Wood-mizer LT40DC Series User Manual Download Page 21

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Safety & General Information

Sawmill Maintenance

Safety & General Information

30Sdoc120507

1-12

S12005G

CAUTION! Always wear protective ear
muffs when operating the sawmill!

P11789

Aligning the blade on the wheels

P85070

CE safety certification

099401

Russian safety certification

TABLE 1-1

099401

Summary of Contents for LT40DC Series

Page 1: ......

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Page 3: ... Setup Operation Maintenence Manual LT40DC Series MH rev E2 00 Safety is our 1 concern Read and understand all safety information and instructions before oper ating setting up or maintaining this machine February 1998 Form 533 ...

Page 4: ...e day they are ordered Second Day and Next Day shipping are available at additional cost If You Need Service From Europe call our European Headquarters and Manufacturing Facility in Kolo Poland at 48 63 2626000 or 48 3912 1319 From the continental U S call us toll free at 1 800 525 8100 Ask to speak with a Customer Service Representative Please have your vehicle identification number and your cust...

Page 5: ...iana Weight Class A Under 3 000 lbs B 3 001 4 000 lbs C 4 001 5000 lbs Product No 1 LT15 2 LT20 4 LT40 Series 7 LT70 Series Length of the Trailer 20 20 Ft 24 24 35 35 Number of axles on the trailer Year of Manufacture Y 2001 Z 2002 A 2003 B 2004 C 2005 D 2006 State of Manufacture N Indiana P Poland Month of Manufacture A January B February C March etc Revision Level Sequence Number Ranging from 00...

Page 6: ...or a description of the model number When you pick up your mill you will receive a customer number Both the VIN and your customer number expedite our service to you Please write these numbers below so you have quick easy access to them MODEL NUMBER DESCRIPTION Customer No Model No V I N Revision LT40 Basic Sawmill I D D42 Configuration Engine Motor ...

Page 7: ... 1 2 1 Stationary Sawmill Setup 2 1 2 2 Portable Sawmill Setup 2 3 2 3 Middle Track Cover 2 5 2 4 Replacing The Blade 2 6 2 5 Tensioning The Blade 2 7 2 6 Tracking The Blade 2 8 2 7 Starting The Engine or Motor 2 10 2 8 Board Return 2 11 2 9 Loading Turning and Clamping Logs 2 14 2 10 Up Down Operation 2 17 2 11 Blade Guide Arm Operation 2 18 2 12 Clutch Brake Operation 2 19 2 13 Power Feed Operat...

Page 8: ...ment 3 10 3 11 Drive Belt Adjustment 3 11 3 12 Clutch Handle Adjustment 3 14 3 13 Autoclutch Option Adjustment 3 15 3 14 Drive Bearing 3 16 3 15 Up Down System 3 17 3 16 Power Feed 3 19 SECTION 4 TROUBLESHOOTING GUIDE 2 1 4 1 Sawing Problems 2 1 4 2 Electrical Problems 2 3 4 3 Power Feed Problems 2 5 4 4 Power Feed Circuit Troubleshooting 2 7 4 5 Engine Motor and Drive Pulleys Alignment 2 9 4 6 Po...

Page 9: ...de Arm Vertical Adjustment 3 14 5 8 Blade Guide Arm Horizontal Adjustment 3 16 5 9 Aligning the Blade Guides 3 18 5 10 Blade Deflection 3 19 5 11 Blade Guide Vertical Tilt Adjustment 3 20 5 12 Blade Guide Spacing 3 22 5 13 Horizontal Tilt Adjustment 3 23 5 14 Blade Guide Block Adjustment 3 24 5 15 Horizontal Adjustment of Side Supports 3 25 5 16 Vertical Adjustment of Side Supports 3 26 5 17 Clamp...

Page 10: ...g stripes Read and observe all safety instructions before operating this equipment Also read any additional manufacturer s manuals and observe any applicable safety instructions includ ing dangers warnings and cautions Always be sure that all safety decals are clean and readable Replace all damaged safety decals to prevent personal injury or damage to the equipment Contact your local distribu tor ...

Page 11: ...ilure to do so will result in serious injury WARNING Always wear gloves and eye protection when handling bandsaw blades Changing blades is safest when done by one person Keep all other persons away from area when coiling carrying or changing a blade Failure to do so may result in serious injury WARNING Do not spin the blade wheels by hand Spinning the blade wheels by hand may result in serious inj...

Page 12: ...re the trailer is supporting the sawmill frame when operating a sawmill with adjustable outriggers Failure to do so may result in serious injury or death The adjustable outriggers are intended to support the saw frame with assistance from the trailer WARNING Do not set up the mill on ground with more than a 10 degree incline If setup on an incline is necessary put blocks under one side of the mill...

Page 13: ... so will result in serious injury DANGER Maintain a clean and clear path for all necessary movement around the mill and lumber stacking areas Fail ure to do so will result in serious injury DANGER Always be sure the blade is disengaged and all persons are out of the path of the blade before starting the engine or motor Failure to do so will result in serious injury DANGER Keep all persons out of t...

Page 14: ...ces sory Never use flammable fuels or liquids If these types of liquids are necessary to clean the blade remove it and clean with a rag Failure to do so may result in serious injury or death CAUTION Be sure the pivot rails turning arm clamp and toe boards are below bed level before loading a log onto the bed Failure to do so may result in machine damage or cause misalignment CAUTION Before loading...

Page 15: ...al Information 30Sdoc120507 1 6 1 result in severe machine damage CAUTION Be sure to stop the blade when returning the carriage This will not only prevent the blade from being pulled off and ruined by a wood sliver but also will increase the life of the blade ...

Page 16: ...tant If introduced into eyes flush with water for at least 15 minutes If film or irrita tion persists seek medical attention Wash skin with soap and water If ingested do not induce vomiting contact a physician KEEP OUT OF THE REACH OF CHILDREN CAUTION Do not over grease the blade guide bearings Over greasing will push the seals out of the bearings caus ing premature failure CAUTION Reinstall the t...

Page 17: ... Pads adjusted too tight will cause premature up down motor failure CAUTION It is important that the lower stop bolts are prop erly adjusted to secure the carriage on the track rail Failure to properly adjust the stop bolts can cause saw head dam age especially during mill transportation CAUTION Failure to remove sawdust buildup from the bat tery box lid and or track rail cover could result in dam...

Page 18: ...cal View W M No Description 096317 CAUTION Read thoroughly the manual before operating the machine Observe all safety instructions and rules when operating the sawmill 099220 CAUTION Close all guards and covers before starting the machine 099219 Blade tension Turning the bolt clockwise will increase the blade tension and turning the bolt counterclockwise will decrease the tension 099220 099219 ...

Page 19: ...tion 30Sdoc120507 1 10 1 099223 Blade tension See manual 099221 CAUTION Keep all persons a safe distance away from work area when operating the machine 098176 CAUTION Keep away from debarker blade 099222 CAUTION Sawdust outlet Protect eyes TABLE 1 1 099223 099221 098176 ...

Page 20: ...ntenance 1 1 11 30Sdoc120507 Safety General Information 099542 CAUTION Trailer 086099 CAUTION Keep away hot parts 096321 Blade movement direction S12004G CAUTION Always wear safety goggles when operating the sawmill TABLE 1 1 099542 086099 ...

Page 21: ... Safety General Information 30Sdoc120507 1 12 1 S12005G CAUTION Always wear protective ear muffs when operating the sawmill P11789 Aligning the blade on the wheels P85070 CE safety certification 099401 Russian safety certification TABLE 1 1 099401 ...

Page 22: ...iption Belt Size Wood Mizer Part Motor Drive Belt E25 50Hz 3BX74 014249 Engine Drive Belt D42 3BX72 014085 Alternator Belt D42 6PK1080 088181 Blade Pulley Belts B57 1 1 To insure proper blade tracking use Goodyear Dayco Super II or Browning belts only P04185 Power Feed Drive Belt AX35 015175 Up Down Drive Belt AX23 015257 Board Return Belt 3L190 015477 TABLE 1 2 ...

Page 23: ...specifica tions Softwood Medium Hardwood Frozen Timber or Dense Hardwood 5 15HP Gas B275IH1030 B275IH741030 B375IH929 B375IH929 1 1 TRU SHARP F blades use a 9 29 profile 9 hook angle and 29 back angle and are designed to cut frozen and or extremely dense hard to cut wood Standard TRU SHARP blades use a 10 30 profile 7 4 11kW 10 15HP Electric 16 25HP Gas 33HP Diesel B376IH1030 B376IH741030 B275IH10...

Page 24: ...H 36 91 5 cm 21 6 4 m LT40 S MH with Optional 6 Bed Extension 2 36 91 5 cm 22 8 6 9 m LT40M MH with Optional 6 Bed Extension 2 36 91 5 cm 27 8 2 m LT40 S MH with Optional 12 Bed Extension 2 2 Logs over 4400 lbs must be distributed so that neither the basic mill or extension is loaded beyond the 4400 lb maximum weight rating Loading logs heavier than 4400 lbs 1996 Kg on a mill equipped with bed ext...

Page 25: ...BB EC L T STD 1 42KM 4 cylinders 1498 cm3 25HP Electric 2 2 The electric motors supplied on Wood Mizer sawmills carry a rating assigned by the motor manufacturer for the continuous duty operation of the motor potentially 24 hours per day day after day This rating is useful in sizing motors for use in applications like blowers for heating and ventilation that are never cycled off except for system ...

Page 26: ...0 25 mp Weight 110 kg Recommended conveying air velocity in the duct 20 m s Model Length 1 1 Length from hitch to chain bracket Width 2 2 Width from fender to fender With Operating Position with Loading Arms Height 3 3 Height from ground to mast Placing head in maximum position will add to total height Weight Weight w Trailer LT40 S MH 21 11 6 7 m 6 6 2 m 11 5 3 5 m 7 8 2 4 m lbs lbs LT40 M MH 26 ...

Page 27: ...e Figure 1 1 The major components of the Wood Mizer LT40 Series MH are shown below FIG 1 1 Engine Drive Assembly Cutting Head Outer Blade Guide Arm Blade Tensioner Side Support Log Clamp Loading Ramps Bed Frame Outrigger Leg Pivot Bed Rail Control Panel Water Lube Clutch Brake Handle Trailer Hitch 300001 ...

Page 28: ...ould be rated to support 6350 lbs sq ft at each sawmill foot position NOTE Make sure the unit is level before securing It IS possible to twist the mill frame by jacking one foot higher than the others WARNING Securely fasten the feet of a stationary sawmill to the floor before operating the sawmill Failure to do so may result in serious injury or death FIG 2 1 LT40S MH Stationary Metric Dimensions...

Page 29: ...ery operated accessories Use the up down switch on the control panel to raise the cut ting head from the carriage rest pin Swing the rest pin down below bed level 3 Use the carriage forward reverse switch left side of control box to move the cutting head toward the front end of the mill Raise the two side supports that will prevent a log from falling off the side of the mill when loaded See Figure...

Page 30: ...ment before unhitching it from the towing vehicle Failure to do so may result in serious injury or death WARNING Always make sure the trailer is supporting the sawmill frame when operating a sawmill with adjustable outriggers Failure to do so may result in serious injury or death The adjustable outriggers are intended to support the saw frame with assistance from the trailer 1 Unhitch the mill fro...

Page 31: ...ion may result in serious injury 5 Remove the fenders by lifting them out of the slots CAUTION To prevent fender damage remove fenders before operating sawmill or loading logs 6 Use the carriage forward reverse switch left side of control box to move the cutting head toward the front end of the mill Lower and set the remaining rear outriggers 7 Level the sawmill by adjusting the outriggers to rais...

Page 32: ...r from its storage position 3 Soak the felt wiper with Dexron III transmission fluid 10W30 motor oil or 3 in 1 turbine oil 4 Install the middle track cover so it fits against the rail and secure with two thumb screws See Figure 2 4 CAUTION Install the track cover so that it lightly touches the track rail If the wiper presses too firmly against the rail it can cause the power feed to bind FIG 2 4 I...

Page 33: ...nged middle blade housing cover Turn the blade tension handle to release the blade tension until the wheel is pulled in and the blade is lying loose in the blade housing Lift the blade out of the blade housing When installing a blade make sure the teeth are pointing the correct direction The teeth should be pointing toward the operator side of the mill when you are looking at the blade below the b...

Page 34: ...rature changes will cause tension to change Adjust the ten sion handle as necessary to maintain the recommended tension level CAUTION Changes in temperature could cause increased pressure in the blade tensioner and loss of fluid from the gauge Release the blade tension when the mill is not in use to avoid damage to the tensioner FIG 2 5 Blade Type Acceptable Range Ideal Tension B375IH929 12 4 14 5...

Page 35: ... the key and check the position of the blade on the blade wheels See Figure 2 6 Position 1 1 4 wide blades so the gullet is 3 0 mm 0 12 out from the edge of the blade wheel 1 0 mm 0 04 Position 1 1 2 blades so the gullet is 4 5 mm 0 18 out from the edge of the blade wheel 1 0 mm 0 04 5 To adjust where the blade travels on the blade wheels use the cant control shown in Fig ure 2 5 If the blade is t...

Page 36: ...NGER Make sure all guards and covers are in place and secured before operating or towing the sawmill Failure to do so may result in serious injury Be sure the blade housing and pulley covers are in place and secure Use the safety retainer pin and cable to fasten blade housing cov ers IMPORTANT After aligning the blade on the wheels always double check the blade guide spacing and location See Secti...

Page 37: ...overs are in place and secure Use the safety retainer pin and cable to fasten blade housing cov ers DANGER Always be sure the blade is disengaged and all persons are out of the path of the blade before starting the engine or motor Failure to do so will result in serious injury WARNING Always wear eye ear respiration and foot pro tection when operating the sawmill Failure to do so may result in ser...

Page 38: ... stand on This table is designed and intended to assist in the removal of boards only Standing on the table may result in serious injury Super sawmill models are equipped with a board return system This system consists of an arm on the saw head controlled by a toggle switch on the control panel A board return table is also provided to catch the board as it is removed from the log To install the bo...

Page 39: ...sure the edge of the table seats in the slot on the bed frame and the table tab seats in the leg bracket Lower the outrigger and adjust it until it is firmly planted on the ground Store the pins by placing one pin in the hole under the table Loop the second pin through the retainer of the first pin and lock FIG 2 7 Place table edge in provided tabs and lower into operating position 3H0436B ...

Page 40: ...ot always return in the same path or location If a board returns in a manner that does not allow the sawyer or off bearer to maintain control it may be necessary to stop the reverse motion of the saw head When the board return is to be used a second person is required to remove the board as it is returned DO NOT attempt to use the board return feature when sawing alone To bypass the board return f...

Page 41: ...t use this rail 2 Position the log at the foot of the ramps 3 Remove the winch cable from the log turner if applicable and route the cable over the top of the log Wrap the cable around and underneath the log Hook the cable to the third hole in the log clamp bracket See Winch Operation Manual 4 Crank the winch to begin rolling the log up the ramps and onto the sawmill bed Keep the log centered on t...

Page 42: ... If you want to turn the log more do the following steps 3 Raise the turner arm to get a new bite on the log 4 Disengage the clamp 5 The log can be turned now Repeat steps 4 through 7 until the log is turned as desired To Clamp Logs 1 Position the log clamp in the bracket in the hole closest to the log 2 Move the clamp down far enough so that it is below your first few cuts Pivot the clamp so that...

Page 43: ... slightly and push the side supports down until they are positioned below the level of your first few cuts 4 Use the optional toe boards to level the log if desired See the manual supplied with the manual toe boards for details concerning toe board operation To Level A Tapered Log Use the optional toe boards to raise either end of a tapered log if desired See the Toe Board Option Manual for operat...

Page 44: ...old the switch in position until the cutting head reaches the desired height then release The up down switch is designed to return to the neutral or off position when released If the switch remains engaged manually move the switch to the neutral or off position Repair the up down drum switch See Section 4 2 CAUTION Always make sure the up down switch moves to the neutral or off position when relea...

Page 45: ...4 mm 2 Use the blade guide toggle switch on the control panel to adjust the outer blade guide as necessary Push the switch to the left to move the arm in Push the switch to the right to move the arm out See Figure 2 11 3 Use the blade guide toggle switch to readjust the outer blade guide as you are cutting in order to keep the guide within 1 2 5 cm of the log Be sure to adjust the arm back out bef...

Page 46: ... are in place and secured before operating or towing the sawmill Failure to do so may result in serious injury Be sure the blade housing and pulley covers are in place and secure Use the safety retainer pin and cable to fasten blade housing cov ers Be sure the blade housing and pulley covers are in place and secure before starting the engine or motor Use the safety retainer pin and cable to fasten...

Page 47: ...ever down until it locks in the down position This engages the drive mechanism releases the blade brake and increases the engine speed to full throttle To disengage the blade raise the clutch brake lever to the up position This disengages the drive belt engages the blade brake and returns the engine to idle ...

Page 48: ...arriage Forward and Reverse The carriage forward reverse switch controls the direction in which the carriage travels Turn the forward reverse switch upward to move the carriage forward Turn the switch down to move the carriage backward The middle position as shown is the neutral position The power feed switch is designed to return to the neutral or off position when released from operating in the ...

Page 49: ...idle Remove the board from the top of the log CAUTION Be sure to stop the blade when returning the carriage This will not only prevent the blade from being pulled off and ruined by a wood sliver but also will increase the life of the blade See Section 2 16 for optional proce dure for Super series mills 3 Return the carriage to the front of the mill by turning the carriage forward reverse switch do...

Page 50: ...ine Engage the clutch brake lever to start the blade spinning 4 Start the water lube if necessary to prevent sap buildup on the blade See Section 2 18 5 If you want to use the board return function push the toggle switch on the control panel down See Section 2 8 6 Feed the blade into the log slowly See Section 2 13 Once the blade completely enters the log increase the feed rate as desired Always t...

Page 51: ... degrees and you are using toe boards to compensate for taper in the log raise the front or rear toe board again on the second side of the log until the heart is parallel with the bed 11 Repeat the steps used to cut the first side of the log until the log is square Cut boards from the remaining cant by adjusting the blade height for the thickness of boards that you want Example Remember that the b...

Page 52: ...ide supports halfway up the flitch height Wider flitches should be placed to the clamp side When they are edged flip them over to edge the sec ond side without disturbing the other flitches or without having to pull them from the mid dle of the stack 4 Adjust the blade height to edge a few of the widest boards 5 Loosen the clamp and turn the edged boards over to edge the other side 6 Repeat steps ...

Page 53: ...arriage Normal operation procedures recommend disengaging the blade before returning the carriage for maximum blade life and fuel economy DANGER If leaving the blade engaged for maximum pro duction rates make sure the off bearer stays out of the path of the blade Failure to do so will result in serious injury or death CAUTION If you choose to leave the blade engaged raise the blade to clear the lo...

Page 54: ...the carriage head The blade indicator used to read the inch and quarter scales remains stationary Blade Height Indicator The blade height indicator has two horizontal red lines on both sides Readings should be taken with eyes level with the indicator when the two red lines are in line This will allow to avoid the parallax error different scale readings depending on the angle of vision FIG 2 14 Qua...

Page 55: ...are sawing Example You want to cut 1 25 mm random width boards from a log Position the blade for the first cut Move the carriage to an even measurement on the inch scale Make a trim cut Return the carriage for the second cut and lower it 1 1 8 29 mm below the orig inal measurement The extra 1 8 3 mm allows for saw kerf and shrinkage of the lum ber The yellow area on the scale identifies where the ...

Page 56: ... horizontal red line on the indicator with the nearest mark on the scale you want to use Make a trim cut When you return the carriage for a second cut lower the carriage to the next mark on the scale This mark shows where the blade should be positioned to cut a certain thickness of lumber without having to measure on the inch scale Example You want to cut 1 25 mm 4 4 random width boards from a log...

Page 57: ...is needed use just enough water to keep the blade clean This saves water and lowers the risk of stain ing the boards with water Usual flow will be 1 2 gallons 3 8 7 6 liters per hour A squirt of liquid dishwashing detergent in the water bottle will help clean the blade when cutting wood with a high sap content WARNING Use ONLY water with the water lube acces sory Never use flammable fuels or liqui...

Page 58: ...store it in a warm place Blow any remaining water from the water lube hose To remove water from the water valve on Super models turn the key switch to accessory 3 turn the feed rate knob down to 0 and place the feed switch in the forward position Blow any remaining water from the water lube hose and valve Return the for ward reverse switch to neutral and turn the key switch to off 0 ...

Page 59: ...e sawmill exceeds 3 000 lbs 1361 Kg for any reason an auxiliary braking system such as electric brakes must be used Failure to do so may result in severe machine damage 1 Move the saw carriage to the front end of the sawmill Raise the rear outriggers 2 Move the carriage forward to the travel position over the rear bed rail 3 Position the hole in the saw head over the travel rest pin 4 Lower the sa...

Page 60: ...n cause saw head dam age especially during mill transportation 6 If necessary adjust the two stops located at the bottom of the mast so the saw head con tacts them after it is lowered 3 4 19mm past where it contacts the rest pin See Figure 2 17 7 Engage the clutch brake lever This keeps the drive belt tight and the motor from bounc ing while traveling Be sure to disengage the clutch brake handle a...

Page 61: ... head can result in severe machine damage Be sure the blade housing and pulley covers are in place and secure Use the safety retainer pin and cable to fasten blade housing covers 10 Remove all loose objects from the bed of the mill Store the outrigger jack handle in the bracket provided on the rear loading side outrigger guide Reel in the winch cable Remove the winch handle 11 Place both fenders i...

Page 62: ...igure 2 19 2 Measure at the other end of the log and compare distances The distance from the bed to the heart on one end of the log should be within 1 2 12 5 mm of the measurement from the bed to the heart on the other end of the log 3 If adjustment is necessary place the crank handle on the toe board at the end of log to be raised Turn the handle clockwise to raise the end of the log Raise about ...

Page 63: ...he heart CAUTION Be sure the pivot rails turning arm clamp and toe boards are below bed level before loading a log onto the bed Failure to do so may result in machine damage or cause misalignment 5 Repeat these steps to square the remaining two sides of the log If you do not have the toe board option you can achieve the same results by shimming one end of the log so that the blade cuts parallel to...

Page 64: ...d 2 2 37 30Sdoc120507 Setup Operation levelled must rest on the sawmill bed CAUTION While levelling never place your hands under the log CAUTION Always be sure the toe boards are low ered all the way before loading a log onto the bed ...

Page 65: ...er to option and engine manuals for other maintenance procedures 3 1 Wear Life See Table 3 1 This chart lists estimated life expectancy of common replacement parts if proper maintenance and operation procedures are followed Due to the many variables which exist during sawmill operation actual part life may vary significantly This informa tion is provided so that you may plan ahead in ordering repl...

Page 66: ... When the corner wears far enough sawing performance will be affected even if the body of the block is adjusted properly to the blade At this point the block should be replaced If you have access to the appropriate equipment you can grind or mill the blocks to a new flat surface and reuse them It is recommended you develop a routine schedule for replacing the blade guide blocks based on your sawin...

Page 67: ...nt bolt to tilt the insert mounting plate so the insert is parallel to the blade After adjusting the drive side blade guide block insert up check the deflector If neces sary loosen the two deflector mounting screws and adjust the deflector so it does not touch the blade See Figure 3 2 4 Make sure the blade screw in the top center of the C frame is 1 16 1 5 mm below the bottom of the blade If not l...

Page 68: ...UTION Failure to remove sawdust buildup from the bat tery box lid and or track rail cover could result in damage to these parts when the saw head is lowered to its lowest position 3 As required remove sawdust buildup from the power feed belt housing Turn the control panel key switch to OFF 0 and remove the key Disassemble the power feed belt cover and remove sawdust buildup in and around the power...

Page 69: ...the track scrapers as needed Make sure the scrapers fit firmly against the rail If a track scraper needs to be adjusted loosen the thumb screw push the scraper downward until it fits firmly against the rail and retighten the thumb screw Clean and lubricate the upper track wiper every twenty five hours of operation Unbolt the wiper remove it from the sawmill and remove any sawdust buildup Soak the ...

Page 70: ...witches Lubricate the up down and power feed drum switch contacts inside the control panel every fifty hours of operation Use only contact grease supplied by Wood Mizer Remove the control panel cover Use a cotton swab to apply grease to the switch contact ends WARNING Drum switch grease contains Petroleum Hydro carbon Lubricant Eye and skin irritant If introduced into eyes flush with water for at ...

Page 71: ...2 grade lithium grease every fifty hours of oper ation 4 Oil all chains with Dexron III ATF every fifty hours of operation CAUTION Do not use chain lube It causes sawdust buildup in chain links 5 Lubricate the board return pivot every fifty hours of operation with a NLGI No 2 grade lith ium grease Apply grease to the grease fitting on the board return pivot tube 6 Check the mill alignment every se...

Page 72: ...de Tensioner 1 Lubricate the chrome rods of the tensioner system with a heavy duty teflon spray lubri cant such as Gunk L508 every fifty hours of operation 2 Lubricate the tensioner screw handle with a NLGI No 2 grade lithium grease as needed See Figure 3 4 FIG 3 4 50 ...

Page 73: ...tirety and repeat The first pass should add enough fluid to allow the front piston to fully extend The second pass should add enough fluid to completely fill the block Locate the fill plug behind the tension gauge Clean any dirt and debris from the plug area Use a 7 16 wrench to remove the plug making sure to keep the plug o ring with the plug Manually extend the rear piston the front piston shoul...

Page 74: ...djustment Check the brake strap for wear every 200 hours of operation Replace if damaged or worn Also check and adjust the brake strap if the blade does not stop quickly unusual sounds occur when the brake is applied or a sudden change is noticed in the clutch handle posi tion when the clutch is disengaged To access the brake strap remove the belt cover located underneath the engine Engage the clu...

Page 75: ...rs thereafter See the table below for drive belt tension specifications for your model sawmill 1 Remove the two belt covers located underneath the engine 2 For Manual Clutch Handle Loosen the drive belt turnbuckle jam nuts Turn the turn buckle counterclockwise as viewed from the top to tighten the belt clockwise to loosen the belt See Figure 3 7 Engine Motor Belt Tension D42 7 16 11mm deflection w...

Page 76: ...rottle cable should be tensioned just enough so that the engine revs as soon as the clutch brake handle is engaged The throttle linkage should NOT affect engine RPM while the clutch brake handle is disengaged NOTE A properly adjusted throttle will extend the cable spring 1 4 to 3 8 6 4 9 5 mm when running and have a slight amount of slack in the cable when idling Always be sure to check the drive ...

Page 77: ...AND to hold the drive belt away from the engine pulley when the clutch handle is disengaged up position See Figure 3 9 To adjust the drive belt support 1 Make sure the motor is not running Loosen the adjustment bolts 2 Position the bracket so that the prong is close to but does not touch the drive belt with the clutch handle engaged 3 Retighten the adjustment bolts 25 27 pound feet 34 37 newton me...

Page 78: ... turnbuckle See Section 3 13 for optional Autoclutch adjust ment 1 Remove the blade from the sawmill 2 Remove the inner belt guard and pull the clutch handle down to engage the drive belts 3 Hold a straight edge between the bottom and top pivot centers and measure the distance to the middle pivot 4 Adjust the clutch handle turnbuckle until the center of the middle pivot is 7 16 from the straight e...

Page 79: ... blade from the sawmill 2 Remove the inside belt guard and push the Autoclutch switch up to engage the drive belts 3 With the belts engaged place a straight edge between the upper and lower clutch pivot centers Measure the distance to the middle pivot 4 Adjust the Autoclutch turnbuckle so the middle pivot is positioned 7 16 behind the straight edge See Figure 3 11 FIG 3 11 3H0505 Remote Clutch Tur...

Page 80: ...housing every 500 hours of operation Remove the top and bottom oil plugs Pour an Automatic Transmission Fluid ATF such as UNIVIS J26 or Dexron III ATF into the top hole until it begins to flow from the bottom hole Reinstall the square oil plug to the bottom hole and the vented oil plug to the top hole See Figure 3 12 FIG 3 12 500 ...

Page 81: ...per model up down systems feature a spring loaded belt design Belt tension is auto matically maintained and requires no adjustment Replace the belt when adequate belt tension can no longer be obtained WARNING Always secure the cutting head with a chain or a brace before removing the up down motor belt The cut ting head may fall causing severe injury or death FIG 3 13 1000 3H0016B Up Down Gear Redu...

Page 82: ...can be deflected 3 4 1 9cm forward and 3 4 1 9cm backward with a 5 lb 2 3 Kg deflection force WARNING Always secure the cutting head with a chain or a brace before adjusting the up down chain The cutting head may fall causing severe injury or death CAUTION Do not over tension the chain Over tensioning the chain may lead to early failure of the gear reducer See Figure 3 14 4 Check the up down gearb...

Page 83: ...lts Place a wrench on the jam nut and turn the adjustment bolt clockwise to tighten the belt Retighten the motor bolts and replace the feed motor cover 2 Adjust the power feed chain as needed Measure the power feed chain tension with the saw head all the way toward the front of the mill Use the two lock nuts at the rear of the mill to tighten or loosen the power feed chain Adjust the chain until i...

Page 84: ...Maintenance Power Feed 3 3 20 30Sdoc120507 Maintenance See Figure 3 16 FIG 3 16 Feed Chain Adjustment Nuts 3H0018B ...

Page 85: ... Blade Guide Roller Performance See Section 3 2 Remove Excess Sawdust From Blade Wheel Housings And Sawdust Chute See Section 3 3 Check Blade Screw See Section 3 2 EVERY 8 HOURS Clean And Lubricate Track See Section 3 4 Remove Sawdust From Upper Cam Housings See Section 3 4 Clean Sawdust From Battery Box Lid Track Cover See Section 3 3 EVERY 25 HOURS Clean And Lubricate Upper Track Wiper See Secti...

Page 86: ...rails See Section 3 5 Lubricate drum switches See Section 3 6 Grease pivot points and bearings Oil chains See Section 3 7 See Section 3 15 See Section 3 16 Check belt tensions See Section 3 11 See Section 3 15 See Section 3 16 Check brake strap tension See Section 3 10 Rotate drive idle blade wheel belts Check all belts for wear See Section 3 9 Check feed up down chain tensions See Section 3 15 Se...

Page 87: ... rails See Section 3 5 Lubricate drum switches See Section 3 6 Grease pivot points and bearings Oil chains See Section 3 7 See Section 3 15 See Section 3 16 Check belt tensions See Section 3 11 See Section 3 15 See Section 3 16 Check brake strap tension See Section 3 10 Rotate drive idle blade wheel belts Check all belts for wear See Section 3 9 Check feed up down chain tensions See Section 3 15 S...

Page 88: ... mast rails See Section 3 5 Lubricate drum switches See Section 3 6 Grease pivot points and bearings Oil chains See Section 3 7 See Section 3 15 See Section 3 16 Check belt tensions See Section 3 11 See Section 3 15 See Section 3 16 Check brake strap tension See Section 3 10 Rotate drive idle blade wheel belts Check all belts for wear See Section 3 9 Check feed up down chain tensions See Section 3...

Page 89: ... mast rails See Section 3 5 Lubricate drum switches See Section 3 6 Grease pivot points and bearings Oil chains See Section 3 7 See Section 3 15 See Section 3 16 Check belt tensions See Section 3 11 See Section 3 15 See Section 3 16 Check brake strap tension See Section 3 10 Rotate drive idle blade wheel belts Check all belts for wear See Section 3 9 Check feed up down chain tensions See Section 3...

Page 90: ... mast rails See Section 3 5 Lubricate drum switches See Section 3 6 Grease pivot points and bearings Oil chains See Section 3 7 See Section 3 15 See Section 3 16 Check belt tensions See Section 3 11 See Section 3 15 See Section 3 16 Check brake strap tension See Section 3 10 Rotate drive idle blade wheel belts Check all belts for wear See Section 3 9 Check feed up down chain tensions See Section 3...

Page 91: ... mast rails See Section 3 5 Lubricate drum switches See Section 3 6 Grease pivot points and bearings Oil chains See Section 3 7 See Section 3 15 See Section 3 16 Check belt tensions See Section 3 11 See Section 3 15 See Section 3 16 Check brake strap tension See Section 3 10 Rotate drive idle blade wheel belts Check all belts for wear See Section 3 9 Check feed up down chain tensions See Section 3...

Page 92: ......

Page 93: ...heels Change blade wheel belts B 57 Poor sharpening techniques See Sharpener Manual Tension too tight Tension blade to recom mended specifications Blade Does Not Track Right on Drive Wheel Cant adjustment is incorrect Readjust Flat worn belts Replace B 57 belts Blade Guides Do Not Spin While Cutting Frozen bearings Replace bearings Stiff bearings Grease bearings Blade Does Not Stop Immedi ately Af...

Page 94: ...ed Adjust up down chain Vertical wear pads are too tight Adjust pads Drive belt s loose Adjust belts Lumber Is Not Square Vertical side supports not square to bed Adjust side supports Blade not parallel to bed rails Adjust bed rails parallel to blade Sawdust or bark between cant and bed rails Remove particles Tooth set problems Resharpen and reset blade Sawdust Builds Up On Track Excessive oiling ...

Page 95: ...e wire Check for loose wire or termi nal connections Power Feed Motor Does Not Work Sawdust buildup in the power feed pulleys Sawdust buildup puts mechan ical bind on power feed which causes automatic motor pro tection circuit to activate Remove sawdust from pulleys and operate normally If motor does not operate after sawdust removal reset 70 amp circuit breaker on the front of the con trol box Up...

Page 96: ...n battery post Remove connection and clean posts Battery Will Not Stay Charged Key switch left ON Turn switch OFF when not in use Short in system Visually check for bare wires and or have checked Charging system not function ing Have charging system checked by authorized dealer Bad battery cells Check fluid levels and add proper solution Idle improper Adjust low end RPM per engine manual Loose alt...

Page 97: ...nd lubricate with contact grease supplied by Wood Mizer Drum switch contacts are bad Check that contacts are in good condition and positively close cir cuit Components are loose or wires are broken Replace or repair PC board Power Feed Is Jerky When Shaft Of Feed Rate Dial Is Moved Back And Forth Variable speed switch is bad perform the variable speed switch test Replace variable speed switch Powe...

Page 98: ...estarting Chain is dragging Make sure chain is centered on cam follower bearing Clean and lubricate chain Adjust chain ten sion Allow motor to cool before restarting Chain is improperly tensioned Adjust chain tension Allow motor to cool before restarting Seat load is excessive Check seat bearings for freedom of movement Loosen clamping screw 1 4 turn Allow motor to cool before restarting Power fee...

Page 99: ...n or defective feed rate switch OV This light indicates an overvoltage condition This can be caused by a defective alternator not regulating voltage properly or a bad connection The OV light will come on and deactivate the power feed control output until the problem is corrected OL This light indicates an extreme overload condition of the power feed motor caused by a mechanical bind or a short in ...

Page 100: ...ooting Guide Power Feed Circuit Troubleshooting 4 4 8 Sdoc120507 Troubleshooting Guide damaged Call Customer Service for assistance PWR Indicates battery power is present at the power feed control circuit board ...

Page 101: ... 4 1 32 from the belt while engaged 4 6 Power Feed Preliminary Test This test will determine if the problem is a mechanical or electrical 1 Remove the drive belt from the power feed drive pulley 2 Turn the key switch to the ACC position Put the carriage forward reverse switch into the forward position and turn the feed rate dial through all speeds If the power feed motor runs properly at all speed...

Page 102: ... power feed chain cam bearing is not touching the main frame tube 7 Make sure there is no sap or rust on the rails 8 Make sure the block on the lower track roller assembly is not rubbing the lower rail Also make sure the track rollers are not too tight 9 Make sure the power feed belt is properly tightened ...

Page 103: ...nly Do not attempt to start the engine or operate any other electrical function until direct battery charging can be performed Do not attempt to move the saw head by attaching jumper cables from a sec ondary power source to the up down motor terminals Dam age to the electrical system will result See Figure 4 2 1 Remove the fuse box cover and remove the stud from its storage position inside the fus...

Page 104: ...head 6 After the saw head is raised remove the negative cable from ground 7 Remove the positive cable from the extension stud 8 Remove the extension stud from the fuse terminal and return it to its storage location 9 Remove the battery box lid and connect the positive cable directly to the positive battery terminal 10 Connect the negative cable to a grounded metal surface 11 After the battery is c...

Page 105: ...ol box The blade guide accessory ignition start and board return breakers are located inside the control box Remove the circuit breaker panel from the control box to access the internal breakers NOTE If the breaker is still hot you may not be able to reset it immediately Allow the breaker to cool for a few min utes before attempting to reset FIG 4 3 External Power Feed Circuit Breaker External Up ...

Page 106: ...he lower track rollers if necessary See Section 5 18 3 Check and adjust the vertical alignment of the blade guide arm See Section 5 7 4 Check and adjust the horizontal alignment of the blade guide arm See Section 5 8 5 Check and adjust the vertical angle of the blade guides See Section 5 11 6 Check and adjust the horizontal angle of the blade guides See Section 5 13 7 Check and adjust the spacing ...

Page 107: ...mills should also be setup on firm level ground LT40S Adjust the two middle outriggers on the main frame tube down just enough to lift weight from the trailer tire LT40M Adjust the two end outriggers on the main frame tube down just enough to lift weight from the trailer tire All Portable Sawmills Adjust the two outer outriggers down just so they touch the ground but do not bear weight See SECTION...

Page 108: ...g the blade until the blade positions itself on the wheels WARNING Do not spin the blade wheels by hand Spinning the blade wheels by hand may result in serious injury 4 Release the clutch handle to stop the blade Turn off the engine remove the key and check the position of the blade on the blade wheels Check the vertical alignment of the idle side blade wheel The gullet of the blade should ride th...

Page 109: ...ade wheel use the cant control shown in Figure 5 1 If the blade is too far forward on the wheels turn the cant control counterclockwise If it is too far back on the wheels turn the cant control clockwise Some adjustment in blade tension may be needed to compensate for adjustments made with the cant control Adjustment with the cant control is usually all that is required to track the blade properly...

Page 110: ... apart and bring the blade forward If the blade is running too far to the front loosen the jam nuts on the horizontal adjustment bolts and back the adjustment bolts out Tighten the hex nuts on the long U bolt on the back side of the back plate Be sure to tighten all nuts against the mounting plates when the adjustment is complete The vertical angle of the drive side wheel is factory set and should...

Page 111: ...engine side of the mast are referred to as the inner pads The pads on the control side of the mast are referred to as the outer pads NOTE Shims are often used around the clamping bolts between the C frame support bracket and the mast v brace The shims align the v brace to the mast so that the entire face of each slide pad makes contact with the mast Be sure to keep these shims in place when perfor...

Page 112: ... 3 Loosen the upper locking bolts and turn the adjusting bolt as necessary to provide the pad spacing described in Step 1 4 Lower the saw head to the bottom of the vertical mast Check the bottom set of four pads There should be a small gap between one of the outer pads and the mast rail The gap should be just wide enough to slide a business card through The inner two pads should be touching the ma...

Page 113: ...ose enough that you can turn them with your finger Use the ver tical bolts to adjust the bottom track rollers 3 Check the inside lower rollers Both inside rollers should touch the rail so that you cannot spin them by hand If the rollers are not adjusted evenly and you can spin either one adjust the horizontal nuts until the roller cannot be spun by hand Check the other roller and adjust if necessa...

Page 114: ...e arm to within 1 2 15 mm of full open 7 Move the carriage back to the front pivot end rail Raise the cutting head until the bottom of the blade is 17 400 mm above the outside of the pivot rail support by actual mea surement with a tape or ruler FIG 5 5 Inside Lower Rollers 2 Bottom Lower Rollers 2 Upper Rollers 4 Stop Screw 2 Vertical Adjustment Bolt Horizontal Adjustment Nuts SM0135B Stop Bolt 2...

Page 115: ...ustments of the lower track rollers change the angle between the cutting head and sawmill bed rails Only small adjustments of the lower track rollers should ever be needed 10 After the lower track rollers are adjusted properly adjust the upper and lower stop screws Tighten each screw until it just touches the rail Then back the screw off 1 2 turn The gap will be approximately 2 0 mm CAUTION It is ...

Page 116: ...es 14 1 2 360 mm from the top of the clamp Use a rule to determine the actual distance of the blade to the clamp See Figure 5 7 4 Adjust the front pivot rail 90 to the main bed tube 5 Move the saw head to center the blade over the front pivot bed rail 6 Measure the distance from the top of the pivot rail to the bottom of the blade Make this measurement at each end of the pivot rail 7 The two measu...

Page 117: ... rail 10 Move the saw head so the blade is positioned over the center of the front main bed rail 11 Measure the distance between the bottom of the blade and the bed rail at each end of the bed rail The bed rail should measure 15 375 mm 1 0 mm on the outer end from the blade at each end of the rail FIG 5 8 Inner Height Adjustment Nut Outer Height Adjustment B lt SM0134B 15 1 32 375mm to blade 15 37...

Page 118: ...ts and turn the adjustment bolts to move the bed rails to the blade if necessary 13 Retighten the clamping bolts and adjustment bolts 14 Without adjusting the saw head height check the three remaining main bed rails and the rear pivot rail Adjust them so that all measure the same distance from the blade at both ends of the bed rail FIG 5 9 ...

Page 119: ...of full closed Measure again from the top of the bed rail to the arm 5 Adjust the arm so that the measurement from the top of the bed rail to the arm in the closed position is the same as the measurement from the top of the bed rail to the arm in the open position If the arm is too low in the closed position loosen the lower outside roller and tighten the upper outside roller See Step 6 If the arm...

Page 120: ...olt head inside the housing and turn until the arm is lowered or raised as needed Recheck the arm in both the open and closed positions Repeat adjustments until the arm is the same distance from the bed rail in the open and closed position 7 The blade guide arm should be snug but not too tight in the rollers You should be able to move it in and out with firm hand pressure There should be no side t...

Page 121: ...ook it out Put the assembly back so that the flanged collar on the roller is about 1 8 3 0 mm from the back of the blade when the throat is 1 2 15 mm from full open 2 Close the throat to within 1 2 15 mm from fully closed Check to see that the flange is the same distance from the back of the blade See Figure 5 11 FIG 5 11 Flange equal distance from blade in open and closed positions SM0067 ...

Page 122: ...lose the gap See Figure 5 12 4 Adjusting the outside two rollers furthest from the arm motor inward will cause the flange to move away from the blade 5 Adjusting the two outside rollers outward will cause the flange to move toward the blade 6 Adjust until the roller flange is the same distance from the back of the blade in the open and closed position FIG 5 12 Adjustment Nuts Adjustment Nuts SM006...

Page 123: ... saw head It is referred to as the outer assembly and is adjustable for various widths of materials to be pro cessed Blade guide alignment includes four steps Blade Deflection Blade Guide Vertical Tilt Blade Guide Flange Spacing Blade Guide Horizontal Tilt Perform the blade guide alignment after you have aligned the blade on the wheels and adjusted the blade and blade guide arm parallel to the bed...

Page 124: ...2 Install the blade guides Make sure the two set screws shown are threaded into the blade guide shaft until they touch each other See Figure 5 13 3 Loosen the bottom jam nut and tighten the top jam nut until the blade guide deflects the blade down 4 0 mm 4 Repeat for the other blade guide NOTE Be sure that the blade guide deflector rod clears the blade on both guide assem blies The rod on the oute...

Page 125: ... flat on the blade See Figure 5 14 3 Measure the distance from the bed rail to the bottom of the tool NOTE If the sawmill is equipped with stainless steel bed rail covers be sure to measure from the blade guide alignment tool to the top surface of the cover rather than the bed rail tube 4 Move the carriage so that the front end of the tool is positioned above the bed rail 5 Measure the distance fr...

Page 126: ...tilt until the measurement from the bed rail to the tool equals the other two measurements taken 10 Move the tool close to the other blade guide and repeat the previous steps NOTE If major adjustments to blade guide tilt were made measure the distance between the blade and the bed rails again to ensure the correct 4 0 mm blade guide deflection Adjust if necessary FIG 5 15 Sm0070c Loosen jam nuts a...

Page 127: ...Adjust the inner blade guide so the blade guide flange is approximately 1 16 1 8 1 5 3 0 mm from the back of the blade 2 Loosen one side and one top set screw shown Tap the blade guide forward or backward until properly positioned See Figure 5 16 3 Retighten the two set screws 4 Adjust the outer blade guide in the same way so the blade guide flange is approximately 1 16 1 8 1 5 3 0 mm from the bac...

Page 128: ...n the roller and measure between the back edge of the blade and the ruler at the end closest to the inner blade guide B 4 Measure between the back edge of the blade and the other end of the ruler A 5 The roller should be tilted slightly to the left A B 1 4 6 mm 6 Use the side set screws to adjust the horizontal tilt of the roller 7 Repeat steps 3 7 for the inner blade guide roller NOTE Once the bl...

Page 129: ...properly tensioned See Figure 5 18 Loosen both nuts and retaining bolts Use the adjustment bolt to raise or lower the disc until its distance from the blade is 2 25 mm Then retighten the retain ing bolts so that the disc is parallel to the blade Retighten the retaining bolt nuts See Figure 5 19 The gap between the disc and the blade should measure 2 25 mm FIG 5 18 FIG 5 19 Sm0205pl_b Adjustment bo...

Page 130: ... when sawing The sides supports must be square to the bed to ensure square lumber 1 Swing the side support down 2 Measure between the face of the support and the main bed tube Make measurements at both ends of the side support to make sure that it is parallel to the rail See Figure 5 20 3 Use the two lower bolts to adjust the side support so B A 4 Repeat for remaining side supports FIG 5 20 ...

Page 131: ...ide support up so that it is vertical 3 Pull back at the top of the support to eliminate slack as if a log were being clamped against it See Figure 5 21 4 Check the angle of each support with a square on the board 5 The side support should be 90 to the bed rails Loosen the top adjustment bolt adjust the side support and retighten the bolt 6 Repeat for the remaining side supports FIG 5 21 ...

Page 132: ...to their horizontal position 2 Tie a string across the face of the side supports See Figure 5 22 3 Loosen the clamp stop bolts and adjust the clamp stop until it touches the string Loosen the jam nut and adjust the bolt on the middle rear bed rail until it touches the string FIG 5 22 String across side supports Adjust clamp stop to string Adjust stop bolt against string SM0191 ...

Page 133: ...tal bolts to raise the outside of the saw head 1 16 1 5 mm 1 Move the saw head so the blade is positioned 14 3 4 375 mm above a bed rail 2 Adjust the lower track roller horizontal nuts until the blade measures 14 13 16 376 mm from the bed rail near the outer blade guide See Figure 5 23 FIG 5 23 Inside Lower Rollers 2 Bottom Lower Rollers 2 Upper Rollers 4 Stop Screw 2 Vertical Adjustment Bolt Hori...

Page 134: ... on a down set tooth of the blade to the top of the bed rail or stainless steel sleeve if applicable See Figure 5 24 2 View the blade height scale with eyes level with the indicator 3 Loosen the indicator bracket mounting bolts and adjust the bracket until the indicator is aligned with the correct mark on the scale Retighten the bracket mounting nut For example if the measurement from blade to bed...

Page 135: ...f the blade 1 With a square cant on the bed rails lower the blade until it touches the top of the cant Then raise the saw head 1 4 as shown on the scale 2 Lower the board return arm The board return bracket should barely touch the top of the cant 3 Loosen the three bracket mounting bolts to adjust the bracket up or down as necessary See Figure 5 25 FIG 5 25 Bracket Mounting Bolts 3 3H0432 ...

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