woodmizer LT80HD Manual instruction

Wood-Mizer® Sawmill
Safety, Setup, Operation
& Maintenance Manual
LT80HD rev. A3.03
Safety is our #1 concern! Read and understand
all safety information and instructions before oper-
ating, setting up or maintaining this machine.
May 2002
Form #1041
!

Table of Contents Section-Page
ii 60doc011304 Table of Contents
ABOUT THIS MANUAL I
SECTION 1 SAFETY 1-1
1.1 Safety Symbols.......................................................................................1-1
1.2 Safety Instructions ..................................................................................1-2
SECTION 2 SERVICING THE SAWMILL 2-1
2.1 If You Need To Order Parts ...................................................................2-1
2.2 Customer and Sawmill Identification.....................................................2-2
2.3 If You Need Service ...............................................................................2-4
SECTION 3 SAWMILL SETUP 3-1
3.1 Stationary Sawmill Setup .......................................................................3-1
3.2 Portable Sawmill Setup ..........................................................................3-3
3.3 Replacing The Blade ..............................................................................3-6
3.4 Tensioning The Blade.............................................................................3-7
3.5 Tracking The Blade ................................................................................3-8
3.6 Starting The Engine (or Motor)............................................................3-11
SECTION 4 SAWMILL OPERATION 4-1
4.1 Hydraulic Control Operation..................................................................4-1
4.2 Loading, Turning And Clamping Logs ..................................................4-4
4.3 Up/Down Operation ...............................................................................4-7
4.4 Blade Guide Arm Operation...................................................................4-8
4.5 Power Feed Operation ............................................................................4-9
4.6 Cutting The Log ...................................................................................4-11
4.7 Edging...................................................................................................4-13
4.8 Optional Cutting Procedure..................................................................4-14
4.9 Blade Height Scale ...............................................................................4-15
4.10 Water Lube Operation ..........................................................................4-18
4.11 Preparing The Sawmill For Towing .....................................................4-20
SECTION 5 MAINTENANCE 5-1
5.1 Wear Life................................................................................................5-1
5.2 Blade Guides ..........................................................................................5-2
EZ-Glide Guide Blocks .........................................................5-2
Throat Screw .........................................................................5-4
5.3 Sawdust Removal ...................................................................................5-5
5.4 Carriage Track, Wiper & Scrapers .........................................................5-6
5.5 Drum Switches .......................................................................................5-8
5.6 Miscellaneous .........................................................................................5-9
5.7 Blade Wheel Scrapers...........................................................................5-10
5.8 Brake Strap Adjustment .......................................................................5-11
5.9 Drive Belt Adjustment..........................................................................5-13
5.10 Hydraulic System .................................................................................5-15
5.11 Up/Down System..................................................................................5-17

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Table of Contents 60doc011304 iii
5.12 Power Feed ...........................................................................................5-19
5.13 Charging The Battery (DC Only) .........................................................5-21
MAINTENANCE LOG 5-23
SECTION 6 TROUBLESHOOTING GUIDE 6-1
6.1 Sawing Problems....................................................................................6-1
6.2 Electrical Problems.................................................................................6-3
6.3 Power Feed Problems .............................................................................6-5
6.4 Power Feed Circuit Troubleshooting......................................................6-7
6.5 Hydraulic Problems ................................................................................6-9
6.6 Power Feed Variable Feed Rate Switch Test .......................................6-14
6.7 Power Feed Mechanical Test................................................................6-15
6.8 Hydraulic Pressure Test........................................................................6-16
6.9 Fuse Terminal Extension Stud..............................................................6-17
6.10 Circuit Breaker Operation ....................................................................6-19
SECTION 7 SAWMILL ALIGNMENT 7-1
7.1 Routine Alignment Procedure ................................................................7-1
Blade Installation..................................................................7-1
Saw Head Tilt........................................................................7-2
Blade Guide Arm Alignment .................................................7-4
Blade Guides .........................................................................7-5
Blade Guide Vertical Tilt Alignment.....................................7-9
Blade Guide Horizontal Tilt Adjustment.............................7-11
Blade Guide Flange Spacing ..............................................7-13
7.2 Horizontal Adjustment of Side Supports..............................................7-14
7.3 Vertical Adjustment of Side Supports..................................................7-15
Blade Height Scale Adjustment...........................................7-16
7.4 Complete Alignment Procedure ...........................................................7-17
Frame Setup .......................................................................7-17
Blade Installation................................................................7-18
Blade Wheel Alignment.......................................................7-19
Bed Rail Adjustment............................................................7-24
Blade Guide Installation .....................................................7-28
Blade Guide Arm Alignment ...............................................7-31
Blade Guide Deflection.......................................................7-36
Blade Guide Vertical Tilt Alignment...................................7-37
Blade Guide Horizontal Tilt Adjustment.............................7-39
Blade Guide Flange Spacing ..............................................7-41
Blade Guide Level...............................................................7-42
Blade Disk Adjustment ........................................................7-43
Horizontal Alignment of Side Supports...............................7-44
Vertical Alignment of Side Supports ...................................7-45
Clamp Stop/Stop Bolt Adjustment .......................................7-46
Saw Head Tilt......................................................................7-47
Blade Height Scale Adjustment...........................................7-49

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SECTION 8 SPECIFICATIONS 7-1
8.1 Log Capacity ..........................................................................................7-1
8.2 Overall Dimensions ................................................................................7-2
8.3 Engine/Motor Specifications ..................................................................7-2
8.4 Chains .....................................................................................................7-4
8.5 Hydraulic System ...................................................................................7-4
8.6 Belt Sizes ................................................................................................7-5
SECTION 9 HYDRAULIC INFORMATION 8-1
9.1 Hydraulic Schematic ..............................................................................8-1
9.2 Hydraulic Hoses .....................................................................................8-2
INDEX I

About This Manual 60HDdoc011304 i
ABOUT THIS MANUAL
This manual is to replace or to be used with all previous information received on the
Wood-Mizer®* sawmill. 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 in your support package.
*Wood-Mizer®is a registered trademark of Wood-Mizer Products, Inc.
Sawmill U.S. Patent Nos.: 4,559,858, 4,878,411 & 4,930,386
Brevet au Canada Nos.: 1,200,180 & 1,211,684
MILL COMPONENTS

Safety
Safety Symbols
1
1-1 60HDdoc011304 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 60HDdoc0113041-2
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 sawmill. Take notice of all safety warnings throughout this man-
ual 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 sawmill. The sawmill 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, operation and towing of your Wood-Mizer
sawmill. All Wood-Mizer mill owners are encouraged to become
thoroughly familiar with these applicable laws and comply with
them fully while using or towing the mill.
!

Safety
Safety Instructions
1
1-3 60HDdoc011304 Safety
WEAR SAFETY CLOTHING
WARNING! Secure all loose clothing and jewelry before operating
the sawmill. Failure to do so may result in serious injury or death.
WARNING! Always wear gloves and eye protection when handling
bandsaw blades. Changing blades is safest when done by one per-
son! Keep all other persons away from area when coiling, carrying
or changing a blade. Failure to do so may result in serious injury.
WARNING! Always wear eye, ear, respiration, safety clothing,
and foot protection when operating or servicing the sawmill.
KEEP SAWMILL AND AREA AROUND SAWMILL CLEAN
DANGER! Maintain a clean and clear path for all necessary move-
ment around the mill and lumber stacking areas. Failure to do so
will result in serious injury.

Safety
Safety Instructions
Safety 60HDdoc0113041-4
1
HANDLE FUEL/LUBRICANTS SAFELY
DANGER! Due to the flammable nature of fuel and oil, never
smoke, weld, grind or allow sparks near your engine or storage
tanks, especially during times of fueling.
DANGER! Never allow fuel to spill on a hot engine during fueling
operations or otherwise. The hot temperature of your engine could
induce a fire or explosion.
WARNING! Store gasoline away from sawdust and other flamma-
ble materials. Failure to do so may result in serious injury.
WARNING! Use ONLY water with the water lube accessory. Never
use flammable fuels or liquids. If these types of liquids are neces-
sary to clean the blade, remove it and clean with a rag. Failure to
do so may result in serious injury or death.
WARNING! Drum switch grease contains Petroleum Hydrocarbon
Lubricant. Eye and skin irritant. If introduced into eyes, flush with
water for at least 15 minutes. If film or irritation persists, seek med-
ical attention. Wash skin with soap and water. If ingested, do not
induce vomiting - contact a physician. KEEP OUT OF THE REACH
OF CHILDREN.
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
1
1-5 60HDdoc011304 Safety
USE CAUTION WHEN WORKING WITH BATTERIES (GAS & DIESEL SAWMILLS
ONLY)
DANGER! Batteries expel explosive gases. Keep sparks, flames,
burning cigarettes, or other ignition sources away at all times.
Always wear safety goggles and a face shield when working near
batteries. Failure to do so will cause serious injury. 1
WARNING! Battery posts, terminals and related accessories con-
tain lead and lead compounds, chemicals known to the State of
California to cause cancer and reproductive harm. Wash hands
after handling.
WARNING! Charge the battery in a well ventilated area. Do not
attempt to charge a frozen battery.
Use extreme care to avoid spilling or splashing electrolyte (which is
dilute sulfuric acid) as it can destroy clothing and burn the skin. If
electrolyte is spilled or splashed on clothing or the body, it should
be neutralized immediately and then rinsed with clean water. A
solution of baking soda, or household ammonia, and water may be
used as a neutralizer.
Electrolyte splashed into the eyes is extremely dangerous. If this
should happen, force the eye open and flood it with cool, clean
water for approximately fifteen minutes. A doctor should be called
immediately when the accident occurs and “on-the-spot” medical
attention given if possible. If a doctor cannot come to the scene of
the accident immediately, follow his instructions concerning actions
to take. Do not add eye drops or other medication unless advised
to do so by the doctor. Do not place a battery or acid within the
reach of children. If acid (electrolyte) is taken internally drink large
quantities of water or milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Call a physician immediately.
If electrolyte is spilled or splashed on any surface of the machine, it
should be neutralized and rinsed with clean water.
CAUTION! Do not overcharge the battery. Overcharging may
reduce the overall service life of the battery.
CAUTION! Be sure the battery is fully charged before transporting
the sawmill. If the battery is not fully charged, excessive vibration
could reduce the overall service life of the battery.
1 Battery Council International, copyright 1987

Safety
Safety Instructions
Safety 60HDdoc0113041-6
1
CAUTIONS FOR SAWMILL SETUP
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 or dig out areas for the outrigger legs to keep
mill level. Setting up the mill on an incline could cause it to tip over,
resulting in serious personal injury.
WARNING! Chock the trailer wheels to prevent movement before
unhitching it from the towing vehicle. Failure to do so may result in
serious injury or death.
WARNING! Put front outrigger down before moving saw head from
the rest position. Failure to do so may result in serious injury.
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 out-
riggers are intended to support the saw frame with assistance from
the trailer.
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.

Safety
Safety Instructions
1
1-7 60HDdoc011304 Safety
CHECK SAWMILL BEFORE OPERATION
DANGER! 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 closed (i.e. the
safety switches located on them are engaged).
KEEP PERSONS AWAY
DANGER! Stay clear of the area between the trailer axle and saw
carriage. Failure to do so will result in serious injury.
DANGER! Keep all persons out of the path of moving equipment
and logs when operating sawmill or loading and turning logs. Fail-
ure to do so will result in serious injury.
DANGER! Always be sure that 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.

Safety
Safety Instructions
Safety 60HDdoc0113041-8
1
KEEP HANDS AWAY
DANGER! Always shut off the sawmill engine before changing the
blade. Failure to do so will result in serious injury.
DANGER! Engine components can become very hot during opera-
tion. Avoid contact with any part of a hot engine. The exhaust com-
ponents of your engine are especially hot during and following
operation. Contact with hot engine components can cause serious
burns. Therefore, never touch or perform service functions on a hot
engine. Allow the engine to cool sufficiently before beginning any
service function.
DANGER! Always keep hands away from moving bandsaw blade.
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.
WARNING! Do not for any reason adjust the engine drive belts or
belt support bracket with the engine running. Doing so may result
in serious injury.

Safety
Safety Instructions
1
1-9 60HDdoc011304 Safety
CAUTIONS FOR GAS OR DIESEL ENGINE OPERATION
DANGER! Operate your engine/machine only in well venti-
lated areas. The exhaust gases of your engine can cause
nausea, delirium and potentially death unless adequate
ventilation is present.
DANGER! Never operate an engine with a fuel or oil leak.
The leaking fuel or oil could potentially come in contact with
hot surfaces and ignite into flames.
WARNING! Do not operate engine without proper and
operational spark arrester/muffler. Sparks emitted from the
engine exhaust could ignite surrounding materials, causing
serious injury or death.

Safety
Safety Instructions
Safety 60HDdoc0113041-10
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 electric boxes and at the
motor can cause shock, burns, or death. Disconnect and lock out
power supply before servicing! Keep all electrical component cov-
ers closed and securely fastened during mill operation.
WARNING! Consider all electrical circuits energized and danger-
ous.
WARNING! Never assume or take the word of another person that
the power is off; check it out and lock it out.
WARNING! Do not wear rings, watches, or other jewelry while
working around an open electrical circuit.
WARNING! Before performing service near moving parts such as
blades, pulleys, motors, belts and chains, first turn the key switch
to the OFF (#0) position and remove the key. If the key is turned on
and moving parts activated, serious injury may result.
WARNING! Remove the blade before performing any service to
the engine or sawmill. Failure to do so may result in serious injury.

Safety
Safety Instructions
1
1-11 60HDdoc011304 Safety
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.
USE CAUTION WHEN WORKING WITH HEAVY LOGS
WARNING! Always make sure log is clamped securely before saw-
ing. Failure to do so may result in serious injury or death.
AUTOMATIC BOARD RETURN SAFETY
DANGER! Keep all persons out of the path of returning boards.
Failure to do so will result in serious injury.
WARNING! The automatic board return is intended to assist a sec-
ond operator in removing boards quickly. Do not use the board
return when operating the sawmill alone. Serious injury, death or
damage to the equipment may result.
WARNING! Never use the board return table as a platform to 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.
POWER FEED SYSTEM SAFETY
DANGER! If leaving the blade engaged for maximum production
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.
WARNING! Be sure the power feed switch is in the neutral position
before turning the key switch to the #1, #2 or #3 position. This pre-
vents accidental carriage movement which may cause serious
!
!

Safety
Safety Instructions
Safety 60HDdoc0113041-12
1
injury or death.
GENERAL TRAILER SAFETY
DANGER! Be sure that the hitch and the safety cable are secured
before towing the sawmill. The safety cable automatically operates
the trailer handbrake lever in case the hitch should become disen-
gaged. Failure to do so may result in serious personal injury and/or
severe machine damage.
DANGER! Make sure all light connections have been made and
are working properly before towing the sawmill. Failure to do so
may result in serious personal injury and/or severe machine dam-
age.

Servicing The Sawmill
If You Need To Order Parts
2
2-1 60HDdoc011304 Servicing The Sawmill
SECTION 2 SERVICING THE SAWMILL
Wood-Mizer is committed to providing you with the latest technology, best quality and
strongest customer service available on the market today. We continually evaluate our
customers’ needs to ensure we’re meeting current wood-processing demands. Your com-
ments and suggestions are welcome.
2.1 If You Need To Order Parts
From Europe call our European Headquarters and Manufacturing Facility in Kolo, Poland
at [phone] or [phone]. From the continental U.S., call our toll-free Parts
hotline at 1-800-448-7881. Please have the vehicle identification number and your cus-
tomer number ready when you call. Wood-Mizer will accept these methods of payment:
Visa, Mastercard, or Discover
COD
Prepayment
Net 15 (with approved credit)
Be aware that shipping and handling charges may apply. Handling charges are based on
size and quantity of order. In most cases, items will ship on the day they are ordered.
Second Day and Next Day shipping are available at additional cost.

Servicing The Sawmill
Customer and Sawmill Identification
Servicing The Sawmill 60HDdoc011304 2-2
2
2.2 Customer and Sawmill Identification
Each Wood-Mizer sawmill has a model number and a 17-digit Vehicle Identification Num-
ber (VIN). In addition, when you pick up your mill, you will receive a customer number.
These three numbers will help expedite our service to you. Please locate them now and
write them below so you have quick, easy access to them. See the following figures for
model number and V.I.N. descriptions and locations.
(To be filled in by purchaser)
Mill Model ___________________
Mill VIN ___________________
Customer No. ___________________
See below for a description of the V.I.N.
LT80HD D42
Basic Sawmill I.D. Engine/Motor
Configuration
MODEL NUMBER DESCRIPTION
Company Identification Number
456=Wood-Mizer Indiana
Weight Class; A=Under 3,000 lbs B=3,001-4,000 lbs
C=4,001-5000 lbs
Product No.; 2=LT20/25/27, 3=LT30/40, 4=LT30HD/40HD,
5=LT30/40 Super, 6=LT30HD/40HD Super, 7=LT60/70/80
Length of the Trailer;
20=20 Ft., 24=24’, 35=35’
Number of axles on the trailer
Check Digit
Add all the numbers and divide by 11
Year of Manufacture;
U=1997, V=1998, X=1999
State of Manufacture
N=Indiana, P=Poland
Month of Manufacture
A=January, B=February, C=March, etc...
Revision Level
Sequence Number
Ranging from 000-999
End of 17-Digit VIN
Revision Level (Repeated)
Two-Digit Minor Revision Level
456 A 5 24 1 X S N A F9 017 F9 .01
V.I.N. DESCRIPTION.

Servicing The Sawmill
Customer and Sawmill Identification
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The model number and V.I.N. can be found in the following locations.
MODEL NUMBER AND V.I.N. LOCATIONS