Powermatic DDS-225 Service manual

Operating Instructions and Parts Manual
Dual Drum Sander
Models DDS-225 and DDS-237
JPW Industries, Inc.
427 New Sanford Road
LaVergne, Tennessee 37086 Part No. M-0460278
Ph.: 800-274-6848 Revision A04/2019
www.powermatic.com Copyright © 2014 Powermatic

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Table of Contents
Table of Contents..........................................................................................................................................2
Features........................................................................................................................................................5
Specifications................................................................................................................................................6
Shipping Contents.....................................................................................................................................7
Assembly.......................................................................................................................................................8
Handwheel Assembly................................................................................................................................8
Dust Ports..................................................................................................................................................8
Dust Collection ..........................................................................................................................................8
Drum Height ............................................................................................................................................10
Pressure Rollers......................................................................................................................................11
Table Height ............................................................................................................................................11
Table Parallelism.....................................................................................................................................11
Lead Screw Thread Clearance................................................................................................................12
Conveyor Belt..........................................................................................................................................13
Drive Belts ...............................................................................................................................................13
Pulley Alignment......................................................................................................................................14
Changing Belts........................................................................................................................................14
Maintenance................................................................................................................................................15
Operations...................................................................................................................................................15
Basic Operation.......................................................................................................................................15
Stock Feeding Angle ...............................................................................................................................15
Multiple-Piece Sanding Runs ..................................................................................................................15
Edge Sanding..........................................................................................................................................16
Sanding Imperfect Stock .........................................................................................................................16
Face Frames & Raised Panel Doors.......................................................................................................16
Reversing Conveyor Direction.................................................................................................................16
Switch Lock.................................................................................................................................................17
Functions of digital scale.............................................................................................................................18
Calibration and operation............................................................................................................................19
Maintenance Checklist................................................................................................................................20
Troubleshooting ..........................................................................................................................................20
Performance Problems............................................................................................................................20
Mechanical & Electrical Problems...........................................................................................................21
Parts –DDS-225 Sander ............................................................................................................................22
Drum Assembly –DDS-225 ....................................................................................................................22
Conveyor Assembly –DDS-225..............................................................................................................24
Motor & Cabinet Assembly –DDS-225...................................................................................................26
Gearbox Assembly –DDS-225 ...............................................................................................................29
DDS-225 DRO Assembly........................................................................................................................31
Parts –DDS-237 Sander ............................................................................................................................32
Drum Assembly –DDS-237 ....................................................................................................................32
Conveyor Assembly –DDS-237..............................................................................................................34
Motor and Cabinet Assembly –DDS-237 ...............................................................................................36
Gearbox Assembly –DDS-237 ...............................................................................................................39
DDS-237 DRO Assembly........................................................................................................................41

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1. Read and understand the entire owner's manual before attempting assembly or operation.
2. Read and understand the warnings posted on the machine and in this manual. Failure to comply with
all of these warnings may cause serious injury.
3. Replace the warning labels if they become obscured or removed.
4. This drum sander is designed and intended for use by properly trained and experienced personnel
only. If you are not familiar with the proper and safe operation of a drum sander, do not use until
proper training and knowledge have been obtained.
5. As with all machines, there is a certain amount of hazard involved with the use of this drum sander.
Use the machine with the respect and caution demanded where safety precautions are concerned.
When normal safety precautions are overlooked or ignored, personal injury to the operator can result.
6. Do not use this drum sander for other than its intended use. If used for other purposes, Powermatic
disclaims any real or implied warranty and holds itself harmless from any injury that may result from
that use.
7. ALWAYS WEAR APPROVED SAFETY GLASSES/face shields while using this drum sander.
Everyday eyeglasses only have impact resistant lenses; they are not safety glasses.
8. WEAR PROPER APPAREL. Before operating this drum sander, remove tie, rings, watches and other
jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair. Non-slip
footwear or anti-skid floor strips are recommended. Do not wear gloves.
9. Wear ear protectors (plugs or muffs) during extended periods of operation.
10. Do not operate this machine while tired or under the influence of drugs, alcohol or any medication.
11. Make certain the machine is properly grounded.
12. Except for the feed rate control, make all machine adjustments or maintenance with the machine
unplugged from the power source. A machine under repair should be RED TAGGED to show it must
not be used until maintenance is complete.
13. Before turning on machine, REMOVE ALL EXTRA EQUIPMENT SUCH AS KEYS, WRENCHES,
scrap, and cleaning rags away from the machine.
14. KEEP SAFETY GUARDS IN PLACE at all times when the machine is in use. If removed for
maintenance purposes, use extreme caution and replace the guards immediately.
15. CHECK DAMAGED PARTS. Before further use of the machine, a guard or other part that is damaged
should be carefully checked to determine that it will operate properly and perform its intended
function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting
and any other conditions that may affect its operation. A guard or other part that is damaged should
be properly repaired or replaced.
16. Provide for adequate space surrounding work area and non-glare, overhead lighting.
17. KEEP THE FLOOR AROUND THE MACHINE CLEAN and free of scrap material, saw dust, oil and
other liquids to minimize the danger of tripping or slipping. Be sure the conveyor table is free of all
scrap, foreign material and tools before starting sanding operations.
18. Keep visitors a safe distance from the work area. KEEP CHILDREN AWAY.
19. MAKE YOUR WORKSHIP CHILD PROOF with padlocks, master switches or by removing safety
keys.
20. Give your work undivided attention. Looking around, carrying on a conversation and “horse-play” are
careless acts that can result in serious injury.
21. Maintain a balanced stance at all times so that you do not fall or lean against the blade or other
moving parts. DO NOT OVERREACH or use excessive force to perform any machine operation.

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22. USE THE RIGHT TOOL at the correct speed and feed rate. DO NOT FORCE A TOOL or attachment
to do a job for which it was not designed. The right tool will do the job better and safer.
23. USE RECOMMENDED ACCESSORIES; improper accessories may be hazardous.
24. MAINTAIN TOOLS IN TOP CONDITION. Keep tools sharp and clean for safe and best performance.
Dull tools increase noise levels and can cause kickbacks and glazed surfaces. Check the condition
and adjustment of the tools before making any cuts.
25. Keep hands outside the machine. NEVER reach under the guards to try to clear stock that stops
feeding. Do not clear chips and sawdust with hands; use a brush. Do not have any part of the hands
under that part of the board that is over the table when starting a cut; the pressure roller will engage
the board and force it down against the table causing a pinching action.
26. Do not attempt to sand boards with loose knots or with nails or other foreign material, on its surface.
Do not attempt to sand twisted, warped, bowed or “in wind” stock unless one edge has been jointed
for guiding purposes prior to sanding.
27. Do not attempt to sand long or wide boards unsupported where spring or weight could cause the
board to shift position.
28. If the operator leaves the machine area for any reason, the sander should be turned "off" and come to
a complete stop before his departure. In addition, if the operation is complete, he should clean the
sander and the work area. NEVER clean the machine with power "on" and never use the hands to
clear sawdust and debris; use a brush.
29. TURN OFF THE MACHINE BEFORE CLEANING. Use a brush or compressed air to remove chips or
debris —do not use your hands.
30. DO NOT STAND ON THE MACHINE. Serious injury could occur if the machine tips over.
31. NEVER LEAVE THE MACHINE RUNNING UNATTENDED. Turn the power off and do not leave the
machine until it comes to a complete stop.
32. Remove loose items and unnecessary work pieces from the area before starting the machine.
33. DON’T USE IN DANGEROUS ENVIRONMENT. Don’t use power tools in damp or wet locations, or
expose them to rain. Keep work area well lighted.
34. DIRECTION OF FEED. Feed work into the drum against the direction of rotation of the drum only.
Familiarize yourself with the following safety notices used in this manual:
This means that if precautions are not heeded, it may result in minor injury and/or
possible machine damage.
This means that if precautions are not heeded, it may result in serious injury or possibly
even death.
WARNING: Drilling, sawing, sanding or machining wood products generates wood dust and other
substances known to the State of California to cause cancer. Avoid inhaling dust generated from wood
products or use a dust mask or other safeguards for personal protection.
Wood products emit chemicals known to the State of California to cause birth defects or other
reproductive harm. For more information go to http://www.p65warnings.ca.gov/wood.
WARNING: This product can expose you to chemicals including lead which is known to the State
of California to cause cancer and birth defects or other reproductive harm. For more information go to
http://www.p65warnings.ca.gov.

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Features
Figure 1
Figure 2 –Dust Port Locations

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Specifications
Model Number....................................................DDS-225.............................................................. DDS-237
Stock Number .............................................. 1791290-RU.........................................................1791321-RU
Main Motor .......................................................see below.............................................................see below
Main Motor Speed (RPM) ........................................1,450....................................................................1,450
Electrical Controls ............................................see below.............................................................see below
Conveyor Motor.................................................see below.............................................................see below
Conveyor Speed (m/min)......................................2 and 3.................................................................2 and 3
Sanding Drum Diameter (mm)....................................150.......................................................................150
Drum Length (mm)......................................................635.......................................................................940
Drum Speed (RPM)..................................................1,350....................................................................1,350
Maximum Board Width (mm) ......................................635.......................................................................940
Maximum Board Thickness (mm) ...............................133.......................................................................133
Minimum Board Length (mm)......................................230.......................................................................230
Minimum Board Thickness (mm) .................................0.8........................................................................0.8
Dust Port Diameter...........................................two @ 100............................................................two @ 100
Dust Collection Capacity Required (CFM)................1200....................................................................1,200
Shipping Weight (kgs).................................................383.......................................................................490
Net Weight (kgs) .........................................................325.......................................................................411
Overall Dimensions (L x W x H, mm) 1093 x 1178 x 1093............................................. 1524 x 1143 x 1143
Main Motor :
S/N 1791290..........................................................................(TEFC) 3.7kW (5HP), 3Ph, 400V, 50Hz
S/N 1791321........................................................................ (TEFC) 7.5Kw (10HP), 3Ph, 400V, 50Hz
Conveyor Motor:
S/N 1791290..................................................................... (TEFC) 0.18Kw (1/4HP), 3Ph, 400V, 50Hz
S/N 1791321..................................................................... (TEFC) 0.18Kw (1/4HP), 3Ph, 400V, 50Hz
Electrical Controls (all models)............................................................... 400V magnetic w/ reversing switch
The specifications in this manual are given as general information and are not binding. Powermatic
reserves the right to effect, at any time and without prior notice, changes or alterations to parts, fittings,
and accessory equipment deemed necessary for any reason whatsoever.

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Unpacking
Open the shipping crate and check for shipping
damage. Report any damage immediately. Read
the owner’s manual thoroughly for assembly,
maintenance and safety instructions.
Shipping Contents
Note 1: Some parts are inside a box in the cabinet.
Note 2: Models DDS-225 and DDS-237 Drum
Sanders come from the factory with the first set of
abrasive strips installed with 80 grit sandpaper on
the front drum and 100 grit on the rear drum.
1 dual drum sander
1 handwheel
1 handle assembly
1 handwheel post
2 dust ports
2 open end wrenches (12-14mm and 17-19mm)
4 hex wrenches (2, 3, 4, and 5mm)
1 manual
1 warranty card
Installation and Assembly
Tools needed
1 forklift or hoist with straps
1 14mm open-end wrench (provided)
1 cross-point screwdriver
1 flat head screwdriver
1 set of hex wrenches (provided)
The sander should be placed in a well-lit area with
a sturdy floor and good ventilation. Leave enough
space around the machine for loading and off-
loading stock and general maintenance work.
Do NOT lift the sander directly under the drums or
rollers, as it may damage them. Use a forklift to
move the machine as follows (Refer to Figures 3
through 5):
1. Open the door and remove the four screws
holding the sander to the pallet.
2. Move away the wood block (A) at the front,
which protected the machine from shifting
during transport.
3. Tilt the machine backward just enough to
insert wood block (A).
4. Insert the forks into the gap and carefully lift
the machine.
5. Position the sander in its new location and
gently set it down.
Figure 3
Figure 4
Figure 5

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Exposed metal surfaces, such as the shafts on the
drums and pressure rollers, have been given a
protective coating at the factory. This should be
removed with a soft cloth moistened with kerosene.
Do not use acetone, gasoline, or lacquer thinner
for this purpose. Do not use solvents on plastic
parts, and do not use an abrasive pad because it
may scratch the surfaces.
Assembly
Handwheel Assembly
1. Slide the post up into the handwheel and
secure with the set screws, as shown in Fig 6.
2. Use a flat head screwdriver to screw the bolt of
the handle as far as it will go into the threaded
hole of the handwheel, then tighten the hex nut
down against the handwheel (Fig. 6).
The handle must rotate freely after tightening
the hex nut. If the handle is too tight, loosen
the hex nut and back out the bolt slightly, then
re-tighten the hex nut.
3. The handwheel assembly, used for raising and
lowering the conveyor table, is designed to be
mounted and removed quickly. Set the
handwheel assembly down into the hole of the
hood (Fig. 7) and rotate it until it seats itself
upon the pins of the leadscrew below.
Note: The handwheel must be removed before the
hood can be opened.
Dust Ports
Mount the two dust ports to the top of the hood
with eight 3/16 x 1/2 screws and eight flat washers
(Fig. 7).
Dust Collection
It is strongly recommended that you connect a
proper dust extraction system to the two 4” ports
atop the sander. Make sure the capacity of your
dust collector is at least 1200 CFM. See Figure 2
for a diagram of the dust port spacing.
Electrical Connections
Electrical connections must be
made by a qualified electrician in compliance
with all relevant codes. The machine must be
properly grounded to help prevent electrical
shock and possible fatal injury.
The installer must follow local regulations and
National Electrical Code. This tool should be
connected to a grounded metal permanent wiring
system; or to a system having an equipment-
Figure 6
Figure 7

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grounding conductor.
Make sure the voltage of your power supply
matches the specifications on the motor plate of
the machine
Abrasive Paper Installation
Disconnect machine from
power source.
Proper attachment of the abrasive strips to the
drums is important for achieving top performance
from the sander.
See page 38 for a list of available abrasive strips
with their respective grits and some tips on
choosing the proper strip for a particular job. If
using different size grits simultaneously, always
place the coarser grit on the front drum.
Attach the abrasive paper as follows:
1. Open the hood by removing the handwheel
and turning the two locking handles at the front
counterclockwise.
2. Remove the socket head cap screw and
locking wedge (Fig. 8) from both ends of the
drum.
Note: If the wedge sticks, use a flat head
screwdriver as leverage to free it.
3. Cut a length of the Ready-To-Cut abrasive
strip (14'-9" for the DDS-225, 21'-3" for the
DDS-237). This will be enough to cover one
drum.
Note: The taper on the remaining roll can later
be used for the starting edge of your next strip.
4. Mark and cut a taper at the right end of the
abrasive strip (Fig. 9). Because the tapered
end should use all of the recess at the right
side of the drum, its end must be trimmed back
leaving an edge of about 1/2 inch, as shown.
Now trim the left side of the abrasive paper in
a similar manner (Fig. 10).
Note: An alternate method of tapering the
ends of the abrasive strip is to place the
removed sandpaper strip on top of the new
strip and to use this as a template.
5. Begin at the right end of the drum and tuck the
tapered right end of the abrasive roll into the
recess (Fig. 8). Place the locking wedge into
the recess and tighten firmly with the socket
head cap screw.
6. Begin wrapping the strip around the drum,
keeping it taut as you go. The tapered cut of
the strip should follow the right edge of the
drum. Continue to wrap the abrasive in a
Figure 8
Figure 9
Figure 10
Figure 11

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clockwise spiral fashion by rotating the drum
with your left hand and guiding the strip with
your right hand (Fig. 11). Successive windings
of the strip should be flush with previous
windings without any overlap.
7. The left end of the drum which contains the
recess is an independent piece (Fig. 12) that
can be rotated on the drum. This fastener is
spring-tensioned to take up any slack and hold
the abrasive strip firmly to the drum. Rotate
this fastener backward and hold it there with
your thumb as shown in Fig. 12.
8. Tuck the tapered left end of the strip into the
recess, as shown in Fig. 12, then insert the
locking wedge and socket head cap screw,
tightening the screw until the locking wedge is
firmly seated.
9. Release the spring-tensioned fastener. The
abrasive strip is now ready for use.
10. Repeat this procedure for the other drum.
Adjustments
Drum Height
When using different abrasive grits on the drums,
the height of the drums from the workpiece must
vary. To achieve this, the back drum (which should
always have the finer grit) has been designed for
easy adjustment.
1. Loosen the locking levers (Fig. 13) on both
sides of the machine by rotating them counter-
clockwise.
2. Rotate the adjustment knob to the desired
measurement, using the red triangular
indicator at the base of the dial. A label is
affixed below the locking lever showing the
proper settings. It is also shown in Fig. 14.
3. Repeat this dial setting on the opposite end of
the drum.
Note: It is important that the dial setting be
identical at both ends of the drum.
4. Tighten the locking levers (Fig. 13) by rotating
clockwise, before operating the sander.
Note: The locking levers are spring loaded –
you can move the handle to any position by
pulling out on the lever, rotating it on the hub,
then releasing.
Important: After changing abrasive strips, always
check and, if necessary, reset the back drum
height.
Figure 12
Figure 13
Figure 14