm (M12).
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Note maximum cutter adjustment (a = 4 spaces / 6.4 mm). Blind lugs must be fitted if profiled cutters are more than 20 mm shorter than clamping ledges.
DoubleBack System & Grinding: Identical to PowerLock 538.
Technical Specifications:
- Tool body: High-strength steel.
- Cutters: Two or four profiled, HSS (8 mm blank), Stellite/carbide (10 mm blank) options.
- Blank weight: Max. 50 g per 10 mm blank length.
- Clamping: Positive, form-fitting with serrated back (1/16" x 60°), hardened clamping elements.
- Cutting angle: 12° or 20°.
- Diameter of tool body: 122/137 mm.
- Max. speed: 8,000 rpm.
- Profile depth, projection, max. cutting circle table provided for 122/137 mm diameter cutterhead.

Weinig Tongue and Groove Cutterhead 508 / 518

Function Description: Heavy-duty cutterhead for producing tongue-and-groove parts to DIN 68126.
Safety Instructions: Note markings for minimum cutter clamping length. Ensure correct part fitting. Clamping ledges and cutters must be clamped with at least two screws. Clamping ledge length must correspond to cutter length. Remove unused screws. Check cutter seating. Insert all cutters in same position. Cutters must be fitted successively on opposite sides.
Mechanical Design: Profile cutterhead with profiled cutters. Solid steel body, robust construction. Consists of body, clamping ledge, clamping screw, and profiled cutter (Solid, Tipped, or DoubleBack tip with carrier plate).
Installation/Removal: Removal involves cleaning clamping screws, undoing them from outside inwards, pushing clamping ledge out, and removing cutters. Installation involves cleaning, fitting cutters in serration, sliding in clamping ledge, axially aligning and tightening middle clamping screw (half torque), checking seating, tightening screws from center outwards to 25-26 Nm.
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Note maximum cutter adjustment (a = 4 spaces / 6.4 mm). Blind lugs must be fitted if profiled cutters are more than 20 mm shorter than clamping ledges.
Grinding: Ground with fitted cutters on a Weinig grinder for concentric running. For groove/tongue cutterheads, a specific grinding support and template are used. Groove width must be 0.1 to 0.5 mm larger than tongue thickness. Spacer rings are used for regrinding and adjusting tongue thickness (table provided for 3.5, 4.5, 6.5 mm tongue widths).
Technical Specifications:
- Precision tool for producing tongue-and-groove parts to DIN 68126.
- Speed: Max. 8,000 rpm.

Hydraulic Clamping System

Weinig Centrolock 534 (Heavy-Duty Cutter)

Function Description: Heavy-duty profile cutterhead for planing and profiling on solid wood and wood substitutes.
Safety Instructions: Check cutter seating. Insert all cutters in same position. Leitz DoubleBack system specifications for blank height (60 mm for Z=2, 70 mm for Z=4). Select clamping ledge based on cutter thickness. Fit blind lugs if cutters are more than 20 mm shorter than ledges. Tool must be fitted with anti-twist device. Clamping pressure (300 bar) must be checked daily. Recommended grease: Shell Alvania Fett RL2.
Mechanical Design: Similar to PowerLock 539, with body, clamping ledge, clamping screw, and profiled cutter (Solid, Tipped, or DoubleBack tip with carrier plate).
Installation/Removal: Similar to PowerLock 539, with clamping screws tensioned to 25-26 Nm (M10) or 30-33 Nm (M12).
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Note maximum cutter adjustment (a = 4 spaces / 6.4 mm). Blind lugs must be fitted if profiled cutters are more than 20 mm shorter than clamping ledges.
DoubleBack System & Grinding: Identical to PowerLock 538.
Technical Specifications:
- Tool body: High-strength steel.
- Cutters: HSS (8 mm blank), Stellite/carbide (10 mm blank) options.
- Blank weight: Max. 50 g per 10 mm blank length.
- Clamping: Positive, form-fitting with serrated back (1/16" x 60°), hardened clamping elements.
- Cutting angle: 12° or 20°.
- Diameter of tool body: 137 / 150 / 163 / 195 / 215 mm.
- Max. speed: See legend on tool.
- Profile depth, projection, max. cutting circle table provided for various diameter cutterheads.

Weinig Hydro Cutterhead 501 / 511 and Rotaplan Cutterhead 502 / 512

Function Description: Heavy-duty hydraulic cutterheads with planing knives for planing and edge-jointing on solid wood and wood substitutes.
Safety Instructions: Note markings for minimum cutter clamping length. Cutters only adjusted with setting devices. Refer to anti-twist protection and hydraulic clamping sections.
Mechanical Design: Solid steel body, robust construction for low-noise, vibration-free operation. Consists of body, clamping ledge, clamping screws, planing knife, filling valve, and screw for grease pressure relief.
Installation/Removal: Removal involves cleaning clamping screws, undoing them from outside inwards, and removing cutter and clamping ledge. Installation involves cleaning, fitting clamping ledges, fitting cutters with radial projection (5-6 mm), clamping with two outer screws, adjusting with setting device, tightening clamping screws from center outwards to 25-26 Nm (M10) or 30-33 Nm (M12).
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Note maximum cutter adjustment.
Grinding: Cutters are ground either outside the cutterhead or on a suitable Weinig grinder for concentric running.
Technical Specifications:
- Tool body: High-strength steel.
- Cutters: Four or six or eight straight, 3 x 30 mm, HSS, stellite or carbide options.
- Clamping: Non-positive (frictional) with hardened clamping ledges.
- Cutting angle: 27° with 4 and 6 cutters, 25° with 8 cutters.
- Cutting circle dia.: 143 or 163 mm.
- Max. speed: 9,000 rpm.
- Cutter dimensions: Height = 45 mm, width = 20 mm.

Weinig Hydro Profile Cutterhead 504 / 514

Function Description: Heavy-duty hydraulic profile cutterhead for planing and profiling on solid wood and wood substitutes.
Safety Instructions: Similar to Centrolock 534, emphasizing correct seating, inserting all cutters in same position, Leitz DoubleBack system specifications, blind lugs, minimum clamping length, at least two clamping screws, selecting appropriate ledges for slim cutters, removing unused screws, daily clamping pressure check (300 bar), and recommended grease (Shell Alvania Fett RL2).
Mechanical Design: Solid steel body, robust construction. Consists of body, clamping ledge, clamping screws, profiled cutter, filling valve, and screw for grease pressure relief.
Installation/Removal: Removal involves cleaning clamping screws, undoing them from outside inwards, and removing cutter and clamping ledge. Installation involves cleaning, fitting cutters in serration, sliding in clamping ledge, axially aligning and tightening middle clamping screw (half torque), checking seating, tightening screws from center outwards to 25-26 Nm (M10) or 30-33 Nm (M12).
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Note maximum cutter adjustment (a = 4 spaces / 6.4 mm).
DoubleBack System & Grinding: Identical to PowerLock 538.
Technical Specifications:
- Tool body: High-strength steel.
- Cutters: Four, six or eight profiled, 8 or 10 mm thick, with serrated back, HSS, stellite or carbide options.
- Blank weight: Max. 50 g per 10 mm blank length.
- Clamping: Positive, form-fitting with serrated back (1/16" x 60°), hardened clamping elements.
- Cutting angle: 12° or 20°.
- Cutting circle diameter: 137 mm, 150 mm or 163 mm.
- Max. speed: 6,000 rpm (for 137/163 mm), 8,000 rpm (for 150 mm).
- Maximum cutter projection: 36 mm.

Weinig Hydro Cutterhead 508 / 518 (Tongue and Groove)

Function Description: Heavy-duty hydraulic cutterhead for producing tongue-and-groove parts. Illustrations show hydro groove, hydro tongue, hydro bevel, and hydro tapered groove cutterheads.
Safety Instructions: Note markings for minimum cutter clamping length. Clamping ledges and cutters must be clamped with at least two screws. Clamping ledge length must correspond to cutter length. Remove unused screws. Check cutter seating. Insert all cutters in same position. Cutters must be fitted successively on opposite sides. Tool must be fitted with anti-twist device. Clamping pressure (300 bar) must be checked daily. Recommended grease: Shell Alvania Fett RL2.
Mechanical Design: Hydraulic profile cutterhead with profiled cutters. Solid steel body, robust construction. Components include body, clamping ledge, clamping screws, profiled cutter, filling valve, screw for grease pressure relief, grooving saw (for hydro groove cutterhead), and spacer rings (for hydro tongue cutterhead).
Installation/Removal: Removal involves cleaning clamping screws, pushing clamping ledge out, and removing cutters. Installation involves cleaning, fitting cutters in serration, sliding in clamping ledge, axially aligning and tightening middle clamping screw (half torque), checking seating, tightening screws from center outwards to 25-26 Nm.
Important Note: Never tension the complete cutter groove in one operation. Do not use damaged Allen keys. Note maximum cutter adjustment (a = 4 spaces / 6.4 mm).
Grinding: Hydro groove and hydro tongue cutterheads are ground on a suitable Weinig grinder with specific support and template. Groove width must be 0.1 to 0.5 mm larger than tongue thickness. Grooving saw removed for grinding groove cutterhead cutters. Diamond grinding wheel for grooving saw. Back-clearance angle 15°-18°. Tongue cutterhead cutters ground while fitted. Spacer rings are used for adjusting tongue thickness (table provided for 3.5, 4.5, 6.5 mm tongue widths). Hydro bevel and hydro tapered groove cutterheads are ground with fitted cutters for concentric running.
Technical Specifications:
- Precision tools for producing tongue-and-groove parts to DIN 68126.
- Tool body: High-strength steel.
- Cutters: 6, 8, 10, 12 or 16 cutters, 5 or 6 mm thick, with serrated back, HSS, stellite or carbide options.
- Blank weight: Max. 50 g per 10 mm blank length.
- Clamping: Positive, form-fitting with serrated back (1/16" x 60°), hardened clamping elements.
- Cutting angle: 20°.
- Hydro groove/tongue cutterhead cutting circle diameter: 200 mm (Z6, Z8), 225 mm (Z8, Z10), 250 mm (Z12, Z16).
- Hydro groove/tongue cutterhead max. speed: 6,000 rpm.
- Hydro groove/tongue cutterhead dimensions: Height = 45 mm, width = 20 mm.
- Hydro bevel/tapered groove cutterhead cutting circle diameter: 220 mm.
- Hydro bevel/tapered groove cutterhead max. speed: 7,500 rpm.
- Hydro bevel/tapered groove cutterhead dimensions: Height = 45 mm, width = 20 or 30 mm.

Weinig PowerLock 536 - Page 48

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