Holzstar ZSM 405 User manual

Instruction manual
Cylinder sanding machine
ZSM 405
ZSM 405

2ZSM 405 | Version 2.08
Imprint
Product identification
Cylinder sanding machine Item number
ZSM 405 5901405
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 instructions
Edition: 20.01.2021
Version: 2.08
Language: English
Author: ES/FL
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 Symbol explanation ............................................ 3
2.2 Obligations of the operating company ................ 4
2.3 Qualification of personnel ................................... 5
2.4 Personal protective equipment ........................... 5
2.5 Safety signs on the Machine............................... 6
2.6 Safety equipment................................................ 6
2.7 Danger zones ..................................................... 6
2.8 Workspace.......................................................... 6
2.9 General safety instructions ................................. 7
3 Intended Use................................................... 7
3.1 Foreseeable misuse ........................................... 8
3.2 Residual risks ..................................................... 8
4 Technical Data ................................................ 8
4.1 Table .................................................................. 8
4.2 Type plate........................................................... 8
5 Scope of delivery ........................................... 8
6 Transport, Packaging, Storage ..................... 9
6.1 Delivery and Transport ....................................... 9
6.2 Storage ............................................................... 9
7 Description ................................................... 10
7.1 Space requirement ........................................... 10
8 Specification and standard equipment...... 10
9 Setting up and connection .......................... 10
9.1 Requirements for the installation site................ 10
9.2 Setting up the cylinder sanding machine.......... 11
9.3 Electrical connection......................................... 13
10 Commissioning .......................................... 13
10.1 Test run.......................................................... 14
11 Operation .................................................... 14
11.1 Basic operation .............................................. 14
11.2 Starting the machine...................................... 15
11.3 Set feed rate .................................................. 15
11.4 Height adjustment.......................................... 15
11.5 Grinding process............................................ 15
11.6 Workflow........................................................ 16
12 Adjustment and setup work ...................... 16
12.1 Grinding belt change...................................... 16
12.2 Sandpaper cleaning....................................... 17
12.3 Adjustment of the pressure roller................... 17
12.4 Setting the height stop ................................... 18
12.5 Adjusting the guide rails................................. 19
12.6 Align feed belt to grinding drum ..................... 19
13 Care, maintenance and repair................... 20
13.1 Cleaning......................................................... 20
13.2 Regular control and maintenance.................. 20
13.3 Replacing the feed belt .................................. 21
13.4 Tensioning the feed belt ................................ 22
14 Disposal, recycling of old equipment ...... 23
14.1 Decommission ............................................... 23
14.2 Disposal of electrical equipment.................... 23
14.3 Disposal of lubricants..................................... 23
14.4 Disposal via municipal collection points......... 23
15 Troubleshooting ......................................... 24
16 Spare parts ................................................. 26
16.1 Ordering spare parts...................................... 26
16.2 Spare parts drawings ZSM 405 ..................... 27
17 Electrical Schematic .................................. 29
18 EC Declaration of Conformity ................... 30

Introduction
ZSM 405 | Version 2.08 3
1 Introduction
You have made a good choice by purchasing the Cylin-
der sanding machine made by HOLZSTAR.
Thoroughly read the operating instructions before
commissioning the machine.
It informs you about the proper commissioning, the in-
tended use as well as the safe and efficient operation
and maintenance of the Cylinder sanding machine. The
operating instructions are part of the Cylinder sanding
machine. Always keep it at the place of use of the Cylin-
der sanding machine. Furthermore, the local accident
prevention regulations and the general safety notes are
applicable for the field of application of the Cylinder san-
ding machine. The illustrations in these operating in-
structions serve the general comprehension and may
deviate from the actual type.
1.1 Copyright
The contents of these instructions are copyright. Their
application is admissible in the frame of the device. An
application beyond the described application is not allo-
wed without written approval of the manufacturer.For the
protection of our products, we shall register trademark,
patent and design rights, as this is possible in individual
cases. We strongly oppose any infringement of our intel-
lectual property.
1.2 Customer service
Please contact your dealer if you have questions on the
machine or if you need technical advice. They will help
you with specialist information and expert advice.
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 part 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 information and notes in these operating instructions
were summarised taking the applicable standards and
rules, the state-of-the-art and our long-term knowledge
and experiences into consideration.
In the following cases the manufacturer is not liable for
damages:
- Non-observance of the operating instructions,
- Inappropriate use
- Use of untrained staff,
- Unauthorised modifications
- Technical changes,
- Use of not allowed spare parts.
The actual scope of delivery may deviate from the expla-
nations and presentations described here in case of spe-
cial models, when using additional ordering options or
due to latest technical modifications.
The obligations agreed in the delivery contract, the gen-
eral terms and conditions as well as the delivery conditi-
ons of the manufacturer and the legal regulations at the
time of the conclusion of the contract are applicable.
2 Safety
This paragraph will give you an overview of all important
safety packages for the protection of the people using it
well as for a safe and undisturbed operation. Other task-
based safety notes are included in the individual chapters.
2.1 Symbol explanation
Safety instructions
The safety notes in these operating instructions are high-
lighted by symbols. The safety notes are introduced by
signal words which express the concern of the risk.
DANGER!
This combination of symbol and signal words indi-
cates an imminently dangerous situation which may
lead to death or severe injuries if they are not avoided.
WARNING!
This combination of symbol and signal word indicates
a potentially dangerous situation that can lead to
death or serious injury if not avoided.

4ZSM 405 | Version 2.08
Safety
Tips and recommendations
It is necessary to observe the safety notes quoted in
these operating instructions in order to reduce the risks
for personal injuries and damages to property.
2.2 Obligations of the operating com-
pany
The operating company is the person who operates the
machine for business or commercial reasons by herself,
or leaves it to a third party for use or application, and who
bears the legal product responsibility for the protection of
the user, the staff or for third parties.
Obligations of the operating company:
If the machine is used for commercial purposes, the op-
erating company must comply with the legal working
safety regulations. Therefore, the safety notes in this op-
erating manual, as well as the safety, accident preven-
tion and environment protection regulations applying for
the area of application of the machine must be met. The
following applies in particular:
- The operating company must be informed about
the applying industrial safety regulations and fur-
ther analyse hazards resulting from the special
working conditions at the place of use machine.
She must implement these in form of operating
manuals for the operation machine.
- During the entire lifetime of machine, the operating
company must verify whether the operating manu-
als prepared by her correspond to the current sta-
tus of the regulations, and must adapt these if nec-
essary.
- The operating company must unambiguously regu-
late and determine the responsibilities for installa-
tion, operation, troubleshooting, maintenance and
cleaning.
- The operating company must ensure that all per-
sons who work with machine, have read and un-
derstood this manual. Furthermore she must in-
struct the staff in regular intervals and inform them
about the hazards.
- The operator must provide the necessary protec-
tive equipment to the staff and order the use of the
necessary protective equipment in a binding way.
Furthermore the operating company is responsible to
keep the Machine always in a technically flawless state.
Thus, the following applies:
- The operator must ensure that the maintenance in-
tervals described in this manual are kept.
- The operator must have all safety devices checked
regularly for their good working order and their in-
tegrity.
CAUTION!
This combination of symbol and signal word indicates
a potentially dangerous situation that can result in
minor injury if it is not avoided.
ATTENTION!
This combination of symbol and signal words indi-
cates a possibly dangerous situation which may lead
to property and environmental damages if they are
not avoided.
NOTE!
This combination of symbol and signal words indi-
cates a possibly dangerous situation which may lead
to property and environmental damages if they are
not avoided.
Tips and recommendations
This symbol highlights useful tips and recommenda-
tions as well as information for an efficient and trou-
ble-free operation.

Safety
ZSM 405 | Version 2.08 5
2.3 Qualification of personnel
The different tasks described in this manual represent
different requirements to the qualification of the persons
entrusted with these tasks.
Only persons reliable working procedures can be ex-
pected from, are allowed to perform all works. Persons
the responsiveness of which is affected by e. g. drugs,
alcohol or medication, are not allowed to work with the
machine.
The qualifications of the personnel for the different tasks
are mentioned below:
Operator:
The operator is instructed by the operating company
about the assigned tasks and possible risks in case of
improper behaviour. Any tasks which need to be perfor-
med beyond the operation in the standard mode must
only be performed by the operator if it is indicated in
these instructions and if the operating company expres-
sively commissioned the operator.
Electrical specialist:
Due to his professional training, knowledge and experi-
ence as well as his knowledge of respective standards
and regulations the electrical specialist is able to perform
works on the electrical system and to recognise and
avoid any possible dangers himself.
Specialist staff:
Due to their professional training, knowledge and experi-
ence as well as their knowledge of relevant regulations
the specialist staff is able to perform the assigned tasks
and to recognise and avoid any possible dangers them-
selves.
Manufacturer:
Certain works may only be performed by specialist per-
sonnel of the manufacturer. Other personnel is not au-
thorized to perform these works. Please contact our cus-
tomer service for the execution of all arising work.
2.4 Personal protective equipment
The personal protective equipment serves to protect per-
sons against impairments of safety and health while wor-
king. The staff has to wear personal protective equip-
ment while performing different works on and with grind-
ing system which are indicated in the individual paragra-
phs of these instructions.
The personal protective equipment is explained in the
following paragraph:
WARNING!
Danger in case of insufficient quali-
fication of the staff!
Insufficiently qualified persons cannot estimate the
risks while using machine and expose themselves
and others to the danger of severe injuries.
- Have all works only performed by qualified persons.
- Keep insufficiently qualified persons and children
out of the working area.
Ear and head protection
The hearing protection protects the ears against
damages of hearing due to noise. The industrial hel-
met protects the head against falling objects and
bumping into fixed objects.
Eye protection
The protective goggles protect the eyes against parts
flying off and splashes of liquids.
Breathing protection
The breathing protection serves for protecting the
respiratory passages and the lung against the intake
of dust particles.
Protective gloves
The protective gloves serve to protect the hands
against sharp components as well as against friction,
abrasions or deep injuries.
Safety boots
The safety boots protect the feet against crushes, fal-
ling parts and slipping over on slippery underground.
Protective clothes
The protective clothes are tight clothes of little tensile
strength.

6ZSM 405 | Version 2.08
Safety
2.5 Safety signs on the Machine
The following safety markings are attached to the Cylin-
der sanding machine and must be observed and follo-
wed.
Fig. 1: safety labels
Damaged or missing safety symbols at the machine may
lead to errors with personal and material damages. The
safety symbols which are applied on the machine must
not be removed. Damaged safety symbols must be re-
placed immediately.
The machine must be put out of operation from the mo-
ment when the labels are unable to be recognized and
understood at first glance, until new labels are attached.
2.6 Safety equipment
2.6.1 Electrical connections
All necessary measures for connection are described in
this manual. The connection may only be made after rea-
ding and understanding the instructions. If you have any
questions, please contact the dealer.
The machine may only be connected by qualified per-
sonnel. Installation errors, including electrical Connec-
tion errors are not covered by warranty. Before connec-
ting and disconnecting the machine, the power
connection must be interrupted.
2.7 Danger zones
Persons under the age of 16 are strictly prohibited from
operating the machine (EC Directive). The operator must
have read these operating instructions and understood
the dangers he is exposed to in case of misuse of the
machine. For illegible or unrecognizable passages of this
manual contact the manufacturer or dealer.
The machine owner is responsible for staffing the ma-
chine with qualified operators.
Fig. 2: Danger zones
1 Danger area
2 Safety leash
2.8 Workspace
Fig. 3: Work space
WARNING!
Danger due to insufficient qualifica-
tion of persons!
All electrical connections must be made by a qualified
professional to avoid the risk of personal injury from
improperly performed work.
2
1
DANGER!
Before using for the first time, the following points
should be carefully checked:
- Is the work area around the machine free?
- Are the switches on the control panel functional?
1
2

Intended Use
ZSM 405 | Version 2.08 7
Personal security
During operation safety glasses, gloves and head pro-
tection should be worn.
2.9 General safety instructions
- Read the operating instructions before operating the
machine.
- Keep the work area clean and well lit. Cluttered or
dark areas invite accidents. Keep the floor free of
tripping hazards and dirt.
- Do not operate power tools in potentially explosive
atmospheres, e.g. in the presence of flammable li-
quids, gases or dust. Power tools produce sparks
that can ignite dust or the fumes.
- Do not expose the machine to rain or wet conditions.
- Check power supply at regular intervals. Do not use
defective cables.
- Never use the cord to carry, pull or unplug the ma-
chine. Keep the cable away from heat, oil, sharp
edges or moving parts.
- Never touch rotating or moving parts.
- Never work with the machine when you are not con-
centrated.
- Keep children and untrained personnel away from
the machine.
- As soon as a safety device has been triggered or
has failed, the machine may only be put into opera-
tion after you have eliminated the cause of the fault
and made sure that there is no danger to persons or
objects.
- Always report electrical faults to an electrician.
- Switch off the machine when work is interrupted.
- Wear appropriate safety clothing (safety shoes,
safety goggles, respiratory protection, etc.).
- Check the safety devices for correct function before
starting work. If safety devices are damaged, the
machine must not be put into operation.
- Read and understand the safety instructions atta-
ched to the machine.
- Carry out regular maintenance work.
- Do not overload the machine.
- In case of abnormal operation of the machine, in-
form the supervisor immediately.
- Exercise caution when people are in the work area.
- Never modify electrical or safety devices.
- Never remove mechanical or electrical safety de-
vices.
- Always keep hands away from the working area of
the grinding drum.
- Check feed belt from time to time to make sure
there is no dirt or sawdust between components.
- Pay special attention when transporting or reas-
sembling; follow transport instructions.
- Securely fasten the machine to the work area if pos-
sible.
- Never perform a grinding operation if the cover of
the grinding drum has been removed.
- Before starting work, check all screws and safety
devices for tightness.
- Never force the workpiece into the feed opening of
the machine.
- Allow the grinding drum to reach full speed before
starting work.
- Only process wood that has as few knots as pos-
sible.
- Make sure that the workpiece is free of nails, screws
or other foreign bodies that could damage the grin-
ding drum or the feed belt.
- Use only original spare parts and accessories.
3 Intended Use
The Cylinder sanding machine ZSM 405 is designed for
surface grinding of workpieces up to 405 mm wide and is
not suitable for working with flammable or harmful sub-
stances. The customer is responsible for the choice of
the material to be processed. It must be connected to a
suitable extraction system.
The Cylinder sanding machine is suitable for private use,
not for industrial use. Proper use also includes com-
pliance with all information in this manual. Any use
beyond the intended use or otherwise is considered mi-
suse. Unauthorized modifications or changes to the san-
ding machine may void the CE conformity of the sanding
machine and are prohibited.
The company Stürmer Maschinen GmbH assumes no
liability for design and technical changes to the Cylinder
sanding machine.
DANGER!
- Caution is advised for people who are in the work
area.
- Switch off the machine if it is not immediately conti-
nued.
- If a workpiece gets stuck, lift the sanding drum with
the machine off.
Tips and recommendations
In the case of missing or illegible signs, manufactu-
rers or dealers must be contacted for subsequent
delivery.

8ZSM 405 | Version 2.08
Technical Data
The improper use of the Cylinder sanding machine as
well as the disregard of the safety regulations or the ope-
rating instructions exclude a liability of the manufacturer
for resulting damage to persons or objects and cause the
warranty to lapse!
3.1 Foreseeable misuse
- Simultaneous machining of several workpieces.
- Machining of unauthorized materials such as me-
tals or plastics Bypassing or modifying the safety
devices.
- Installation of spare parts and use of accessories
not approved by the manufacturer. Maintenance
work on an unsecured machine.
3.2 Residual risks
The machine has been built with modern technology ac-
cording to the recognized safety rules. Nevertheless,
some residual dangers may still exist.
- The rotating guide drum can cause injuries to fin-
gers and hands.
- Ejected workpieces can cause injuries if the work-
piece is not properly secured or fed.
- Wood chips and sawdust can be hazardous to
health. Be sure to wear personal protective equip-
ment such as safety glasses and dust mask. Use
an extraction
- system.
- Injuries due to defective grinding belts. Check the
grinding belts regularly to ensure that they are in
perfect condition.
- Hearing damage due to noise exposure when wor-
king on the machine. Wear suitable hearing protec-
tion.
- Health hazard due to long hair and loose clothing
being drawn in. Wear personal protective equip-
ment such as hair nets and tight-fitting clothing.
- Risk of injury from starting grinding belts when swit-
ching on the machine. Remove the adjusting key
and workpieces before switching on the machine.
Keep hands away from the grinding belts.
- Risk of injury from electricity when using damaged
extension cables. Only use undamaged extension
cables that have been tested by a specialist.
4TechnicalData
4.1 Table
4.2 Type plate
Fig. 4: Type plate ZSM 405
5 Scope of delivery
- Extraction unit
- Front table extension
- Rear table extension
- Transport device
WARNING!
Danger in case of misuse!
Misuse of the cylinder sanding machine can lead to
dangerous situations.
- Only operate the cylindrical grinding machine 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 cylinder grinding machine in a
technically perfect condition.
- Never work on several workpieces at the same time.
Type ZSM 405
Motor output 230 V / 50Hz 1,5 kW
Speed 1.440 rpm
Sanding length x width max. 60 x 405 mm
Workpiece thickness max. 130 mm
Feed speed continuously ad-
justable
0 - 3,5 m/min
Sanding roller-Ø 132 mm
Extraction port-Ø 100 mm
Dimensions (L x W x H) 1.030 x 950 x 1.300
mm
Weight 85 kg

Transport, Packaging, Storage
ZSM 405 | Version 2.08 9
6 Transport, Packaging, Sto-
rage
6.1 Delivery and Transport
Delivery
Check the cylinder sanding machine after delivery for vi-
sible transport damage. If you discover any damage to
the Cylinder sanding machine, immediately report it to
the transport company or the 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.
6.2 Packaging
All used packaging materials and packaging aids of the
grinding system are recyclable and generally need to be
transported to the material recycling.
Crush the packaging material made of cardboard and
supply it to the waste paper collection.
The films are made of polyethylene (PE) and the uphol-
stery parts are made of polystyrene (PS). These materi-
als have to be delivered to a recycling station of the re-
sponsible dumping company.
6.3 Storage
The cylinder sander must be thoroughly cleaned before
storing in a dry, clean and frost-free environment. Cover
the machine with a protective tarpaulin.
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.

10 ZSM 405 | Version 2.08
Description
7Description
Illustrations in this manual may differ from the
original.
Fig. 5: Cylinder sanding machine ZSM 405
1 Scale for height adjustment
2 Engine
3 Clamping screw
4 Work table
5 Automatic table feed
6 Substructure
7 Handwheel for height adjustment
8 Sanding drum
9 Start button
7.1 Space requirement
Fig. 6: Space requirement of the machine
8 Specification and standard
equipment
- The grinding unit is adjusted quickly and precisely
to the workpieces by means of height adjustment
crank and scale
- With powerful drive motor for best grinding results,
even with continuous use
- Standard with insert and extension extension
- Standard with suction device for a clean workplace
- Infinitely adjustable feed rate for optimum grinding
results
- With extension and extension
- Suitable for the use of commercial abrasive cloths
operating manual
- EU standard according to (CE mark)
9 Setting up and connection
9.1 Requirements for the installation
site
The cylindrical sanding machine must be set up stable
on a level and firm ground. It is important to ensure that
there is enough freedom of movement to work. On each
side must be at least 1 m from the wall to the cylinder
sanding machine. The site should meet the following cri-
teria:
- 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 Working place must have good lighting.
1
5
2
3
4
6
7
8
WARNING!
It is not allowed to use profiles exceeding the specifi-
cation strength. Use the machine only for the intended
purpose.

Setting up and connection
ZSM 405 | Version 2.08 11
9.2 Setting up the cylinder sanding
machine
The machine must be fully assembled before it can be
put into operation. To ensure that the assembly process
runs smoothly, first clean any parts that are covered or
coated with a rust inhibitor (if applicable). Avoid chlorine-
based solvents, such as acetone or brake parts cleaner,
which can damage painted surfaces.
Proceed as follows to assemble the machine:
Step 1: Unpack the machine and check the carton con-
tents for the following.
Fig. 7: Mounting parts of the machine
Step 2: Turn the cross struts (B and C, Fig.7) over and
fold them rectangularly onto a flat surface.
Step 3: Connect the machine feet (D,Fig.7) to the upper
crossbars (B and C, Fig.7) and hand-tighten
the screws.
Fig. 8: Mount the machine feet
Step 4: Mount the lower cross braces (A and E, Fig.7) to
the machine feet using the remaining screws.
Fig. 9: Assemble cross braces of the machine
Step 5: Insert rubber cover (F,Fig.7) at the bottom of the
4 feet.
Fig. 10: Insert rubber cover
Step 6: Turn over the base frame, align the struts and
machine feet and tighten all screws.
Step 7: Fasten the wheel holder to the two machine feet
using 4 screws.
Wear safety shoes!
Wear protective gloves!
CAUTION!
Risk of injury due to an unstable machine!
Check the stability of the machine after setting it up on
a stable surface..
CAUTION!
Observe the weight of the machine!
The machine may only be set up by two persons to-
gether.
Check the auxiliary equipment for sufficient dimensio-
ning and load-bearing capacity.

12 ZSM 405 | Version 2.08
Setting up and connection
Fig. 11: Mount the transport wheels of the machine
Step 8: Push the wheel axle through the previously
mounted bracket.
Step 9: Mount the two wheels at the end of the wheel
axle and insert 2 cotter pins through the hole
of the wheels to secure them.
Step 10: Mount the transport handles to the machine
using 4 screws.
Fig. 12: Mount the transport handle of the machine
Step 11: With the help of another person, lift the cylinder
grinding machine onto the previously moun-
ted base frame and align it. Align mounting
holes on machine with holes on base.
Step 12: Mount machine to base using (4) hex bolts and
washers.
Fig. 13: Mount machine on base frame
Step 13: Mount the table extension to the feed opening
of the machine with screws and washers. The
height of the table extension can be adjusted
by turning the adjustment screws.
Fig. 14: Mount table extension
Step 14: Mount the handwheel for height adjustment on
the machine head using the screw, washer
and cap nut.
Table extension
table extension
Screws
Table
connection

Commissioning
ZSM 405 | Version 2.08 13
Fig. 15: Mount handwheel
Step 15: Place the suction nozzle on the opening of the
grinding drum cover and attach a suction
hose to the suction nozzle using a hose
clamp.
Fig. 16: Mount suction nozzle
Step 16: Connect the suction hose to a suitable suction
unit.
9.3 Electrical connection
When making electrical connections, make sure that the
characteristics (voltage, mains frequency, protection)
match those on the rating plate and for the motor.
1. The lines must be connected directly to the machine
without intermediate points.
2. For the purpose of a safe working operation, the eart-
hing must be checked (see wiring diagram).
3. If the motor is overloaded, it automatically switches
off. After a cooling time of approx. 2 minutes, the ther-
mal protection switch on the motor terminal box can
be pressed in again.
4. The customer's power supply and the extension ca-
bles used must comply with the regulations.
10 Commissioning
DANGER!
Danger to life due to electric shock!
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 must only be car-
ried out by a qualified electrician in order to avoid the
risk of personal injury due to improperly performed
work.
DANGER!
The machine must be connected to an extraction sy-
stem before start-up.
DANGER!
Before commissioning, check the electrical connec-
tion, cables and contacts.
Wear hearing protection!
Wear protective goggles!
Wear safety shoes!
Wear protective work clothing!
Wear dust mask!

14 ZSM 405 | Version 2.08
Operation
10.1 Test run
Once assembly is complete, perform a test run to ensure
that your machine is running properly and is ready for re-
gular operation.
Make sure that all tools and objects used during setup
have been removed from the machine and that the grin-
ding drum is safely above the feed belt so that no contact
can occur during operation.
The test run consists of checking the following items:
- Switch on the machine and check for correct ope-
ration.
- Check safety shut-off mechanism on switch and
cover.
- Check rotary switch for variable feed speed.
The following settings have been set in advance at the
factory and must be checked before commissioning the
machine.
- Belt tension
- Alignment from feed belt to drum
- Pressure roller adjustment
- Adjusting the height stop
11 Operation
11.1 Basic operation
The cylindrical grinding machine has a drum. which is
driven by the motor. The workpiece is fed with the auto-
matic feed against the rotation of the drum. However, a
certain level of experience is necessary to work effi-
ciently.
The following recommendations should be helpful
during processing:
- The operator should have a basic knowledge of
this type of machine.
- The material removal is better when working in se-
veral passes with low delivery and higher feed rate.
- Operators should not wear wide garments, neck-
laces, rings, etc. to prevent them from being pulled
into the running machine.
- However, the best surface finish can be achieved
by grinding in the fiber direction.
- The optimum delivery requires some experience,
and depends on the abrasive grain size, feed rate
and type of wood.
- Before processing, remove nails and other foreign
objects from the workpiece.
- Never operate the machine with the guards remo-
ved - Risk of injury!
- It is important to ensure that all workpieces are
held and guided safely during machining.
- Only work on a workpiece that rests securely on
the table.
- Only remove chips and workpiece parts when the
machine is at a standstill.
DANGER!
Danger to life from electric shock!
There is a danger to life in case of contact with live
components. Switched-on electrical components can
perform uncontrolled movements and lead to serious
injuries.
- Disconnect the power plug before starting any adju-
stments on the machine.
WARNING!
Danger to life!
There is danger to the life of the operator and other
persons if they do not observe the following rules.
- The Cylinder sanding machine may only be opera-
ted by an instructed and experienced person.
- The operator must not work if he is under the influ-
ence of alcohol, drugs or medication.
- The operator must not work if he is overtired or suf-
fers from diseases that impair concentration.
- The Cylinder sanding machine may only be opera-
ted by one person. Other persons must keep away
from the working area during operation.
CAUTION!
Risk of crushing!
Improper work on the machine may result in injury to
the upper limbs.
Wear hearing protection!
Wear protective goggles!
Wear safety shoes!
Wear protective work clothing!
Wear dust mask!

Operation
ZSM 405 | Version 2.08 15
11.2 Starting the machine
The following steps can be used to start the machine and
perform the editing process:
Step 1: Make sure the electrical connection is correct.
Step 2: Press the start button.
Step 3: Switch on automatic table feed.
Fig. 17: Starting the Machine
11.3 Set feed rate
When selecting the feed rate for machining, consider va-
riables such as the hardness and condition of the wood,
the grit of sandpaper used, the desired surface finish,
etc. As a guideline, wide or hard workpieces and the use
of finer grit sandpaper require a slower feed rate. The
goal in setting the proper feed rate is to achieve the desi-
red results for the operation without damaging the work-
piece.
To adjust the feed rate, turn the variable feed rate knob
clockwise.
Fig. 18: Set feed rate
11.4 Height adjustment
The proper depth of cut for surface sanding depends on
many variables, such as the hardness of the wood, the
width of the workpiece, and the feed rate.
Generally, for coarser grits or softer woods, a 1⁄4 turn of
the handwheel (1⁄32" depth of cut) per pass is accep-
table. A 1⁄8 turn of the handwheel (1⁄64" depth of cut) is
recommended for finer grits or harder woods.
Proceed as follows to set the height:
Step 1: Loosen the clamping screw (Fig.19).
Step 2: Turn the raising handwheel counterclockwise to
lower the grinding drum.
Step 3: Once the correct cutting depth for your operation
is set, retighten the clamping screw (Fig.19).
Fig. 19: Height adjustment
11.5 Grinding process
11.5.1 Rules for grinding on the machine
The grinding operation may only be performed by quali-
fied personnel experienced on these machi-
nes.
The workpiece is fed with the automatic feed against the
direction of the drum. Feed the workpiece with the thic-
ker end first. Do not machine highly twisted or bent work-
pieces or those whose thickness varies greatly. Support
long workpieces with roller blocks. Use the height adjust-
ment handwheel to set the grinding drum to the desired
chip removal rate.
Follow these precautions to ensure a safe grinding
process and high-quality results:
Engine
Start button
Automatic
table feed
Table feed
Handwheel
Screw
Scale

16 ZSM 405 | Version 2.08
Adjustment and setup work
- Replace the sandpaper with a higher grit to
achieve a finer final result.
- When making multiple passes on the workpiece,
do not lower the sanding drum more than 1⁄32" or
1⁄4".
- If possible, feed the workpiece to the grinding drum
at a 60° angle. This will ensure more effective ma-
terial removal, less stress on the motor, and more
even wear on the abrasive paper.
- Extend the life of the abrasive paper by regularly
using an abrasive pad.
- DO NOT edge grind workpieces. This can cause
boards to recoil and cause serious injury.
- Replace damaged and worn sanding belts immedi-
ately.
11.6 Workflow
Step 1: Check the correct mounting of the sanding paper
on the sanding drum.
Step 2: Check the workpiece for foreign bodies such as
nails.
Step 3: Place the workpiece to be machined on the work
table of the machine.
Step 4: Set the chip removal.
Step 5: Start the machine.
Step 6: Start feed and select feed rate.
Step 7: Start the suction unit.
Step 8: Feed workpiece (if possible, place workpiece at a
slight angle, as the sandpaper load is lower
here).
Step 9: Switch off the suction system and the machine.
Fig. 20: Workflow
12 Adjustment and setup work
12.1 Grinding belt change
Proceed as follows to remove the grinding belt:
Step 1: Switch off the cylinder grinding machine and dis-
connect the power plug.
Step 2: Loosen the locking hook of the cover below the
handle.
Step 3: Swing the cover up to access the sanding drum
and sandpaper.
Step 4: Reach under the right clamp and press the lever
to release the sandpaper.
Fig. 21: Clamping device right
Step 5: Unwind the sandpaper strip from the drum until
you reach the clamping device on the left side.
Fig. 22: Clamping device left
Handwheel for
Suction port
Scale for height
Automatic
table feed
adjustment
height adjustment
NOTE!
Before adjustment and setup work, the
The machine must be secured against start-up.
Pull out the mains plug!
Wear protective work clothing!
Wear protective gloves!
Clamping device
Clamping device

Adjustment and setup work
ZSM 405 | Version 2.08 17
Step 6: Reach under the left clamp and press the lever to
remove the sandpaper from the machine.
Proceed as follows to install the grinding belt:
Step 1: Reach under the left clamp and press the lever.
Step 2: Insert the end of the new sandpaper into the
clamp and align the sandpaper with the left
side of the drum slot.
Step 3: Close the lever to clamp the sandpaper.
Step 4: Pull the sandpaper to make sure it is securely
and tightly clamped.
Step 5: Hold the sandpaper under tension with one hand
and rotate the drum clockwise with the other
hand to wind the sandpaper.
Fig. 23: Wind up sandpaper
Step 6: Lift the right clamp forward and press the lever.
Step 7: Insert the end of the sandpaper at the drum slot
between the clamp and the lever.
Step 8: Close the lever to clamp the sandpaper.
Step 9: Make sure the sandpaper is tight and flush
against the drum, edges do not protrude more
than 1⁄8" and do not overlap.
Step 10: Close the cover and turn on the machine.
12.1.1 Sandpaper selection
Choosing the right abrasive belt grit is extremely import-
ant for optimizing grinding performance. Always grind
with a coarse grit first and then gradually switch to finer
grits. Do not skip more than one grit level. Grain sizes
that are too fine and worn grinding belts can leave burn
marks on the workpiece.
Grain 36:
Extra coarse, maximum stock removal e.g. for
paint removal.
Grain 60- 80:
Surfaces and light calibration, most common
grits
Grain 100 and 120:
Surfaces and finishing
Grain 150, 180 and 220:
Fine tuning only
12.2 Sandpaper cleaning
Clean the sanding paper regularly with a fine brush.
By removing the abrasive dust deposits, the life of the
abrasive paper is significantly increased.
Step 1: Start the sanding drum with the cover open.
Step 2: Guide the brush along the rotating sanding drum.
It is recommended to remove the resulting
abrasion with a brush.
By turning the sandpaper its life can be increased. Here
new grain tips are used.
Fig. 24: Sandpaper cleaning
12.3 Adjustment of the pressure roller
The height of the pressure rollers is set below the grin-
ding drum to hold the workpiece firmly against the feed
belt as it passes through the grinder and to prevent the
workpiece from kicking back.
NOTE!
Align the direction arrow printed on the bottom of the
sandpaper with the direction of rotation of the drum.
Sanding wheel

18 ZSM 405 | Version 2.08
Adjustment and setup work
Fig. 25: Pressure rollers
The pressure that the pressure rollers exert on the work-
piece while the workpiece is being machined is control-
led by pressure springs and adjusting screws.
Fig. 26: Adjustment screws pressure rollers
The correct pressure on the workpiece helps to prevent
kickback. However, if the pressure on the workpiece
from the rear pressure roller increases, the pressure on
the grinding drum also increases. In this case, reduce
the pressure on the rear pressure roller.
If you want to increase or decrease the pressure that
these rollers exert on the workpiece, perform the follo-
wing steps.
Step 1: Switch off the machine and disconnect the power
plug.
Step 2: Loosen the locking hook of the cover below the
handle.
Step 3: Swing the cover up to include access to the pres-
sure roller adjustment screws.
Step 4: To increase the pressure exerted by the rollers,
tighten all four screws in small, even turns and
test the pressure of the rollers by pushing them
upwards. Conversely, loosen the adjustment
screws to decrease the pressure.
Step 5: Perform test run. If the workpiece tends to recoil,
decrease the pressure by turning the screws
counterclockwise.
Step 6: If the workpiece slips on the belt, increase the
pressure by turning the screws clockwise one
turn and perform the test again.
12.4 Setting the height stop
The adjustment screw, which protrudes through the bot-
tom of the frame, serves as a stop to prevent the grinding
drum from coming into contact with the feed belt when
adjusting the height.
Fig. 27: Height stop adjustment screw
The setting of the screw was set correctly at the factory.
However, if it is necessary to readjust the stop screw, per-
form the following steps.
Step 1: Switch off the machine and disconnect the power
plug.
Step 2: Make sure that the belt is correctly tensioned.
Step 3: Crank the grinding drum to the highest position.
Step 4: Loosen the hexagon nut on the adjustment
screw and adjust the height of the screw that
protrudes above the frame so that it does not
protrude less than 6.3 mm.
Step 5: Tighten the hex nut and lower the grinding drum un-
til the adjustment screw touches the frame of the
holder.
Pressure rollers
Screws
Screw

Adjustment and setup work
ZSM 405 | Version 2.08 19
Step 6: Ensure that the grinding roller is at least 4.8 mm
above the surface of the feed belt.
12.5 Adjusting the guide rails
The guide rails exert pressure on the slides of the grin-
ding head. This allows the grinding head assembly to
move up and down precisely when using the handwheel.
If the ledges are too loose, the grinding roller will be pus-
hed up during operation, resulting in poor grinding re-
sults.
If the bars are too tight, it is difficult to adjust the grinding
roller height, resulting in excessive wear.
Proceed as follows to adjust the bars:
Step 1: Switch off the machine and disconnect the power
plug.
Step 2: Loosen the lock nut on both guides.
Fig. 28: Loosen guide sides
Step 3: Screw each of the six cap screws in or out in
short, equal turns. Then turn the handwheel for
height adjustment to test the movement of the
grinding head.
Note: Tighten the cap screws to increase the
pressure on the bar.
Fig. 29: Set guide sides
Step 4: Repeat step 3 until you are satisfied with the grin-
ding head movement.
Step 5: Tighten the lock nut on the two guides again.
12.6 Align feed belt to grinding drum
To ensure a good grinding result, the feed belt and grin-
ding drum must be parallel to each other from side to
side. Otherwise, more material will be removed from one
side of the workpiece than the other. The goal of this
procedure is to set the parallelism of the feed belt and
sanding drum within 0.05" difference from side to side.
Fig. 30: Parallelism of feed belt and grinding drum
Proceed as follows to set the parallelism of the feed belt
to the grinding drum:
Step 1: Switch off machine.
Step 2: Make sure that the guide pads are set correctly.
Step 3: Select a workpiece that has an equal thickness on
each side.
NOTE!
If the grinding drum is not at least 4.8 mm above the
feed belt, repeat this process until the grinding drum is
at least 4.8 mm above the feed belt.
Nut
Guide
Screws
Guide rails
Correct
Incorrect
Sanding drum
Sanding drum
Conveyor Belt
Conveyor Belt

20 ZSM 405 | Version 2.08
Care, maintenance and repair
Step 4: Switch on the machine.
Step 5: Make several light sanding passes without rotating
or turning the board.
Step 6 : Remove the workpiece and switch off the machine.
Step 7: Perform measurement at location A and B as
shown in Figure 31.
- If dimension "A" is smaller than "B", loosen or re-
move the screws on the right hinge support. Re-
move or place a washer between the support and
the frame to compensate for the difference bet-
ween "A" and "B".
- If the "B" dimension is less than "A", loosen or re-
move the screws on the left hinge bracket. Re-
move or place a washer between the support and
the frame to compensate for the difference.
Fig. 31: Set parallelism of feed belt to grinding drum
Step 8: Repeat steps 1-5 to verify adjustment.
If necessary, repeat step 5 until the parallelism of
the feed belt and grinding drum is within 0.05"
from side to side.
13 Care, maintenance and repair
13.1 Cleaning
Step 1: Disconnect the power plug from the power outlet.
Step 2: Empty and clean the suction device.
Step 3: Clean the machine from sawdust and sawdust.
Step 4: Thoroughly clean resin deposits on the machine
using resin remover.
Step 5: Spray all unpainted metal surfaces with some
anti-rust spray.
Step 6: Inspect the machine for damage to the safety de-
vices and the sanding belt. If necessary, carry
out the repair or arrange for it, observing the
safety instructions.
Step 7: Check the machine for damage to the safety de-
vices and the grinding belt. If necessary, carry
out the repair or arrange for it to be carried out,
observing the safety instructions.
13.2 Regular control and maintenance
Lubrication of the machine
Regularly check the grinding belt for defects.
1. Replace a damaged grinding belt immediately. Check
the correct setting of the feed belt at regular intervals.
Lubricate monthly all moving parts (Fig.32) such as
threaded spindle, pulleys and bearing bushes inclu-
ding the depth limiter, sliding surfaces and bushes
connected to the depth control mechanism. Do not use
oil or grease for this purpose as it tends to bind saw-
dust.
DANGER!
Danger to live due to electrical
voltage!
Contact with live components can be fatal. Activated
electrical components can execute uncontrolled mo-
vements and cause serious injuries.
- Switch off the machine before carrying out cleaning
and maintenance work and unplug the power cord.
- Connections and repairs of electrical equipment
may only be performed by a qualified electrician.
Left
bracket
Right
bracket
Wear safety gloves!
Wear protective clothing!
NOTE!
Never use harsh cleaning agents for cleaning. This
can lead to damage or destruction of the device.
Provide adequate ventilation when using solvents.