Holzstar DB 900 User manual

VARIABLE SPEED
WOOD LATHE
Model DB900
INSTRUCTION MANUAL

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TABLE OF CONTENTS
SECTION .. .PAGE
Technical data ..1
Generalsafetyrules ... .1-3
Specificsafetyrulesforwood lathe .... .3
Electricalinformation .4
Assembly .4-7
Adjustments ..8-9
Operation ...10
Maintenance .10
Wiring diagram .. 11
Partsbreak-down .... 11-12
Partslist ..13
TECHNICAL DATA
Modelnumber ... DB900
Motor ..550W
Speeds ... .. 500-2000RPM
Distancebetweencenters .... ..900mm
Swing overbed .305mm
Drivespindle .M33X3.5
Drivespindlethrough hold ... 10mm
Tailstock spindlethrough hole .. 10mm
Tailstock spindletravel ..57mm
Netweight . .80kgs
Noise .. ....68dB(A)
GENERAL SAFETY RULES
WARNING! WHENUSINGELECTRICTOOLSBASICSAFETYPRECAUTIONSSHOULD
ALWAYS BEFOLLOWEDTOREDUCETHERISKOF FIREELECTRICSHOCKAND
PERSONALINJURYINCLUDINGTHEFOLLOWING.
Read alltheseinstructionsbeforeattemptingtooperatethisproductand savethese
instructions.
SAFETY RULES
1. Keep work area clear
Cluttered areasand benchesinviteinjures.
2. Consider work area environment
Do notexposetoolstorain.Do notusetoolsindamporwetlocations.Keep work area well lit.
Do not usetoolsinthe presenceofflammableliquidsorgases.

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3. Guard against electric shock
Avoidbodycontact withearthen orgrounded surfaces.
4. Keep other persons away
Do notletpersonsespeciallychildren notinvolvedinthe work touchthetoolsortheextension
cordand keep themawayfromthe work area.
5. Store idle tools
When not inuse, toolsshouldbe stored inadry locked up placeout ofreachofchildren.
6. Do not force the tool
It will do the job betterand saferat the rateforwhichit wasintend.
7. Use the right tool
Do not forcesmall toolstodo the job ofaheavy-dutytool.
8. Dress properly
Do notwearlooseclothingorjewelry,theycanbecaughtinmovingparts.Non-skidfootwearis
recommended when working outdoors. Wearprotectivehaircovering tocontainlong hair.
9. Use protective equipment
Usesafetyglasses. Usefaceordust maskifcutting operationscreatedust.
10. Connect dust extraction equipment
Ifdeviceareprovided fortheconnectiondo dustextraction andcollectingequipment.Ensure
theseareconnected and properlyused.
11. Do not abuse the cord
Neverrankthe cordtodisconnectitfromthe socket. Keep the cordawayfromheatoiland
sharpedges.
12. Secure work
Wherepossibleuseclampsoravicetoholdthe work, it issaferthan using yourhand.
13. Do not overreach
Keep properfooting and balanceat all times.
14. Maintain tools with care
Keep toolssharpand clean forbetterand saferperformance.
Followinstructionsforlubricating and changing accessories.
Inspecttoolcordsperiodicallyand ifdamaged havethemrepaired byan authorized service
facility.
15. Disconnect tools
When notinuse,beforeservicing and when changingaccessoriessuchasblades,bitsand
cutters, disconnect toolsfromthe powersupply.
16. Remove adjusting keys and wrenches.
Formthe habitofchecking tosee thatkeysandadjusting wrenchesareremoved fromthe tool
beforeturning it on.
17. Avoid unintentional starting
Ensureswitchisin"off"position when plugging in.
18. Use outdoor extension leads
When the toolisused outdoorsuseonlyextension cordsintended foroutdooruseand marked.
19. Stay Alert
Watchwhat you aredoing using common senseand do not operatethe toolwhen you aretired.
20. Check damaged parts
Beforefurtheruseoftool,it shouldbe carefullycheckedtodetermine thatit willoperateproperly
and performitsintended function.

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Check foralignmentofmoving parts,binding ofmovingparts,breakage ofparts,and anyother
conditionsmayaffect itsoperation.
Aguardorotherpartthatisdamaged shouldbeproperlyrepairedorreplacedbyan authorized
servicecenterunless otherwiseindicated inthisinstruction manual.
Havedefectiveswitchesreplaced byan authorized servicecenter.
Do not usethe toolifthe switchdoesnot turnit on and off.
21. Warning!
The useofanyaccessory orattachmentotherthan onrecommended inthisinstruction manual
maypresent ariskofpersonalinjury.
22. Have your tool repaired by a qualified person
Repairsshouldonlybe carried outbyaqualifiedperson using original spareparts,otherwise
mayresult inconsiderabledangertothe user.
Specific safety rules for the wood lathe
WARNING! Do notoperateyourwood lathe untilitiscompletelyassembled and installed
according tothe instructions.
1. Foryourownsafety, read the entireinstruction manualbeforeoperating the lathe.
2.Alwaysweareyeprotection.
3. Do not weargloves, necktie, orlooseclothing.
4.Tighten all locksbeforeoperating.
5. Do not mount asplit workplace.
6. Usethe lowest speed when starting anewworkpiece.
7. Read the warning labelattached tothe wood lathe.
8.When turning aworkpiece,alwaysroughthe woodtoround formpleasestop wood lathe at
slowspeed.If the latheisrun sofastthatitvibrates,thereisariskthattheworkplacewillbe
thrownorthe tooljerked fromyourhands.
9.Alwaysrotatethe workplacebyhand beforeturning on the lathe.Ifthe workpiecestrikesthe
toolrest, it couldsplit and be thrownout ofthe lathe.
10.Do notallowthe turning toolstobiteintothe wood.The wood couldsplitorbethrownfrom
the lathe.
11.Alwaysposition the toolrest abovethe centerline ofthe lathe when shaping apieceofstock.
12. Do not operatethe lathe ifit isrotating inthe wrong direction.
The workpiecemust alwaysbe rotating towardyou.
13.Beforeattachingaworkpiecetothefaceplate,alwaysrough itouttomakeitasround as
possible,thisminimizesthe vibrationswhilethe pieceisbeing turned.Alwaysfasten the
workpiecesecurelytothe faceplate,failuretodo thiscouldresult inthe workpiecebeing thrown
awayfromthe lathe.
14. Position yourhandssothat theywill not slipontothe workpiece.
15.Removealllooseknobsinthestock beforemounting between the centersoronthe
faceplate.
Save thesesafetyrules!

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Electrical information
Guidelines for using extension cords
WARNING! THISWOODLATHEISFORINDOORUSE ONLY.DONOTEXPOSETORAIN
ORUSE INDAMPLOCATIONS.
Makesureyourextension cordisingood condition.Whenusing anextension cord,besureto
useone heavyenough tocarrythe currentyourproduct willdraw. Anundersized cordwillcause
adrop inline voltage resulting inloss ofpowerand overheating.The tablebelowshowsthe
correctsizetouseaccording tocordlengthand nameplateampererating.Ifindoubt, usethe
next heaviergauge.
Extension lead sizes shown assure a voltage drop of not more than 5% at rated load of
tool.
Ampererating
(on nameplate) 3 6 10 13
Extension cablelength
Wiresizemm²
7.5m 0.75 0.75 1.0 1.25
15m 0.75 0.75 1.0 1.5
22.5m 0.75 0.75 1.0 1.5
30m 0.75 0.75 1.25 1.5
45m 0.75 1.25 1.5 2.5
WARNING! THISTOOLMUSTBEGROUNDEDWHILEINUSETOPROTECTTHE
OPERATORFROMELECTRICALSHOCK.
SAVE THESE SAFETYRULES!
Assembly
Unpacking (Fig 1)
1. Carefullyremovethe leg set and wood lathe fromthe carton.
CAUTION! THEWOODLATHEISVERYHEAVYANDMUSTBELIFTEDWITHTHEHELPOF
2PEOPLEORMORE.THEASSEMBLYPROCESSREQUIRES 2PEOPLEORMORETO
SAFETYASSEMBLETHELATHETOTHELEG SET.
2. Separatethe partsforthe leg set fromthe partsofthe lathe.
3. Layout all partsand check themagainst the partslisted below. Examine all partscarefully.

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WARNING! IFANYPARTISMISSING ORDAMAGED,DONOTPLUGTHEWOODLATHEIN
UNTILYOUHAVE REPLACEDTHEMISSING ORDAMAGEDPART.
Foryou satiety, completethe assemblyofthe lathe beforeplugging it intothe powersupply.
1. Lathe bed assembly
2. Faceplate
3. Headstock spurcenter
4.Tailstock cup center
5. Pushrod
6. Flat wrench
7. Hexkey
8. Instruction manual
9. Hexbolt and nut
10. Stand
11. Handle
12. Extension bed
Assembly
Leg SetAssembly
q Attachone frontlegand oneback leg (1)tothe outside edgesofthe top
plate(2)using carriage bolts(3),washers(4)and nuts(5).Thetop plate
(2)shouldfit inside the legs(1).Donottighten nutsatthistime.
Fig 2
q Repeat thisprocedureforthe remaining legsand top plate.
q Attachthe long plate(6)tothe legsusingcarriage bolts,washersand
nuts.
q Placetheleg stand onalevelsurfaceand tighten all nutssecurelyusing
a14mm wrench.

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Installing the lathe on the leg set
CAUTION: The lathe is heavy , use assistance for lifting.
q Placethe lathe unit on the leg set.
q Position theheadstock (2)assembly
overthetopplateandaligntheholes
ofthe lathebed (3)withthe holesin
the top plate(4).
q Align the tailstockassemblyboltholes
withthe top plateholes.
q Installthe Allen bolts(5)intoallofthe
mounting holesandthroughthetop
plates.
Fig 3
q Installawasher(6)and nut (7)ontoeachboltand tightensecurelywitha
wrenchand the supplied Allen keys.
q Verifythat all nutsand boltsaresecurelyfastened.
q Install extension bed (1)toheadstock (2)withtwoboltsand washers.
Headlock Handle
q Locateand assemblethe headlocking
handle(1),spring (2)and Allenbolt(3)
asshown.
q Threadthe head lock assemblyintothe
head locking clampand tighten.
Note: Spring loaded handles
The spring-loaded handleson the latheare
designed tominimizeinterferencewithother
Fig 4
lathepartsorthe workpiece.Tooperatethesehandles,pushthehandleinand
rotateclockwisetotighten.Releasingthehandlewilldisengagethethreaded
shaft allowing you toreposition the handlesothat it isout of the way.
Install digital readout
q Securethedigitalreadouttothetopof
headstock, asshowninFig4.1.
Fig 4.1

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Spurs
q Removethe faceplate(iffactoryinstalled)
(1)fromthe headstockusing the
wrenchand pushrod (2)provided and
set aside.
q Insertthe headstock spur(3)intothe
spindlehole.
q Installthe tailstock livecenterintothe
tailstock hole.
Removal of spurs
q Toremoveeitherthe headstock spuror
the tailstock livecenterinsertthe push
rod (5)through thebackaccess holesof
the headstock and tailstock.
q Removetherodandstoreitforfuture
use.Fig 6
Faceplate Installation
q Removetheheadstock spurfromthe
spindlebyusing the push-out rod.
q Threadthe 6”diameterfaceplate
ontothespindleand tightenwiththe
supplied wrenches.
q Mountyourworkpiecetothe
faceplateusing flathead brass
screws.Becertainthatthe endsof
the screwswill not interferewithyourplanned turning.
Extension Bed
q The extension bed isattachedtothe
leftofthe headstock foroutboard
faceplateturning when the useof the
articulated toolrest isrequired.
q If outboardfaceplateturning does
notrequiretheuseofthe toolrest,
do notattachthe extension beduntil
required.
q Toattachthe extension bed (1)to
the lathe bed, align the bolt holes(2)withthe threaded bed holes(3).
q Install alock washer(4)ontoan Allen bolt (5).

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q Fingertighten and then securetightlywiththe Allen keyprovided.
DONOTATTEMPTTOOPERATEYOUR LATHEUNTILITISCOMPLETELY
ASSEMBLEDAND ADJUSTEDACCORDINGTOTHEINSTRUCTION
MANUAL.
Adjustments
Headstock
q The headstockhas5pre-setpositions.
0degreesforallspindleturning
applications, 60,90and120 degreesfor
usewhen makingfaceplateturningsand
180 degreeswhen using the extension
bed and the toolrest.
q Tosettheheadstock inthedesired
position you mustfirstturntheheadlock handle(1)untilyou have
completed at least one full rotation.
q Pull out the headstock release(2).
q Rotatethe entireheadstock ina
clockwiserotation tothe desired position.
The headstock will ‘click’intooneofthe
pre-set settings.
q Tighten the headlock handle(1).

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Tailstock
q Movethe tailstock(1)byloosening
the tailstock lock lever(2)and
sliding the tailstock assemblyto
the desired positionon the lathe
bed.Securelylockthetailstock
intoposition bytightening the lock
lever.
q The tailstockspindle(3)canextend upto21/2"fromthe tailstock
housing. You can movethe tailstock spindlebyloosening thespindlelock
lever(4)and then rotating the spindlehand wheel(5).
q Besurethat lock levers(4)and (2)aresecurebeforeoperating the lathe.
q The tailstock spindleishollowand can be accessed fromthe hand wheel
end. Usethe push-out rod toremovethe MorseTapertailstock spindle.
Articulated Tool Rest
q The articulated toolrest(1)maybe
used withorwithouttheextension
arm(2).
q Tomovethe toolrestbase(3)
loosen thelocklever(4)andslide
the toolrestbaseleftorrightalong
the lathe bed oritmaybe moved
forwardorbackwards.
q Whenusingthetoolrestextension
armyou can loosen lock levers(5)and (6)tomakeanynecessary
adjustments.
q Becertaintotightenalltoolrestlocking leversbeforeturningonthe
lathe.
q The articulatedtoolrestmayalsobe repositioned ontothe extensionbed
foruseon outboardturnings.
IMPORTANT: Make sure that the tool rest is adjusted to be as close to the
workpiece as possible. Rotate the workpiece by hand to check the
clearance before turning the lathe on.