Holzstar ZSM 560 User manual

Instruction Manual
Cylinder Sanding Machine
ZSM 560
ZSM 560 Vario
ZSM 560
ZSM 560 Vario

2ZSM 560 | Version 1.01
Imprint
Product identification
Cylinder Sanding Machine Item number
ZSM 560 5903560
ZSM 560 Vario 5903565
Manufacturer
Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Fax: [phone] - 55
E-Mail: [email protected]
Internet: www.holzstar.de
Information on the operating instructions
Original operating instructions
Edition: 21.12.2020
Version: 1.01
Language: English
Author: MS/FL
Copyright information
Copyright © 2020 Stürmer Maschinen GmbH, Hallstadt,
Germany.
The contents of this operating manual are the sole
property of Stürmer Maschinen GmbH.
Passing on as well as duplication of this document, utili-
zation and communication of its contents are forbidden,
as far as not expressly permitted. Any infringement will
result in compensation for damages.
Technical changes and errors excepted.
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 labels at the Cylinder Sanding Machine .. 6
2.6 Safety devices .................................................... 6
2.7 General safety instructions ................................. 6
3 Intended use ................................................... 7
3.1 Foreseeable misuse ........................................... 7
3.2 Residual risks ..................................................... 7
4 Technical Data ................................................ 8
4.1 Table .................................................................. 8
4.2 Type plate........................................................... 8
5 Scope of delivery ........................................... 8
6 Accessories .................................................... 8
7 Transport, Packaging, Storage ..................... 9
7.1 Delivery and Transport ....................................... 9
7.2 Packaging........................................................... 9
7.3 Storage ............................................................... 9
8 Description of the device ............................ 10
8.1 Space requirement ........................................... 10
9 Set up and connection................................. 10
9.1 Requirements for the installation site................ 10
10 Setting up the Cylinder Sanding Machine .. 10
10.1 Electrical connection...................................... 12
11 Commissioning .......................................... 12
11.1 Test run.......................................................... 12
12 Operation .................................................... 13
12.1 Notes on operation ........................................ 13
12.2 Starting the machine..................................... 13
12.3 Set feed rate .................................................. 14
12.4 Adjust height adjustment ............................... 14
12.5 Grinding process............................................ 14
12.6 Workflow....................................................... 15
13 Adjustment and setup work ...................... 15
13.1 Grinding belt change...................................... 15
13.2 Sandpaper cleaning....................................... 16
13.3 Adjustment of the pressure roller................... 17
13.4 Setting the height stop................................... 17
13.5 Adjusting the guide rails................................. 18
13.6 Align feed belt to grinding drum ..................... 18
14 Care, maintenance and repair................... 19
14.1 Cleaning......................................................... 19
14.2 Regular check and maintenance ................... 19
14.3 Replacing the feed belt .................................. 20
14.4 Tensioning the feed belt ................................ 21
14.5 Installation grinding rollers (Accessories) ...... 22
15 Disposal, recycling of old equipment ...... 22
15.1 Decommission ............................................... 22
15.2 Disposal of electrical equipment.................... 22
15.3 Disposal of lubricants..................................... 22
15.4 Disposal via municipal collection points......... 22
16 Troubleshooting ......................................... 23
17 Spare parts ................................................. 25
17.1 Ordering spare parts....................................... 25
17.2 Spare parts drawing....................................... 26
18 Electrical circuit diagrams ........................ 30
18.1 Electrical circuit diagram ZSM 560 ................ 30
18.2 Electrical circuit diagram ZSM 560 VARIO .... 30
19 EC - Declaration of Conformity ................. 31

Introduction
ZSM 560 | Version 1.01 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 ma-
nufacturer 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
Safety instructions are identified in these operating instruc-
tions by symbols. The safety instructions are introduced by
signal words that express the extent of the hazard.
DANGER!
This combination of symbol and signal word indicates
an imminently hazardous situation which, if not avoi-
ded, will result in death or serious injury.
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 560 | Version 1.01
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.
DANGER!
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 560 | Version 1.01 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.
Hearing protection
Hearing protection helps to protect the hearing from
harmful noise and other loud sounds.
Head protection
The industrial helmet protects the head against fal-
ling objects and bumping against 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 560 | Version 1.01
Safety
2.5 Safety labels at the Cylinder San-
ding Machine
The following safety markings are attached to the Cylin-
der Sanding Machine, which must be observed and follo-
wed.
Fig. 1: Safety labels
The safety markings attached to the machine must not
be removed. Damaged or missing safety markings can
lead to incorrect actions, personal injury and damage to
property. They must be replaced immediately.
If the safety markings are not recognizable and compre-
hensible at first glance, the machine must be taken out of
operation until new safety markings have been applied.
2.6 Safety devices
All necessary measures for connection are described in
this operating manual. The connection may only be
made after reading and understanding the instructions.
In case of any ambiguity, contact the dealer.
Installation errors, including electrical
connection errors, are not covered by the warranty.
Before connecting or disconnecting the machine, the po-
wer connection must be interrupted.
2.7 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 conditi-
ons.
- 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
concentrated.
- 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 started up if
you have eliminated the cause of the fault and
have 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 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.
- If the machine does not operate normally, inform
the supervisor immediately.
- Use 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.
- If possible, secure the machine at the workplace.
- Never carry out 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 grinding drum or the feed belt.
- Use only original spare parts and accessories.

Intended use
ZSM 560 | Version 1.01 7
3 Intended use
The Cylinder Sanding Machine ZSM 560 and ZSM 560
Vario is designed for surface sanding of wood or wood-
like materials. The machine must not be set up and ope-
rated in potentially explosive atmospheres and only in
dry and ventilated rooms.
Intended use also includes compliance with all the infor-
mation in these instructions. Any use beyond the inten-
ded use or any other use is considered misuse. Un-
authorized conversions or modifications to the grinding
machine can invalidate the CE conformity of the cylindri-
cal grinding machine and are prohibited.
Stürmer Maschinen GmbH accepts no liability for design
and technical modifications to the cylindrical grinding
machine.
3.1 Foreseeable misuse
- Simultaneous machining of several workpieces.
- Machining of unacceptable materials such as me-
tals.
- 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.
- Machining of flammable or harmful materials.
- Use of the cylindrical grinding machine in an indu-
strial environment.
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 rotating grinding belts when
switching on the machine.
- Remove the adjusting key and workpieces before
switching on the machine. Risk of injury from rota-
ting grinding belts ! Keep hands away from the
grinding belts.
- Risk of injury from electric shock when using a da-
maged extension cord. Only use undamaged ex-
tension cables that have been tested by a specia-
list.
DANGER!
The non-intended use of the Cylinder Sanding Ma-
chine as well as the disregard of the safety regulations
or the operating instructions exclude a liability of the
manufacturer for resulting damages to persons or ob-
jects and cause an expiration of the warranty claim!

8ZSM 560 | Version 1.01
Technical Data
4 Technical Data
4.1 Table
4.2 Type plate
Fig. 2: Type plate ZSM 560
5 Scope of delivery
- Tool
- Grinding roller K80
- Operating instructions
6 Accessories
ZSM 560 Vario
- Lamellar grinding roller K240
Item number: 5913856
- Nylon grinding roller
Item number: 5913857
- Wire brush roller Ø 0,4mm
Item number: 5913858
ZSM 560 and ZSM 560 Vario
- Grinding roller 50.000x80mm K60
Item number: 5918760
- Grinding roller 50.000x80mm K80
Item number: 5918780
- Grinding roller 50.000x80mm K100
Item number: 5918710
- Grinding roller 50.000x80mm K120
Item number: 5918712
- Grinding roller 50.000x80mm K150
Item number: 5918715
- Grinding roller 50.000x80mm K180
Item number: 5918718
- Grinding roller 50.000x80mm K220
Item number: 5918722
Model ZSM 560 ZSM 560
Vario
Length 1070 mm 1070 mm
Width/depth 1080 mm 1080 mm
Height 1150 mm 1200 mm
Weight 116 kg 119 kg
Supply voltage 230 V 230 V
Sanding belt length 3280 mm 3280 mm
Sanding belt width 78 mm 78 mm
Speed 1400 min⁻¹ 0-1800 min⁻¹
Sanding surface
width
555 mm 555 mm
Max. sanding height 80 mm 80 mm
Sand roller diameter 132 mm 132 mm
Drive roller diameter 19 mm 19 mm
Work table length 592 mm 592 mm
Work table width 505 mm 505 mm
Work table height 695 mm 695 mm
Min. workpiece
height
5 mm 5 mm
Min. workpiece
height
80 mm 80 mm
Min. workpiece
length
120 mm 160 mm
Feed speed 0-3.5 m/min 0-3.5 m/min
Extraction port dia-
meter
100 mm 100 mm
Starting current 27 A 25 A
Rated current 8.8 A 5.3 A
Feed motor output 80 W 80 W
Drive motor output 1,5 kW 1,5 kW

Transport, Packaging, Storage
ZSM 560 | Version 1.01 9
7 Transport, Packaging, Sto-
rage
7.1 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.
7.2 Packaging
All packaging materials and packing aids used in the
Cylinder Sanding Machine are recyclable and must al-
ways be sent for material recycling.
Shred cardboard packaging components and take them
to the waste paper collection.
The films are made of polyethylene (PE) and the cushio-
ning parts of polystyrene (PS). These materials should
be taken to a collection point for recyclable materials or
to your local waste disposal company.
Keep the packaging material out of the hands of child-
ren, as some plastic packaging may pose a choking ha-
zard, etc. when used as a toy.
7.3 Storage
The cylinder grinding machine must be thoroughly cle-
aned before it is stored in a dry, clean and frost-free env-
ironment. 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 560 | Version 1.01
Description of the device
8 Description of the device
Illustrations in these operating instructions may de-
viate from the original
Fig. 3: Cylinder Sanding Machine ZSM 560
A Machine base
B Feet
C Feed belt
D Extension table
E Grinding roller cover
F Handwheel for height adjustment
G Motor
H Feed belt drive
I On / Off switch
J Feed controller
8.1 Space requirement
Fig. 4: Space requirement
9 Set up and connection
9.1 Requirements for the installation
site
The cylindrical grinding machine must be set up on a le-
vel and solid surface in a stable manner. It must be ensu-
red that there is sufficient freedom of movement for wor-
king. There must be at least 1 m clearance from the wall
to the Cylinder Sanding Machine on each side. The in-
stallation site should meet the following criteria:
- The substrate must be level, firm and vibration-
free.
- The surface must not allow any lubricants to pass
through.
- The installation or work area must be dry and well
ventilated.
- No machines causing dust and chips should be
operated in the vicinity of the machine.
- There must be sufficient space for the operating
personnel, for material transport and for setting
and maintenance work.
- The installation site must have good lighting.
10 Setting up the Cylinder Sanding
Machine
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.