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Table of Contents

Section-Page

ii

MO01doc091902

Table of Contents

ABOUT THIS MANUAL

IV

SECTION 1

SAFETY

1-1

1.1

Safety Symbols.......................................................................................1-1

1.2

Safety Instructions ..................................................................................1-2

SECTION 2

SETUP

2-1

2.1

Moving The Moulder .............................................................................2-1

2.2

Installation ..............................................................................................2-2

2.3

Electrical Installation..............................................................................2-3

2.4

Air Installation........................................................................................2-4

SECTION 3

ADJUSTMENTS

3-1

3.1

Cutting Head #1......................................................................................3-1

Vertical Adjustment...............................................................3-1
Horizontal Adjustment ..........................................................3-2

3.2

Feed Table & Infeed Guides Adjustment...............................................3-3

Feed Table .........................................................................3-3
Infeed Guide Fence ...............................................................3-3
Rear Infeed Guide Fence ......................................................3-4

3.3

Cutting Head #2......................................................................................3-5

Horizontal Adjustment ..........................................................3-5
Vertical Adjustment...............................................................3-6

3.4

Cutting Head #3......................................................................................3-7

Horizontal Adjustment ..........................................................3-7
Vertical Adjustment...............................................................3-8
Rear Guide Fence & Chip Breaker/Roller Assembly ...........3-9

3.5

Cutting Head #4....................................................................................3-12

Vertical Adjustment.............................................................3-12

.......................................................................3-12

Horizontal Adjustment ........................................................3-13
Chip Breaker Adjustments ..................................................3-14

3.6

Cutting Head #5....................................................................................3-16

Vertical Adjustment.............................................................3-16
Horizontal Adjustment ........................................................3-17

3.7

Hold-Down Roller Adjustment ............................................................3-18

3.8

Feed System Adjustments ....................................................................3-19

Feed Rollers .......................................................................3-19
Feed Speed Adjustment .......................................................3-20
Lower Feed Roller Adjustment ...........................................3-21

3.9

Auxiliary Guide Adjustments...............................................................3-22

SECTION 4

OPERATION

4-1

4.1

Control Description ................................................................................4-1

4.2

Preparing For Operation .........................................................................4-2

4.3

Test Run..................................................................................................4-3

Summary of Contents for 4015X5

Page 1: ...fety Operation Manual 4015X5 rev A1 00 4020X5 rev A1 00 M485SP rev A1 00 Safety is our 1 concern Read and understand all safety information and instructions before oper ating setting up or maintaining this machine Form 1107 ...

Page 2: ...de Fence 3 4 3 3 Cutting Head 2 3 5 Horizontal Adjustment 3 5 Vertical Adjustment 3 6 3 4 Cutting Head 3 3 7 Horizontal Adjustment 3 7 Vertical Adjustment 3 8 Rear Guide Fence Chip Breaker Roller Assembly 3 9 3 5 Cutting Head 4 3 12 Vertical Adjustment 3 12 3 12 Horizontal Adjustment 3 13 Chip Breaker Adjustments 3 14 3 6 Cutting Head 5 3 16 Vertical Adjustment 3 16 Horizontal Adjustment 3 17 3 7 ...

Page 3: ...2 iii SECTION 5 LUBRICATION AND MAINTENANCE 5 1 SECTION 6 TROUBLESHOOTING 6 1 6 1 Problems to the Processed Items and Remedies 6 1 6 2 Mechanical Problems 6 4 SECTION 7 SPECIFICATIONS 7 1 SECTION 8 ELECTRICAL INFORMATION 8 1 8 1 Electrical Schematics 8 1 INDEX I ...

Page 4: ...of individual sections of this manual as we obtain new information The information and instructions given in this manual do not amend or extend the limited warranties for the equipment given at the time of purchase For general information regarding Wood Mizer and our Forest to Final Form products please refer to the All Products Catalog 1 Wood Mizer is a registered trademark of Wood Mizer Products...

Page 5: ...About This Manual MO01doc091902 v M4015X5 MOULDER MO0001 ...

Page 6: ... result in death or serious injury WARNING suggests a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION refers to potentially hazardous situations which if not avoided may result in minor or moderate injury or damage to equipment IMPORTANT indicates vital information NOTE gives helpful information Warning stripes are placed on areas where a single...

Page 7: ...hine at all times regardless of ownership Also read any additional manufacturer s manuals and observe any applicable safety instructions including dangers warnings and cautions Only persons who have read and understood the entire operator s manual should operate the machine The machine is not intended for use by or around children IMPORTANT It is always the owner s responsibility to comply with al...

Page 8: ...ne Failure to do so may result in serious injury or death WARNING Always wear eye ear respiration and foot protection when operating or servicing the machine KEEP MACHINE AND AREA AROUND MACHINE CLEAN DANGER Maintain a clean and clear path for all necessary move ment around the machine and lumber stacking areas Failure to do so will result in serious injury ...

Page 9: ...ng hair does not engage rotating members resulting in possi ble injury CHECK MACHINE BEFORE OPERATION DANGER Make sure all guards and covers are in place and secured before operating the machine Remove all loose objects from the machine before operating Failure to do so may result in serious injury DANGER Make sure all adjustable components are tightened securely and the blades turn freely before ...

Page 10: ...ING Keep all persons out of the path of material being fed into the machine Failure to do so may result in serious injury WARNING Do not adjust the feed roller while the machine is run ning The parts may fly out and cause serious injury KEEP SAFETY LABELS IN GOOD CONDITION IMPORTANT Always be sure that all safety decals are clean and readable Replace all damaged safety decals to prevent personal i...

Page 11: ...ns or death Disconnect and lock out power sup ply before servicing Keep all electrical component covers closed and securely fastened during machine operation WARNING Turn off the machine and lock out the electrical supply before performing service or maintenance to the machine Con sider all electrical circuits energized and dangerous Never assume or take the word of another person that the power i...

Page 12: ...ving the moulder Failure to do so may cause damage to the machine The machine can also be moved with an overhead crane using lifting straps through the strap holes at the base of the machine and or the hooks on each side of the machine Fasten the straps securely Place pieces of wood or cardboard between the straps and the machine to prevent scratches or damage to the paint Be sure the load is even...

Page 13: ...ping skid from the moulder frame Lift the moulder up and remove the skid See Figure 2 2 Place the machine on a firm level concrete surface at least 6 inches 150mm thick Place 3 8 inch 10mm thick steel plates under each leg Adjust the level ing bolts to level the machine FIG 2 2 ...

Page 14: ...modate larger cable Secure the cable to the con trol box with an appropriate cable clamp Connect the power wires to the L1 L2 L3 ter minals in the control box Connect the ground wire to the ground terminal Turn the machine on and start the front horizontal blade Check to see if the rotation of the blade is clockwise as viewed from the front of the machine If not turn off the main power supply and ...

Page 15: ...ly hose to the fitting The regulator is set by the factory at 50 psi This should be adequate for most applications If necessary the air pressure may be adjusted Use as little air pressure as necessary to adequately feed the material being worked Lift up and turn the regulator knob to adjust Do not adjust below 25 psi or above 75 psi Fill the oil cup with appropriate pneumatic lubricating oil FIG 2...

Page 16: ...d See Figure 3 1 Place a flat steel rule on the fixed table so it extends over cutting head 1 Spin the head by hand counterclockwise and check the contact of the blades against the steel rule NOTE When spinning the head be sure to spin in a coun terclockwise direction to avoid nicking the blades on the steel rule The cutting head blades should just lightly touch the steel rule Adjust the cutting h...

Page 17: ... reset the counter to zero Loosen the setscrew on the counter dial and turn the dial until it reads 0 Retighten the setscrew Horizontal Adjustment It will not usually be necessary to adjust cutting head 1 in the horizontal direction but adjustment is provided Be sure there is not a gap between the infeed guide fence and the blades of the cutting head See Figure 3 2 To adjust cutting head 1 horizon...

Page 18: ...number indicated on the handle is the distance relative to the fixed table behind cutting head 1 in millimeters This will determine how much material is removed from the bottom of the workpiece by cutting head 1 Retighten the feed table adjustment handle Infeed Guide Fence Turn and then pull the guide fence adjustment handle to move the guide fence in or out in relation to cutting head 1 Retighten...

Page 19: ...tment Adjustments MO01doc091902 3 4 3 Rear Infeed Guide Fence See Figure 3 4 Adjust the guide fence behind cutting head 2 so that it is 1 4 from the blades Use a hex wrench to loosen the screws adjust the fence and retighten the screws FIG 3 4 ...

Page 20: ...Spin the head by hand counterclockwise and check the contact of the blades against the steel rule NOTE When spinning the head be sure to spin in a coun terclockwise direction to avoid nicking the blades on the steel rule The cutting head blades should just lightly touch the steel rule Adjust the cutting head in or out as necessary Loosen the locking handle and use the supplied wrench to turn the a...

Page 21: ...ce in front of the cutting head Adjust the cutting head up or down as necessary See Figure 3 6 Loosen the locking handle and use the supplied wrench handle to turn the adjustment shaft clockwise to raise the cutting head counterclockwise to lower the cutting head Retighten the locking handle and reset the counter to zero NOTE When lowering the blade lower it further than desired then back up to re...

Page 22: ...sition of cutting head 3 Lay the sample on the table against the guide fence in front of the cutting head Adjust the cutting head in or out as necessary See Figure 3 7 Loosen the locking handle and use the supplied wrench to turn the adjustment shaft clockwise to move the blade back counterclockwise to move the blade forward Retighten the locking handle and reset the counter to zero FIG 3 7 ...

Page 23: ...s necessary See Figure 3 8 Loosen the locking handle and use the supplied wrench handle to turn the adjustment shaft clockwise to raise the blade counterclockwise to lower the blade Retighten the locking handle and reset the counter to zero NOTE When lowering the blade lower it further than desired then back up to remove slack from the adjusting screw FIG 3 8 ...

Page 24: ...flat steel rule against the rear guide fence so it extends over cut ting head 3 Loosen the fence locking bolt and spin the blade by hand counterclockwise Adjust the fence until the steel rule just touches the blade Retighten the locking bolt NOTE When spinning the blade be sure to spin in a coun terclockwise direction to avoid nicking the cutting edge on the steel rule Loosen the horizontal lockin...

Page 25: ... the locking bolts Loosen the horizontal locking bolt and adjust the assembly so the chip breaker is 1 4 from the blades Retighten the locking bolt The rollers are spring loaded and can be adjusted to provide more or less pressure Loosen the jam nuts on the two adjustment bolts and turn the bolts clockwise to increase roller tension counterclockwise to reduce roller tension FIG 3 10 ...

Page 26: ...e 3 11 Ring shaped plates are provided to place in the recessed area around each cutter head Use the plates when working small mouldings that may get caught in the recesses Place two plates in position around each cutter head and secure with the provided screws FIG 3 11 ...

Page 27: ...or down as necessary See Figure 3 12 Loosen the locking handle and use the supplied wrench handle to turn the adjustment shaft clockwise to raise the blade counterclockwise to lower the blade Retighten the locking handle and reset the counter to zero NOTE When lowering the blade lower it further than desired then back up to remove slack from the adjusting screw FIG 3 12 ...

Page 28: ...ished sample of moulding as a guide adjust cutting head 4 in or out as nec essary See Figure 3 13 Loosen the locking handle and use the supplied wrench to turn the adjustment shaft clockwise to move the blade back counterclockwise to move the blade forward Retighten the locking handle FIG 3 13 ...

Page 29: ...e front chip breaker verti cally loosen the two locking bolts and turn the adjustment handle Retighten the locking bolts The pressure of the front chip breaker can be adjusted by turning the two pressure adjustment screws The chip breaker can be adjusted toward or away from the blade by loosening the mounting screws on the bottom side of the breaker pads Adjust the plate 1 8 1 4 from the blade and...

Page 30: ...behind cutting head 4 to within 1 8 1 4 from the blade Turn the rear chip adjustment handle to raise or lower the rear chip breaker Loosen the horizontal locking bolts to move the rear chip breaker toward or away from the blade Adjust to 1 8 1 4 from the blade and retighten the locking bolts FIG 3 15 ...

Page 31: ... 16 Place a flat steel rule on the fixed table so it extends over cutting head 5 Spin the head by hand counterclockwise and check the contact of the blades against the steel rule NOTE When spinning the head be sure to spin in a coun terclockwise direction to avoid nicking the blades on the steel rule The cutting head blades should just lightly touch the steel rule Adjust the cutting head up or dow...

Page 32: ...ck up to remove slack from the adjusting screw After adjusting cutting head 5 vertically tighten the lock handle and reset the counter to zero Loosen the setscrew on the counter dial and turn the dial until it reads 0 Retighten the setscrew Horizontal Adjustment Using a finished sample of moulding as a guide adjust cutting head 5 in or out as nec essary See Figure 3 17 Loosen the locking handle an...

Page 33: ...ee Figure 3 18 Loosen the vertical clamp bolt to slide the hold down roller up or down Loosen the horizontal clamp bolt to move the hold down roller in or out so it is centered on the workpiece Turn the pressure adjustment screw so the hold down roller applies the desired pressure to the work piece FIG 3 18 ...

Page 34: ... Feed Rollers See Figure 3 19 The feed rollers move up and down with the upper head All of the feed rollers should be adjusted in the same vertical plane to apply equal pressure to the work piece To move a roller up or down turn the corresponding adjustment knob at the top of the moulder FIG 3 19 ...

Page 35: ...he feed speed adjustment knob to select the appropriate feed rate as indicated by the gauge Choose the highest speed possible that still allows the material to be cut smoothly Low speed is required for thick cuts or when cutting hard wood CAUTION Adjust the feed speed only while the feed motor is running FIG 3 20 ...

Page 36: ...rollers are spring loaded and should be adjusted to 005 above the table surface To adjust the lower feed roller height locate the adjust ment bolt at the back of the machine Turn the lower adjustment nut to raise or lower the rollers Turn the top adjustment nut to increase or decrease spring tension of the lower rollers FIG 3 21 ...

Page 37: ...and slide the assembly in or out so the roller contacts the side of the workpiece Retighten the locking handles Turn the adjustment bolt to adjust the pressure of the guide roller against the workpiece Adjust the front guard plate as close to the workpiece as possible without interfering with the travel of the workpiece Loosen the locking knobs and slide the plate toward or away from the workpiece...

Page 38: ...uxiliary Guide Adjustments 3 3 23 MO01doc091902 Adjustments See Figure 3 23 To adjust the rear guide loosen the lock handles and slide the assem bly in or out so the guide contacts the side of the workpiece FIG 3 23 ...

Page 39: ...n overload condition is detected at any of the cutting heads UP Push this button to raise the upper head assembly DOWN Push this button to lower the upper head assembly Feed Stop Push this button to stop feeding material into the machine Feed On Push this button to start feeding material into the machine Jog Forward Use this button to feed material forward a short dis tance and stop Jog Backward U...

Page 40: ...ntenance to the machine Consider all electrical circuits energized and dan gerous Never assume or take the word of another person that the power is off check it out and lock it out Failure to do so may result in serious injury 1 Wipe the protective oil from machined surfaces 2 Be sure the electrical power supply is OFF Install the blades and make adjustments as described in the previous section Se...

Page 41: ...ing the machine Failure to do so may result in serious injury or death WARNING Always wear eye ear respiration and foot protection when operating or servicing the machine WARNING Use the appropriate feed wheel and adjust it properly for the material being processed WARNING Inspect the material to be worked for embed ded objects such as stones or nails Feeding material with such objects may cause s...

Page 42: ... being processed 5 When the operation is finished turn the machine off Disconnect the air supply to the machine attach an OSHA approved nozzle and blow all sawdust from the moulder WARNING Do not leave the machine running Turn the machine off and allow it to come to a full stop before leaving the site Failure to do so may result in serious injury ...

Page 43: ...Shifts Rails of Horizontal Axes Machine Oil N46 Once Every Three Shifts Fine Rods of Vertical Axes Screws Machine Oil N46 Once A Week Axle Bearings of Horizontal Axes Grease ZG 3 Once Every Six Month Fine Rods for Vertical Axes Screws Nuts Machine Oil N46 Once A Week Rails of Vertical Axes Machine Oil N46 Once Every Three Shifts Axle Bearings for Vertical Axes Grease ZG 3 Once Every Three Months A...

Page 44: ...eed Wood Material a Over high Position of the Front Pressing Board of the Upper Blade Axis a Adjust the Front Pressing Board Lower b Wood Material is crook b Keep the concave side down ward Defects on the Lower Side of the Outfeed Wood a Over High Position of Lower Blade Axis a Adjust the Blade Downward b Back Pressing Board of the Upper Blade Axis Not at Parallel Position b Keep the pressing Boar...

Page 45: ...It at the Same Level with the Board The processed item crook upward or downward when being planed Over low or high position of the blade or the blade is blunt Adjust the blade to the parallel position of the platform or sharpen the blade Processed item twisted a Infeed roller shifted to one side or the other or the different thickness of the item make the rollers give different pressures a Adjust ...

Page 46: ...e ruler a Make renewed adjustment to the blade b One of the blades are seri ously blunt b Sharpen the blade The sides on the length direc tion not parallel Over low position of the horizon tal blade Adjust the blade upward The two sides on the length direction not parallel Blade deviated from the board Make adjustment to the blade and keep it close to and parallel with the board ...

Page 47: ... for lifting up and motor B Check if the button of the Up Down speed reducer is out of place C Check the nuts of the up down device have been worn or torn D The infeed beam is in touch with the switch of the axle of the upper blade Slightly lower down the axle 3 Too Noisy A Check the tear and wear of all the bear ings B Check if the blades are properly installed 4 Strange noise in the motor when i...

Page 48: ...m Material Capacity 7 W x 32 H 18mm x 8mm 1 W x 32 H 25mm x 8mm Front Platform Length 52 3 4 1340mm Feed Speed Up to 80 ft 25m per minute Electrical Requirements 230V 60Hz 460V 60Hz or 380V 50Hz All 3 Phase Weight Approximately 3520 Lbs 1600 Kg Top Spindle Motor 10 HP 7 5kW Side Bottom Spindle Motors 7 5 HP 5 5kW Spindle RPM 6000 Spindle Bearings 40mm FAG Germany Cutter Blocks 40mm x 125mm diamete...

Page 49: ...ont Platform Length 52 3 4 1340mm Feed Speed 5 to 25m per minute Electrical Requirements 230V 60Hz 460V 60Hz or 380V 50Hz All 3 Phase Weight Approximately 5958 Lbs 2700 Kg Top Spindle Motor 10 HP 7 5kW Side Bottom Spindle Motors 7 5 HP 5 5kW Spindle RPM 6000 Spindle Bearings 40mm FAG Germany Cutter Blocks 40mm x 125mm diameter Cutter Knives Corrugated High Speed Steel Replacements re grinding or p...

Page 50: ...Electrical Information Electrical Schematics 8 8 1 MO01doc091902 Electrical Information SECTION 8 ELECTRICAL INFORMATION 8 1 Electrical Schematics FIG 8 1 PAGE 1 OF 3 ...

Page 51: ...Electrical Information Electrical Schematics Electrical Information MO01doc091902 8 2 8 FIG 8 1 PAGE 2 OF 3 ...

Page 52: ...Electrical Information Electrical Schematics 8 8 3 MO01doc091902 Electrical Information FIG 8 1 PAGE 3 OF 3 ...

Page 53: ...own roller 3 18 infeed roller 3 19 rear lower blade 3 16 rear vertical blade 3 7 upper blade horizontal 3 13 M maintenance lubrication 5 1 O operation preparation 4 2 test run 4 3 S safety instructions 1 2 symbol definitions 1 1 setup hoisting 2 1 installation 2 2 specifications 7 1 T troubleshooting material processing 6 1 mechanical problems 6 4 INDEX ...

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