woodmizer 4015X5 Guide

Wood-Mizer®Moulder
Safety & 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

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

Table of Contents Section-Page
Table of Contents MO01doc091902 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

iv MO01doc091902 About This Manual
ABOUT THIS MANUAL
This manual is to replace or to be used with all previous information received on the
Wood-Mizer®1 moulder. All future mailings will be an addition to or a revision 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, Inc.
M485SP MOULDER

About This Manual MO01doc091902 v
M4015X5 MOULDER
MO0001

Safety
Safety Symbols
1
1-1 MO01doc091902 Safety
SECTION 1 SAFETY
1.1 Safety Symbols
The following symbols and signal words call your attention to instructions concerning your
personal safety. Be sure to observe and follow these instructions.
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 or
damage to equipment.
IMPORTANT! indicates vital information.
NOTE: gives helpful information.
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.

Safety
Safety Instructions
Safety MO01doc091902 1-2
1
1.2 Safety Instructions
NOTE: ONLY safety instructions regarding personal injury are listed in this section. Cau-
tion statements regarding only equipment damage appear where applicable throughout
the manual.
OBSERVE SAFETY INSTRUCTIONS
IMPORTANT! Read the entire Operator's Manual before operating
the machine. Take notice of all safety warnings throughout this
manual and those posted on the machine. Keep this manual with
this machine 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
all applicable federal, state and local laws, rules and regulations
regarding the ownership and operation of your Wood-Mizer
machine. All Wood-Mizer machine owners are encouraged to
become thoroughly familiar with these applicable laws and comply
with them fully while using the machine.

Safety
Safety Instructions
1
1-3 MO01doc091902 Safety
WEAR SAFETY CLOTHING
WARNING! Secure all loose clothing, jewelry and long hair before
operating 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.
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.

Safety
Safety Instructions
Safety MO01doc091902 1-4
1
KEEP HANDS AWAY
DANGER! Always keep hands away from moving blades. Failure
to do so will result in serious injury.
DANGER! Always be aware of and take proper protective mea-
sures against rotating shafts, pulleys, fans, etc. Always stay a safe
distance from rotating members and make sure that loose clothing
or long 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 starting the machine.
Failure to do so may result in serious injury.
WARNING! Use the appropriate feed wheel and adjust it properly
for the material being processed.

Safety
Safety Instructions
1
1-5 MO01doc091902 Safety
SAFETY PRECAUTIONS DURING OPERATION
WARNING! Inspect the material to be worked for embedded
objects such as stones or nails. Feeding material with such objects
may cause severe personal injury.
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.
WARNING! The blades should spin smoothly and in the opposite
direction the material is fed in. Using unbalanced blades or chang-
ing the spinning direction of the blades could cause the material to
fly out, causing serious injury.
WARNING! 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
injury or damage to the equipment. Contact your local distributor,
or call your Customer Service Representative to order more
decals.
IMPORTANT! If replacing a component which has a safety decal
affixed to it, make sure the new component also has the safety
decal affixed.
DISPOSE OF SAWING BY-PRODUCTS PROPERLY
IMPORTANT! Always properly dispose of all sawing by-products,
including sawdust and other debris, coolant, oil, fuel, oil filters and
fuel filters.

Safety
Safety Instructions
Safety MO01doc091902 1-6
1
USE PROPER PROCEDURE WHEN CONDUCTING ELECTRICAL SAFETY CHECKS
AND MAINTENANCE
DANGER! Make sure all electrical installation, service and/or
maintenance work is performed by a qualified electrician and is in
accordance with applicable electrical codes.
DANGER! Hazardous voltage inside the electrical cabinet can
cause shock, burns, 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 is off; check it out
and lock it out. Failure to do so may result in serious injury.
WARNING! Do not wear rings, watches, or other jewelry while
working around an open electrical circuit.

Setup
Moving The Moulder
2
2-1 MO01doc091902 Setup
SECTION 2 SETUP
2.1 Moving The Moulder
See Figure 2-1. Transport the moulder with a forklift using the provided forklift skid.
CAUTION! Be sure all cables and hoses are clear of the
forks when moving 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 evenly bal-
anced when moving the machine.
FIG. 2-1

Setup
Installation
Setup MO01doc091902 2-2
2
2.2 Installation
Unbolt the shipping 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

Setup
Electrical Installation
2
2-3 MO01doc091902 Setup
2.3 Electrical Installation
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.
Install an appropriately rated disconnect box near the
machine and use proper cable/wiring to supply power to the
moulder.
See Figure 2-3. Route the incoming power cable through the hole in the control box
(enlarge the hole if necessary to accommodate 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 exchange the position of the wires connected to terminals L1 and L2.
WARNING! The blades should spin smoothly and in the
opposite direction the material is fed in. Using unbalanced
blades or changing the spinning direction of the blades
could cause the material to fly out, causing serious injury.
FIG. 2-3

Setup
Air Installation
Setup MO01doc091902 2-4
2
2.4 Air Installation
See Figure 2-4. The moulder requires an air supply of 80 psi (minimum). Install a fitting to
the air regulator and connect the air supply 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. 2-4

Adjustments
Cutting Head #1
3
3-1 MO01doc091902 Adjustments
SECTION 3 ADJUSTMENTS
The cutting heads are referred to as #1 - #5 starting at the front (infeed) end of the moul-
der.
3.1 Cutting Head #1
Vertical Adjustment
Adjust cutting head #1 vertically so the blades are the same height as the fixed table
behind the cutting head.
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 head up
or down as necessary.
Turn the locking handle counterclockwise to loosen. Use the supplied wrench handle to
FIG. 3-1

Adjustments
Cutting Head #1
Adjustments MO01doc091902 3-2
3
turn the adjustment shaft clockwise to raise the blade, counterclockwise to lower the
blade.
NOTE: When lowering the blade, lower it further than
desired then back up to remove slack from the adjusting
screw.
After adjusting cutting head #1 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
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 horizontally, loosen the locking bolt and turn
the horizontal adjustment bolt to move the blade as desired. Retighten the locking bolt.
FIG. 3-2

Adjustments
Feed Table & Infeed Guides Adjustment
3
3-3 MO01doc091902 Adjustments
3.2 Feed Table & Infeed Guides Adjustment
Feed Table
See Figure 3-3. Turn the feed table adjustment handle and lift or lower the table to the
desired position. The 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 the guide fence adjustment handle.
FIG. 3-3

Adjustments
Feed Table & Infeed Guides Adjustment
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

Adjustments
Cutting Head #2
3
3-5 MO01doc091902 Adjustments
3.3 Cutting Head #2
Horizontal Adjustment
Adjust cutting head #2 so the blades are even with the rear infeed guide fence. This cut-
ting head will be readjusted in or out depending on the side profile being used.
See Figure 3-5. Place a flat steel rule against the rear guide fence so it extends over cut-
ting head #2. 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
adjustment shaft clockwise to move the cutting head back, counterclockwise to move the
cutting head forward. Retighten the locking handle and reset the counter to zero.
FIG. 3-5