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.