woodmizer 096009 Guide

Automatic Toothsetter
(Safety, Operation, Maintenance
& Parts Manual)
096009 rev. A.00
Safety is our #1 concern! Read and understand
all safety information and instructions before oper-
ating, setting up or maintaining this machine.
Form #1032
!

Table of Contents Section-Page
ii doc112009 Table of Contents
SECTION 1 GENERAL INFORMATION AND SAFETY 1-1
1.1 Electrical Safety......................................................................................................... 1-1
1.2 Blade Handling.......................................................................................................... 1-2
1.3 Machine Operation .................................................................................................... 1-2
1.4 Noise Level................................................................................................................ 1-2
1.5 Motor Specifications ................................................................................................. 1-3
1.6 Technical Data........................................................................................................... 1-3
1.7 Setter Components..................................................................................................... 1-4
1.8 Control Panel Components........................................................................................ 1-5
1.9 Start Up Modes.......................................................................................................... 1-7
1.10 Blade Settings............................................................................................................ 1-8
1.11 System Parameters................................................................................................... 1-10
1.12 Diagnostic & Setup.................................................................................................. 1-11
1.13 Power Supply Specification .................................................................................... 1-11
SECTION 2 OPERATION 2-1
2.1 Machine Setup ........................................................................................................... 2-1
2.2 Preliminary Setup ...................................................................................................... 2-3
2.3 Machine Operation .................................................................................................... 2-5
SECTION 3 MAINTENANCE 3-1
3.1 Setter Calibration....................................................................................................... 3-1
3.2 Miscellaneous ............................................................................................................ 3-1
SECTION 4 ALIGNMENT 4-1
4.1 Sensor Adjustment..................................................................................................... 4-1
SECTION 5 TROUBLESHOOTING 5-1
5.1 Error Messages .......................................................................................................... 5-1
SECTION 6 REPLACEMENT PARTS 6-1
6.1 Pivoting Index Assembly .......................................................................................... 6-1
6.2 Pivoting Index Motor Assembly ............................................................................... 6-3
6.3 Cam Drive Unit Assembly ........................................................................................ 6-5
6.4 Front & Back Clamp Assembly ................................................................................ 6-7
6.5 Cylinder Clamp Assembly ...................................................................................... 6-10
6.6 Air Regulator Assembly.......................................................................................... 6-12
6.7 Rear Adjuster, Blade Height, Index Ramp Assemblies .......................................... 6-13
6.8 Control Base Assembly ........................................................................................... 6-15
6.9 Blade Support Arms ................................................................................................ 6-18

Table of Contents Section-Page
Table of Contents doc112009 iii
SECTION 7 ELECTRICAL INFORMATION 7-1
7.1 Electrical Symbol Diagram ....................................................................................... 7-1

General Information and Safety
Electrical Safety
1
1-1 SISdoc112009 General Information and Safety
SECTION 1 GENERAL INFORMATION AND SAFETY
This symbol calls your attention to instructions concerning your personal safety. Be sure
to observe and follow these instructions. This symbol accompanies a signal word. The
word DANGER indicates an imminently hazardous situation which, if not avoided, will
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 to per-
sons or equipment. Read all safety instructions before operating this equipment and
observe all safety warnings!
Warning stripes are placed on areas where a single decal would be insufficient. To avoid
serious injury, keep out of the path of any equipment marked with warning 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, or call your Customer Service Representative to order more decals.
Always properly dispose of all by-products, including debris, coolant and oil.
Safety instructions are listed in this section by the following operations:
Electrical Safety
Blade Handling
Machine Operation
1.1 Electrical Safety
DANGER! Make sure all electrical installation, service
and/or maintenance work is performed by a qualified elec-
trician and is in accordance with applicable electrical codes.
DANGER! HAZARDOUS VOLTAGE can cause shock,
burns, or death. SHUT OFF & LOCK OUT POWER before
performing service in any area of this machine. DO NOT
restore power until all access panels are replaced and
secured.

General Information and Safety
Blade Handling
General Information and Safety SISdoc112009 1-2
1
WARNING! Always turn off and disconnect power at control
console AND at main supply circuit breaker before perform-
ing any service to the machine.
1.2 Blade Handling
WARNING! Always wear gloves and eye protection when
handling bandsaw blades. Keep all persons away from
area when coiling or carrying a blade.
1.3 Machine Operation
DANGER! Make sure all guards and covers are in place
and secured before operating the toothsetter. Failure to do
so may result in serious injury.
DANGER! Keep all persons away from moving parts when
operating this machine. Failure to do so will result in serious
injury.
DANGER! Always keep hands away from moving bandsaw
blade. Failure to do so will result in serious injury.
WARNING! Always wear eye protection when operating
this machine. Failure to do so may result in serious injury.
WARNING! Secure all loose clothing and jewelry before
operating this machine. Failure to do so may result in seri-
ous injury or death.
1.4 Noise Level
See Table 1-1. The level of noise generated by the AS80 Toothsetter is given in the

General Information and Safety
Motor Specifications
1
1-3 SISdoc112009 General Information and Safety
table below1.
1.5 Motor Specifications
See Table 1-2. The motor specifications are listed below.
1.6 Technical Data
See Table 1-3. See the table below for technical data on the AS80 Toothsetter.
See the table below for air supply specification:
Max. Noise Level
IS203 74,8 dB (A)
TABLE 1-1
1. The measured values refer to emission levels, not necessarily to noise levels in the workplace.
Although there is a relation between emission levels and exposure levels, it is not possible to
determine with certainty if preventives are needed or are not needed. The factors affecting
a current level of noise exposure during work are inter alia room characteristics and characteristics
of other noise sources, e.g. number of machines and machining operations nearby. Also, the
permissible exposure level value may vary depending on country. This information enables
the machine’s user to better identify hazards and a risk.
Type Manufacturer Model Power Other Data
Electric Motor Klauber K01134J800 0,04 kW 65 r.p.m.
TABLE 1-2
Maximum Blade Width 76 mm
Feed Rate 24 teeth / min
Cam Motor Power 0,04 kW
Total Power 0,25kW
Weight 83 kg
TABLE 1-3
Air supply Prfessure
AS80 Min. 4 bar
TABLE 1-3

General Information & Safety
Setter Components
General Information & Safety SISdoc112009 1-4
1
1.7 Setter Components
See Figure 1-1. The major component and dimensions of the Automatic Setter are listed
below.
FIG. 1-1
SI0001B
Blade Support Tube
Cam Index Motor
Cam Drive Motor
Co
ntr
o
l P
a
n
e
l
Blade Height
Adjustment Air Valve

General Information & Safety
Control Panel Components
1
1-5 SISdoc112009 General Information & Safety
1.8 Control Panel Components
See Figure 1-2. The control panel component locations and their functions are listed
below.
On/Off Switch - turn the switch to the ON position to turn on electrical power to the
machine.
Start/Resume/Clear - press to start or resume setting cycle; button also used to clear an
error.
Stop/Pause - press to stop or pause machine.
Menu - press once to get to the menu.
Up arrow - press to select menu or option; used to increase values.
Down arrow - press to select menu or option; used to decrease values.
Clear/Abort - press once to clear the setting, cancel your action, or clear an error.
Enter - press once to confirm your choice.
FIG. 1-2
MENU CLEAR/
ABORT ENTER
F1
Clamp
F2
Manual
Index
F3
Manual
Bend
F4
Single
Cycle
F5
Zero
Calibrate
SI0003
Start/Resume/Clear
Stop/Pause
Off On
Wood-Mizer
Semi-Automatic Setter
I
I
U
P
a
rr
o
wDOWN arrow
Display ON/OFF Switch

General Information & Safety
Control Panel Components
General Information & Safety SISdoc112009 1-6
1
F1 Clamp - press to close or open the blade clamp.
F2 Manual Index - press to move the blade to the next tooth.
F3 Manual Bend - used to bend the blade teeth manually regardless of set; the tooth set
is not checked.
F4 Single Cycle - press to set the blade using the single cycle mode. The indexer pawl
moves the blade. The blade is clamped and the tooth set is checked. The setter sets the
tooth if necessary.
F5 Zero Calibrate - used during calibration of the blade clamp. See Section 3.1 Setter
Calibration.

General Information & Safety
Start Up Modes
1
1-7 SISdoc112009 General Information & Safety
1.9 Start Up Modes
Press the MENU button once to get to the menu selection mode. Press the UP or DOWN
button twice to find the MODE menu.
The following options are available in the MODE menu:
Set Single Clamp - The setter clamps and checks the blade tooth. The tooth
is set if necessary. The blade is unclamped, and moved to the next tooth. The
setter skips the pattern recognition while using the Set Single Clamp mode.
The final tooth correction follows, i.e. if the toot is unbend not enough - setter
bend it, if the tooth is bended too much - setter unbend it.
Set Double Clamp - Just like using the Set Single Clamp mode, but the blade
is clamped once more after releasing and checked for the tooth set. The pat-
tern recognition is turned off. The Set Double Clamp mode is more accurate
but more time-consuming. (It doesn’t apply this toothsetter version!)
Pattern Single Clamp - The mode similar with the Set Single Clamp mode,
but the setter checks the teeth pattern. See System Parameters, for how to set
the maximum number of pattern errors (only 1 in most cases). When the num-
ber of possible errors is exceeded, the setter stops the setting process and the
"Error --- Blade Set Pattern" message appears. (It doesn’t apply this
toothsetter version!)
Pattern Double Clamp - Using the Pattern Double Clamp mode, the setter
works like using the Pattern Single Clamp mode, but the blade is released and
clamped again to check the tooth set. The Pattern Double Clamp mode takes
more time to set the whole blade but it is more accurate.
Inspection - After the Inspection mode has been selected, the setter checks
the tooth set only. The process is stopped when the number of pattern errors
has been exceeded.
NOTE: The Pattern Single Clamp and Pattern Double Clamp modes can be used only
when the tooth setter has been set to push every tooth of the blade.
Push the ENTER button to select the mode you want the setter to operate.

General Information & Safety
Blade Settings
General Information & Safety SISdoc112009 1-8
1
1.10 Blade Settings
Press the MENU button on the control panel once to enter the BLADE SETTINGS mode.
Use the UP or DOWN arrows if necessary. Push the ENTER button to enter the settings.
The following options are available in the BLADE SETTINGS menu:
No. of teeth to set - The number of teeth to be set. Press ENTER to see the
"Qty Teeth To Set #" message. Use the UP and/or DOWN arrows to enter the
number of teeth to be set. See Table 1-1 below. NOTE: Enter the number of
teeth divided by three if the setter pushes every third tooth of the blade.
Upper Set Limit - The desired tolerance for the upper set. When entered the
"Upper Set Limit #" appears. Use the UP and/or DOWN arrows to set the limit
value. The upper set limit is the upper limit of the tolerance for the blade tooth
set. If the tooth set exceeds the upper limit, the setter adds the tooth to the
group of teeth with the incorrect set. The setter stops when the number of set
errors is exceeded.
Lower Set Limit - The desired tolerance for the lower set. When entered the
"Lower Set Limit #" appears. Use the UP and/or DOWN arrows to set the limit
value. The lower set limit is the lower limit of the tolerance for the blade tooth
set. If the tooth set is below the limit, the setter adds the tooth to the group of
teeth with the incorrect set. The setter stops when the number of set errors is
exceeded.
Maximum Raker Set - The desired tolerance for raker set teeth. When
entered the "Max. Raker Set #" appears. Enter the desired tolerance for rak-
ers. Use the lowest possible tolerance that still allows the setter to efficiently
operate. If the raker set exceeds the provided limit, the tooth set error
appears.

General Information & Safety
Blade Settings
1
1-9 SISdoc112009 General Information & Safety
See Table 1-4. Recommended blade settings are shown below.
Blade Type 1
1 Only standard blade types are shown.
Blade
Thickness
Number of teeth
(standard blades) 2
2 Increase the number of teeth to be set by 1 or 2 to make sure all the teeth have been checked and set.
Lower Set Limit
(Value Entered)
Upper Set Limit
(Value Entered)
Raker Set
(Value Entered)
175 158 10 S .035" 180 0.017" (17.0) 0.019" (19.0) 0.009" (9.0)
274 158 10 S .042" 180 0.020" (20.0) 0.022" (22.0) 0.009" (9.0)
274 158 9 S .042" 180 0.019" (19.0) 0.021" (21.0) 0.009" (9.0)
275 158 9 S .042" 180 0.020" (20.0) 0.022" (22.0) 0.009" (9.0)
375 158 10 S .045" 180 0.024" (24.0) 0.026" (26.0) 0.009" (9.0)
375 158 9 S .045" 180 0.020" (20.0) 0.022" (22.0) 0.009" (9.0)
376 158 13 S .045" 180 0.024" (24.0) 0.026" (26.0) 0.009" (9.0)
376 158 10 S .045" 180 0.024" (24.0) 0.026" (26.0) 0.009" (9.0)
376 158 9 S .045" 180 0.020" (20.0) 0.022" (22.0) 0.009" (9.0)
475 158 9 S .055" 180 0.024" (24.0) 0.026" (26.0) 0.009" (9.0)
475 158 10 S .055" 180 0.027" (27.0) 0.029" (29.0) 0.009" (9.0)
476 158 10 S .055" 180 0.027" (27.0) 0.029" (29.0) 0.009" (9.0)
476 158 13 S .055" 180 0.027" (27.0) 0.029" (29.0) 0.009" (9.0)
656 158 12 S .038" 240 0.018" (18.0) 0.020" (20.0) 0.009" (9.0)
TABLE 1-4

General Information & Safety
System Parameters
General Information & Safety SISdoc112009 1-10
1
1.11 System Parameters
Press the MENU button once. Push the DOWN arrow button to find the SYSTEMS
PARAMETERS menu. Press ENTER to see parameters needed to be set.
When selected, the following parameters can be set:
Max Tooth Set Errors1- push the ENTER button to enter the "Max Set Errors #" param-
eter. Use the UP and DOWN buttons to adjust the maximum number of teeth that can be
set incorrectly in the setting process. When the number of errors is exceeded the setting
process will be stopped. The "Error -- Bld !! Tooth Set #" message appears. The # mark is
the current tooth set. NOTE: To decrease set, bend the tooth back with the slot in the cor-
rection tool provided. Press the green Start/Resume button to cancel the error. Push the
F3 Manual Bend button to allow the setter to set the tooth again. To add set, press the F3
Manual Bend button.
Dpy Imperial/MM - when selected, the "Standard Selected" appears, followed by the cur-
rent selection: Imperial or Metric. Use the UP and DOWN arrows to switch the units of
measure. Press ENTER to confirm. NOTE: Always turn the setter off after changing the
units of measure. Turn the setter on to use new units of measure.
1. Number of the straightening teeth cylinder cycles. It allows to limit too many cylinders hits (it is
used when the teeth is broken, damaged or it is hard to set it.)

General Information & Safety
Diagnostic & Setup
1
1-11 SISdoc112009 General Information & Safety
1.12 Diagnostic & Setup
To enter the DIAGNOSTIC/SETUP menu, press the MENU button. Press the UP arrow
once, and push ENTER to confirm. Use the UP and DOWN arrows to switch options.
The following options are available in the DIAGNOSTIC/SETUP menu:
Raw A/D value - technical specifications.
Current Zero Cal. - technical specifications.
Right Index Prox - indicates the right indexer proximity sensor status: ON or OFF.
Left Index Prox - indicates the left indexer proximity sensor status.
Indexer Home Prox - indicates the indexer cam proximity sensor status.
Cam Home Prox - indicates the drive cam proximity sensor status.
Linear Sensor Adjust - indicates the linear sensor adjustment status. See Section 4.1
Sensor Adjustment, for the adjustment procedure.
System Tooth Counter - indicates the total number of blade teeth processed. The bot-
tom line shows the last four digits of the number. The upper line shows the first digits of
the number. Example: High Count 3, Low Count is 2117 - 32.117 teeth have been pro-
cessed.
Push the ENTER button after selection is complete to check the option status.
1.13 Power Supply Specification
The power supply must meet the specifications given below.
Voltage Fuse [A] Suggested Wire
Size
230 VAC 2 A 1.5 mm at least
TABLE 1-0

Operation
Machine Setup
Operation SISdoc112009 2-1
2
SECTION 2 OPERATION
2.1 Machine Setup
1. Install the blade to the setter. Rest the blade on the inside of the two blade guides and in
between both blade clamps. Center the blade on the setter stand. Position the three
adjustable blade guide supports so they lightly touch the inside of the blade. The adjust-
able guides should lightly support the blade and keep it from wobbling.
2. Use the blade height knob to adjust the blade height so the bottom of the gullet is aligned
with the top of the blade clamps.
See Figure 2-1.
FIG. 2-1
Blade Height
Adjustment Knob
Pusher Adjustment Knob
SI0006B

Operation
Machine Setup
2
2-2 SISdoc112009 Operation
3. Adjust the pusher pin. To adjust, manually rotate the pusher adjustment knob. Turn the
pusher adjustment knob clockwise to increase the pusher pin force, turn the knob coun-
terclockwise to decrease the force. Make sure the tooth is not being bent too much. Read
the display to check the tooth set while adjusting.
IMPORTANT! Avoid pinching fingers or hand when turning
the cam.
DANGER! Keep all persons away from moving parts when
operating this machine. Failure to do so will result in serious
injury.
4. Adjust the index ramp. The push pawl should push one tooth at a time. To adjust, loosen
the blade ramp set screw. Slide the blade ramp as necessary and retighten the set screw.
The pawls should contact the point of the tooth where the face and gullet meet. Manually
rotate the index cam until the pawl is against the tooth radius. Loosen the index pawl
adjustment nut to position the pawl as necessary. Retighten the nut when adjustment is
complete.

Operation
Preliminary Setup
Operation SISdoc112009 2-3
2
2.2 Preliminary Setup
1. Clean the machine as needed with a solution of 1 part liquid Dawn detergent to 9 parts
water. Use an air hose to blow any dust or debris from the blade clamp and up/down com-
ponents.
WARNING! Never use WD-40 or any other non-specified
lubricant to clean the machine.
Keep liquid away from the sensor assembly.
2. Make sure the voltage selector plate is set properly before turning on electrical power to
the setter.
3. Plug the power cord in the socket at the rear of the setter.
4. Locate the air assembly at the rear right side of the setter. Connect the incoming air sup-
ply line to the fitting. Make sure the air gauge indicates 60 P.S.I. Adjust the pressure if
needed. To adjust the pressure, lift the black cap located behind the air gauge. Turn the
cap clockwise to increase pressure, turn the cap counterclockwise to decrease pressure.
Push the cap down to secure when adjustment is complete.

Operation
Preliminary Setup
2
2-4 SISdoc112009 Operation
See Figure 2-2.
5. Turn the ON/OFF switch to the ON position.
6. Calibrate the setter if necessary. See Section 3.1 Setter Calibration.
7. Make all the adjustments necessary to start the setting operation. See Sections 1.6
through 1.8.
FIG. 2-2

Operation
Machine Operation
Operation SISdoc112009 2-5
2
2.3 Machine Operation
1. Clean the blade and deburr before putting in the toothsetter. Otherwise, sap buildup on
the blade or tooth will give false set readings. Metal burrs created by sharpening will also
cause false readings.
2. Mount the blade in the toothsetter. Place blade between the clamping plates and on the
three guide assemblies. Use the weld as a reference point for starting.
See Figure 2-3. Position the tooth in front of the sensor pin so its edge is approximately
.0625" (1.6mm) away from the edge of the pusher pin.
3. Turn the ON/OFF switch to the ON position.
4. Now all of the adjustments have been made. Push START to begin the setting operation.
All values will remain as set.
5. Toothsetter works automatically.
To adjust the pusher adjustment knobs, push the CLAMP button. Tooth bend value will
appear on the display. This value should be between upper and lower set limit. If, it will be
smaller, turn the pusher adjustment knob to adjust as small value as possible. Next, hold
down the Manual Bend button and observe display readings. Increase tooth tilt by
adjusting the knob.
If the unbended tooth value is between upper and lower set limit, push the START button.
Tooth will be setting automatically.
(Repeated bending of the same tooth can occur. During the setting operation, tooth bend
value should be corrected by using the pusher adjustment knob.)
FIG. 2-3
Edge of tooth
approx. .0625” (1.6mm)
from edge of pusher pin
Si0009

Operation
Machine Operation
2
2-6 SISdoc112009 Operation
6. The machine will automatically stop after the setting operation has been completed.
7. Remove the blade and invert it.
8. Swing the index motor assembly to the other side. Repeat the setting operation.