Holzstar DB 1202 Vario User manual

DB 1202 Vario
Instruction Manual
Wood Lathe
DB 1202 Vario

2DB 1202 | Version 3.05
Imprint
Product identification
Wood Lathe Item number
DB 1202 Vario 5921202
Manufacturer
Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Fax: [phone] - 55
E-Mail: [email protected]
Internet: www.holzstar.de
Indications regarding the operating instructions
Original operating instructions
Edition: 26.01.2021
Version: 3.05
Language: English
Author: ES/MS
Indications regarding the Copyright
Copyright © 2021 Stürmer Maschinen GmbH, Hallstadt,
Germany.
The contents of these operating instructions is the sole
property of the company Stürmer Maschinen GmbH.
Passing on as well as copying of this document, the use
and distribution of its content are prohibited if not explic-
itly permitted. Contraventions are liable to compensa-
tion.
Subject to technical modifications and error.
Contents
1 Introduction ............................................. 3
1.1 Copyright ............................................................ 3
1.2 Customer service................................................ 3
1.3 Limitation of liability............................................. 3
2 Safety ....................................................... 3
2.1 Legend of symbols.............................................. 3
2.2 Responsibility of the operator ............................. 4
2.3 Qualification of the staff ...................................... 4
2.4 Personal protective equipment ........................... 5
2.5 Safety labels on the device................................. 5
2.6 Safety equipment................................................ 5
3 Intended Use ........................................... 6
4 Technical Data......................................... 6
4.1 Type plate ........................................................... 6
5 Transport, packaging, storage............... 7
5.1 Delivery............................................................... 7
5.2 Packaging........................................................... 7
5.3 Storage ............................................................... 7
6 Description of the Device....................... 8
6.1 Machine .............................................................. 8
6.2 Control panel ...................................................... 8
6.3 Scope of delivery ................................................ 9
7 Setting up and connection..................... 9
7.1 Requirements for the installation site.................. 9
7.2 Setting up the Wood Lathe ................................. 9
7.3 Electrical connection......................................... 10
8 Operation ............................................... 10
8.1 Start the machine.............................................. 10
8.2 Turn off the machine......................................... 10
8.3 Speed change with potentiometer .................... 10
8.4 Speed change due to belt change.................... 11
8.5 Adjusting the headstock.................................... 12
8.6 Adjusting the tailstock ....................................... 12
8.7 Adjusting the tool rest ....................................... 12
8.8 Replacing the clamping tools............................ 12
8.9 Material selection.............................................. 13
8.10 Material preparation........................................ 13
8.11 Center workpiece............................................ 14
8.12 Position of the tool rest ................................... 14
8.13 During the turning ........................................... 14
9 Care,maintenance and repair............... 14
9.1 Care after work ................................................. 14
9.2 Maintenance and repair.................................... 15
10 Disposal, recycling of old equipment....15
10.1 Decommissioning ........................................... 15
10.2 Disposal of electrical equipment..................... 15
10.3 Disposal of lubricants...................................... 15
10.4 Disposal via municipal collection points.......... 15
11 Troubleshooting.................................. 16
12 Spare parts .......................................... 17
12.1 Ordering Spare parts ...................................... 17
12.2 Spare parts drawings DB 1202 Vario ............. 18
13 Electrical wiring diagram.................... 20
14 EC-Declaration of Conformity............ 21

Introduction
DB 1202 | Version 3.05 3
1 Introduction
You have made a good choice by purchasing a HOLZ-
STAR Wood Lathe.
Carefully read the operating instructions prior to
commissioning.
They describe correct commissioning, intended use and
safe as well as efficient operation and maintenance of
your Wood Lathe.
The operating instructions form part of the Wood Lathe.
Keep these operating instructions at the installation lo-
cation of your Wood Lathe. Also observe the local acci-
dent prevention regulations and general safety regulati-
ons for the use of the Wood Lathe.
1.1 Copyright
The contents of these operating instructions are pro-
tected by copyright. Their application is permitted within
the context of the use of the Wood Lathe. Any further use
shall not be permitted without written consent by the ma-
nufacturer.
For the protection of our products, we shall register tra-
demark, patent and design rights, as this is possible in
individual cases. We strongly oppose any infringement
of our intellectual property.
1.2 Customer service
Please contact your specialist retailer if you have any
questions regarding your Wood Lathe or require any
technical information. Your specialist retailer will be
happy to support you with specialist advice and informa-
tion.
Germany:
Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Repair service:
Fax: [phone]-111
E-Mail: [email protected]
Internet: www.holzstar.de
Spare parts orders:
Fax: [phone]-119
E-Mail: [email protected]
We are always interested in valuable experience and
knowledge gained from using the application, which-then
could be shared and be valuable to develop our-products
even further.
1.3 Limitation of liability
All data in these operating instructions has been compi-
led on the basis of the state-of-the-art, valid standards
and guidelines as well as our many years of expertise
and experience.
The manufacturer shall not be liable for damage in the
following cases:
- Non-observance of these operating instructions
- Unintended use
- Deployment of untrained staff
- Conversions at one's own responsibility
- Technical modifications
- Use of unauthorised spare parts
The actual scope of delivery may deviate from the de-
scriptions and illustrations in this document as a result of
special variants, optional extras or recent, technical mo-
difications.
The obligations defined in the supply contract shall ap-
ply in addition to the general terms and conditions and
the manufacturer's general terms and conditions as well
as the statutory regulations valid at the time of the con-
clusion of the contract.
2 Safety
This section provides an overview of all important safety
packages for personal protection as well as safe and re-
liable operation. The sections on individual service life
phases contain additional, specifically applicable safety
information.
2.1 Legend of symbols
Safety Instructions
Safety instructions in these operating instructions have
been highlighted with symbols. Safety instructions are in-
dicated by signal terms that express the degree of risk
involved.
DANGER!
This combination of symbol and signal term indi-
cates a directly dangerous situation which may
cause death or serious injury if not averted.
WARNING!
This combination of symbol and signal term indi-
cates potentially hazardous situations which may
cause death or serious injury if not averted.

4DB 1202 | Version 3.05
Safety
Tips and recommendations
Observe the safety information in these operating in-
structions to minimise the risk of personal injury as well
as material damage and prevent hazardous situations.
2.2 Responsibility of the operator
The operator is the person who operates the machine
himself for commercial or economic purposes or leaves it
to a third party for use or use and bears legal product re-
sponsibility for the protection of the user, the personnel
or third parties during operation.
Obligations of the operator:
If the machine is used in the commercial sector, the ope-
rator of the machine is subject to the legal obligations for
occupational safety. Therefore, the safety instructions in
this operating manual as well as the safety, accident pre-
vention and environmental protection regulations appli-
cable to the area of application of the machine must be
observed. The following applies in particular:
- The operator must obtain information about the ap-
plicable occupational safety regulations and, in a
risk assessment, must also identify additional ha-
zards that arise as a result of the special working
conditions at the place of use of the machine. He
must implement these in the form of operating in-
structions for the operation of the machine.
- The operator must check during the entire period of
use of the machine whether the operating instructi-
ons he has prepared comply with the current state
of the regulations and adjust them if necessary.
- The operator must clearly regulate and determine
the responsibilities for installation, operation,
troubleshooting, maintenance and cleaning.
- The operator must ensure that all persons handling
the machine have read and understood this ma-
nual. In addition, he must train the staff at regular
intervals and inform them about the dangers.
- The operator must provide the personnel with the
necessary protective equipment and bind the wea-
ring of the necessary protective equipment in a bin-
ding manner.
Furthermore, the operator is responsible for ensuring
that the machine is always in perfect technical condition.
Therefore, the following applies:
- The operator must ensure that the maintenance in-
tervals described in this manual are adhered to.
- The operator must have all safety equipment regu-
larly checked for functionality and completeness.
2.3 Qualification of the staff
The various tasks described in this manual place diffe-
rent demands on the qualifications of the persons entru-
sted with these tasks.
Only persons who are expected to carry out this work re-
liably are permitted for all work. Persons whose reactivity
z. As influenced by drugs, alcohol or drugs are not allo-
wed.
This manual identifies the qualifications of the persons li-
sted below for the different tasks:
ATTENTION!
This combination of symbol and signal term indi-
cates a potentially hazardous situation which may
cause minor or light injuries if it is not averted.
IMPORTANT!
This combination of symbol and signal term indi-
cates a potentially dangerous situation which may
cause material damage or harm the environment if it
is not averted.
NOTE!
This combination of symbol and signal term indica-
tes a potentially dangerous situation which may
cause material damage or harm the environment if it
is not averted.
Tips and recommendations
This symbol highlights useful tips and recommenda-
tions as well as information for efficient and reliable
operation.
WARNING!
Danger due to insufficient qualifica-
tion of persons!
Insufficiently qualified persons can not assess the
risks involved in handling the machine and expose
themselves and others to the risk of serious or fatal
injuries.
- All work should only be carried out by qualified per-
sons.
- Keep inadequately qualified persons out of the work
area.

Safety
DB 1202 | Version 3.05 5
Operator:
The operator has been instructed in a briefing by the
operator about the tasks assigned to him and possible
dangers of improper behavior. The operator may only
carry out tasks that go beyond normal operation if this is
specified in this operating manual and the operator has
expressly entrusted this to him.
Electrician:
Due to their professional training, knowledge and experi-
ence as well as knowledge of the relevant standards and
regulations, the electrician is in a position to carry out
work on electrical installations and to recognize and
avoid possible dangers independently.
Personnel:
Due to their technical training, knowledge and experi-
ence, as well as knowledge of the relevant standards
and regulations, qualified personnel are in the position to
carry out the work assigned to them and to recognize
possible dangers independently and to avoid hazards.
Manufacturer:
Certain work may only be carried out by specialist per-
sonnel of the manufacturer. Other personnel are not au-
thorized to carry out this work. To carry out the work,
contact our customer service.
2.4 Personal protective equipment
Personal protective equipment is intended to protect the
health and safety of persons at work. Staff must wear the
personal protective equipment indicated in individual
sections of these operating instructions when carrying
out the different tasks on the machine.
The personal protective equipment is described in the
following section:
2.5 Safety labels on the device
The following safety signs are applied on the Wood
Lathe (Fig. 1), which need to be observed and followed. .
Fig. 1: Safety labels
If safety labels on the machine are damaged or missing,
this can cause errors, personal injury and material da-
mage. The safety symbols attached to the machine must
not be removed. Damaged safety symbols must be re-
placed immediately.
As soon as the signs are not clearly visible and compre-
hensible at first glance, the machine must be stopped
until new signs have been attached.
2.6 Safety equipment
Motor protection switch
Ear protection
The ear protection protects against hearing damage
caused by noise.
Eye protection
Protective glasses protect the eyes against pro-jected
parts and splashes of liquid.
Protective gloves
The protective gloves provide protection for the
hands against sharp-edged components, as well as
against friction, abrasions or deeper injuries.
Safety boots
The safety boots protect the feet against crushes, fall-
ing parts and slipping over on slippery underground.
Protective clothes
Protective work clothing means tight-fitting clothing
with low tear resistance.
NOTE!
In the engine of the lathe is a thermal protection
switch, which automatically shuts off the engine in
case of thermal overload.
After eliminating the cause of the overload and wai-
ting for the engine to cool down completely, the
engine can be restarted.
241
5678
910
3

6DB 1202 | Version 3.05
Intended Use
Emergency stop button
Cover-circuit breaker
3 Intended Use
The Wood Lathe DB 1202 Vario is used exclusively for
turning wood or wood-like materials. The maximum tur-
ning length and the maximum workpiece diameter to be
machined (see chapter "Technical Data") must be obser-
ved It is suitable for private use, not for industrial use
Use beyond or beyond the intended use is considered
misuse.
For structural and technical changes to the Wood Lathe
the company Stürmer Maschinen GmbH assumes no lia-
bility.
Claims of any kind due to damage due to improper use
are excluded.
4TechnicalData
4.1 Type plate
Fig. 2: Type plate DB 1202 Vario
NOTE!
The emergency stop button is located above the con-
trol panel. The emergency stop button is used to
quickly put the machine into a safe state in case of
danger or to avert a danger.
NOTE!
The cover circuit breaker is located under the front
cover. If the cover is not mounted or not closed, the
switch prevents the engine from starting.
WARNING!
Danger in case of misuse!
Misuse of the Wood Lathe can lead to dangerous
situations.
- Only operate the Wood lathe in the power range
specified in the technical data.
- Never bypass or override the safety devices.
- Never work on other materials than specified in the
intended use.
- Only operate the Wood lathe in a technically perfect
condition.
- Never work on several workpieces at the same time.
Type DB 1202
Max. turning Ø 460 mm
Max. height 230 mm
Max. width 1185 mm
Spindle head thread M 33 x 3,5
Morse cone MK 2
Speeds 0-3200 min-1
Control of the speed regula-
tion
Electronic variable
Speed stages 2 stages
Motor output 1,5 kW
Electrical connection 230 V / 50 Hz
Dimensions 2060 x 500 x 1200mm
Weight 189 kg

Transport, packaging, storage
DB 1202 | Version 3.05 7
5 Transport, packaging, storage
5.1 Delivery
Check the Wood Lathe for visible shipping damage after
delivery. If you discover damage to the Wood Lathe, im-
mediately report it to the carrier or dealer.
Transport
Improper transport is accident-prone and can cause da-
mage or malfunctions for which we do not grant any liabi-
lity or guarantee.
Transport the scope of delivery secured against shifting
or tilting with a sufficiently dimensioned industrial truck to
the installation site.
General risks during internal transport
Devices may only be transported by authorized and qua-
lified persons. Act responsibly during transport and al-
ways consider the consequences. Refrain from daring
and risky actions.
Gradients and descents (e.g. driveways, ramps and the
like) are particularly dangerous. If such passages are
unavoidable, special caution is required.
Before starting the transport check the transport route for
possible danger points, unevenness and disturban-ces
as well as for sufficient strength and load capacity.
Danger points, unevenness and disturbance points must
be inspected before transport. The removal of danger
spots, disturbances and unevenness at the time of trans-
port by other employees leads to considerable dangers.
Careful planning of internal transport is therefore essen-
tial.
Transport with a forklift / pallet truck:
For shipping, the device packed in a wooden box is deli-
vered on a pallet so that it can be transported by a forklift
or a pallet truck.
5.2 Packaging
All of the machine‘s packaging materials and packing
aids are suitable for recycling and must always be dis-
posed of using material-based recycling systems.
Packaging materials made of cardboard must be shred-
ded and disposed of as part of waste paper recycling.
The foils are made of polyethylene (PE), padding is
made of polystyrene (PS). Dispose of these substances
at a recycling centre or hand them over to the relevant
waste disposal company.
5.3 Storage
The Wood Lathe must be thoroughly cleaned before it is
stored in a dry, clean and frost-free environment. Cover
the machine with a protective tarpaulin.
Ambient temperature range: -25 ° C to +55 ° C.
WARNING!
Severe or fatal injuries may occur if parts of the
machine tumble or fall down from the forklift
truck, pallet truck or from the transport vehicle.
Follow the instructions and information on the trans-
port box.
Note the total weight of the machine. The weight of
the machine is indicated in the "Technical data" of the
machine. When the machine is unpacked, the weight
of the machine can also be read on the rating plate.
Only use transport devices and load suspension gear
that can hold the total weight of the machine.
WARNING!
The use of unstable lifting and load suspension
equipment that might break under load can cause
severe injuries or even death. Check that the lifting
and load suspension gear has sufficient load-bea-
ring capacity and that it is in perfect condition.
Observe the accident prevention regulations issued
by your Employers Liability Insurance Association or
other competent supervisory authority, responsible
for your company.
Fasten the loads properly.
WARNING: DANGER OF TIPPING
The device may be lifted unsecured by a maximum
of 2cm.
Employees must be outside the danger zone, the
reach of loads.
Warn employees and, if necessary, advise employ-
ees of the hazard.

8DB 1202 | Version 3.05
Description of the Device
6 Description of the Device
6.1 Machine
Illustrations in these operating instructions may de-
viate from the original.
Fig. 3: Wood Lathe DB 1202
1 Protective cover pulleys
2 Drive motor
3 Lever belt tension
4 Control panel headstock
5 Machine frame
6 Tool rest
7 Tailstock
8 Machine bed
9 Emergency stop button
6.2 Control panel
Fig. 4: Control panel
1 - Speed display
Here the currently set speed is displayed.
2 - On-off switch with stop function
The lower push-button "ON" switches on the rotation of
the rotary spindle in the preselected operating mode.
The upper pushbutton "OFF" switches off the rotation of
the rotary spindle.
3 - Switch direction of rotation
The direction of rotation of the lathe can be made by the
direction of rotation switch. With the switch, two speed
levels can be selected for each direction of rotation.
- the marking "R" means clockwise rotation (clock-
wise)
- the mark "L" means anticlockwise
f
4 - Potentiometer
Stepless adjustment of the speed
5
8
7
6
1
2
3
4
9
4
1
3
2
DANGER!
Wait until the rotation of the spindle has come to a
complete stop before changing the direction of rota-
tion with the direction switch. Changing the direction
of rotation during operation may destroy the motor
and the direction switch.

Setting up and connection
DB 1202 | Version 3.05 9
6.3 Scope of delivery
- Wood lathe
- Revolving center point
- Digital display
- Cast iron machine bed
- Tailstock with quick release lever and handwheel
- Instruction Manual
7 Setting up and connection
7.1 Requirements for the installation
site
The Wood Lathe must be stable on a level and solid
ground. It is important to ensure that there is enough
freedom of movement to work. The site should meet the
following criteria:
- The substrate must be level, firm and vibration-
free.
- The substrate must not let any lubricant through.
- The installation or work area must be dry and well
ventilated.
- Do not operate machines that cause dust and
chips near the machine.
- There must be sufficient space for the operating
personnel, for material transport as well as for ad-
justment and maintenance work.
- The site need good lighting.
7.2 Setting up the Wood Lathe
The Wood lathe is delivered in a wooden box and is al-
ready mostly assembled. Only a few parts have to be
mounted after delivery.
Assembly of the machine on the machine frame
The following steps will make the machine operational:
Step 1: After unpacking the wooden box, lift the machine
and place it in the desired location.
Step 2: Place the machine frame on a flat work surface.
Step 3: Lift the machine with the help of a second person
on the machine frame. Secure with 8 Allen
screws. Place a spring washer under each of
the nuts. Tighten the Allen screw firmly.
Mounting the machine on the ground
In order to achieve the required stability of the lathe, the
lathe on its machine frame must be connected to the
ground. We recommend the use of composite anchor
cartridges or heavy duty anchors.
Fig. 5: Installation plan
Aligning the machine using the leveling feet
Attach the 4 leveling feet to the machine base and align
the machine horizontally.
Fig. 6: Drillings
ATTENTION!
Danger of injury due to a machine that is not stably er-
ected!
Check the stability of the machine after placing it on
stable ground.
ATTENTION!
Pay attention to the weight of the machine! The ma-
chine may only be set up by two persons. Check the
aid accordingly for sufficient dimensioning and load
capacity.
DANGER!
To ensure sufficient stability of the machine, it should
be screwed to the ground. There are 4 holes at the
bottom of the machine frame (see installation plan).

10 DB 1202 | Version 3.05
Operation
7.3 Electrical connection
Step 1: Plug the plug into a 230V power outlet.
Step 2: The machine is now ready for operation.
8Operation
8.1 Start the machine
Step 1: Select the direction of rotation by means of the
direction switch.
Step 2: Unlock emergency stop button.
Step 3: Press the pressure switch "ON".
8.2 Turn off the machine
Step 1: Press the pressure switch "OFF“
8.3 Speed change with potentiometer
You can continuously set the speed of the lathe in two
speed ranges.
DANGER!
Danger of electrocution!
There is danger to life when in contact with live com-
ponents. Switched on electrical components can
cause uncontrolled movements and lead to serious
injuries.
DANGER!
All work on the electrical installation may only be car-
ried out by a qualified electrician.
NOTE LUBRICATION!
Before starting the lathe, all moving parts must be
greased. To lubricate the shifter shafts and drive
shafts, the belt cover must be removed. Only one
adhesive grease may be used here, otherwise it
could lead to malfunctions!
In addition, guides, sleeves and bearings must be
lubricated or lubricated with commercially available
lubricating grease.
DANGER!
Danger of electrocution!
There is danger to life when in contact with live compo-
nents. Switched on electrical components can cause
uncontrolled movements and lead to serious injuries.
- Disconnect the power before starting adjustments to
the machine.
WARNING!
Risk of Death!
There is danger to life for the operator and other per-
sons if they do not adhere to the following rules.
- The Wood Lathe may only be operated by a trained
and experienced person.
- The operator may not work while under the influ-
ence of alcohol, drugs or medication.
- The operator must not work when he is tired or suf-
fering from concentration-impairing illnesses.
- The Wood Lathe may only be operated by one per-
son. Other persons must keep away from the work
area during operation.
ATTENTION!
Crushing!
Incorrect work on the machine can cause injury to the
upper limbs.
DANGER!
Before commissioning, check the electrical connec-
tion, lines and contacts.
Wear ear protection!
Wear safety glasses!
Wear safety shoes!
Wear protective clothing!
NOTE!
If the turning lathe comes to a standstill, pull out the
connection plug.