Woodpecker KSM9-3000/200 User manual

TRANSLATION OF THE ORGINAL VERSION
WOODPECKER
HOKUBEMA Maschinenbau GmbH
Graf-Stauffenberg-Kaserne, Binger Str. 28 | Halle 120
DE 72488 Sigmaringen | Tel. [phone]
E-Mail: [email protected] | Web: https://www.ichbinwoodpecker.de
Operating Manual
Oscillating Edge Sanding Machines
WOODPECKER KSM9-3000/200 and KSM9-3100/150
Machine Types:
KSM9-3000/200 and KSM9-3100/150

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Table of Contents
1Introduction ................................................................................................................................................... 6
1.1 Legal Notice ............................................................................................................................................................ 6
1.2 Illustrations ............................................................................................................................................................. 6
2Symbols .......................................................................................................................................................... 6
2.1 General Symbols ..................................................................................................................................................... 6
2.2 Symbols in Safety Instructions ................................................................................................................................ 7
3General........................................................................................................................................................... 8
3.1 Target Group and Previous Experience................................................................................................................... 8
3.2 Requirements for the Operators............................................................................................................................. 8
3.3 Accident Prevention................................................................................................................................................ 8
3.4 General Safety Regulations..................................................................................................................................... 9
3.5 Standard Equipment ............................................................................................................................................... 9
3.6 Available Options.................................................................................................................................................... 9
4Safety............................................................................................................................................................ 10
4.1 Basic Safety Instructions ....................................................................................................................................... 10
4.1.1 Application Area and Intended Use............................................................................................................. 10
4.1.2 Usable Sanding Belts ................................................................................................................................... 10
4.1.3 Modifications and Conversions to the Machine.......................................................................................... 10
4.1.1 Residual Risks .............................................................................................................................................. 11
4.1.2 Observe the Environmental Protection Regulations................................................................................... 12
4.1.3 Organisational Measures ............................................................................................................................ 12
4.1.4 Personnel Selection and Qualification - Basic Duties .................................................................................. 13
4.1.5 Training of Personnel .................................................................................................................................. 13
4.2 Safety Instructions for Specific Phases of Operation ............................................................................................ 14
4.2.1 Normal Operation ....................................................................................................................................... 14
4.2.2 Special work within the Scope of Maintenance Work as well as Troubleshooting in the Workflow .......... 15
4.2.3 Safe Work Practices..................................................................................................................................... 15
4.3 Construction-related Safety Devices..................................................................................................................... 16
4.4 Electrical Safety Devices........................................................................................................................................ 16
4.5 Hazardous Areas ................................................................................................................................................... 17
5Machine Data............................................................................................................................................... 18
5.1 Technical Specifications ........................................................................................................................................ 18
5.2 Correspondence in the Case of Service................................................................................................................. 18
5.3 Emission Levels ..................................................................................................................................................... 19
5.3.1 Noise Information ....................................................................................................................................... 19
5.3.2 Noise Emission Values................................................................................................................................. 19
5.4 Workplace Requirements ..................................................................................................................................... 19
5.5 Dimensions ........................................................................................................................................................... 20
5.5.1 KSM9-3000/200 .......................................................................................................................................... 20
5.5.2 KSM9-3100/150 .......................................................................................................................................... 20
6Installation and Connection ......................................................................................................................... 21

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6.1 Check Delivery Conditions .................................................................................................................................... 21
6.2 Transport .............................................................................................................................................................. 21
6.2.1 Unloading with the Forklift Truck................................................................................................................ 21
6.2.2 Setting down with the Forklift Truck........................................................................................................... 21
6.3 Machine Installation ............................................................................................................................................. 22
6.4 Mobile Base (Option)............................................................................................................................................ 22
6.5 Temporary Storage ............................................................................................................................................... 23
6.6 Lashing on a Transport Vehicle ............................................................................................................................. 23
6.7 Connecting the Extraction Unit............................................................................................................................. 24
6.7.1 Automatic Switching of the Extraction (Option) ......................................................................................... 24
6.8 Electrical Connections........................................................................................................................................... 25
6.8.1 Supply Cable and External Fuse Protection................................................................................................. 25
7Machine Overview ....................................................................................................................................... 26
8Machining Possibilities................................................................................................................................. 27
8.1Workpiece Requirements ..................................................................................................................................... 27
8.2 Machining Methods.............................................................................................................................................. 27
8.2.1 Permitted Operations.................................................................................................................................. 27
8.2.2 Improper Operations................................................................................................................................... 27
9Switching the Machine ON and OFF............................................................................................................. 28
9.1 Control Switches ................................................................................................................................................... 28
9.2 Switching ON......................................................................................................................................................... 28
9.3 Switching OFF........................................................................................................................................................ 28
9.4 Emergency Shutdown ........................................................................................................................................... 28
10 Setting up and Adjusting the Machine......................................................................................................... 29
10.1 Mounting, tensioning and replacing the Sanding Belt.......................................................................................... 29
10.2 Height Adjustment of the Table Top..................................................................................................................... 30
10.3 Horizontal Adjustment of the Table Top............................................................................................................... 30
10.4 Adjusting the Inclination of the Sanding Unit ....................................................................................................... 30
10.5 Veneer Sanding Device with Sanding Pad............................................................................................................. 31
10.5.1 Mounting the Veneer Sanding Device......................................................................................................... 31
10.5.2 Disassembly of the Veneer Sanding Device................................................................................................. 31
10.5.3 Calibrating the Veneer Fence (Zeroing)....................................................................................................... 32
10.5.4 Adjusting the Sanding Depth of the Veneer Fences.................................................................................... 32
10.6 Using the Cylindrical Sanding Unit ........................................................................................................................ 33
10.6.1 Preparing the Cylindrical Sanding Unit........................................................................................................ 33
10.6.2 Adjusting the Revolving Turret Head........................................................................................................... 33
10.6.3 Changing the Drum Diameter...................................................................................................................... 34
10.7 Combined Workpiece and Mitre Fence ................................................................................................................ 34
10.7.1 Converting the Fence for high and flat Workpieces.................................................................................... 34
11 Working with the Edge Sanding Machine .................................................................................................... 35
11.1 Machining extra-long Workpieces ........................................................................................................................ 35
11.2 Sanding with the Workpiece Fence....................................................................................................................... 35

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11.3 Angle Machining with inclined Sanding Unit......................................................................................................... 36
11.4 Sanding on the Cylindrical Sanding Unit ............................................................................................................... 36
11.5 Sanding Angles and Chamfers on the Sanding Pad............................................................................................... 37
11.5.1 Sanding Angles on the Sanding Pad ............................................................................................................ 37
11.5.2 Sanding Chamfers on the Sanding Pad........................................................................................................ 37
11.5.3 Sanding off Veneer Protrusions................................................................................................................... 37
12 Troubleshooting ........................................................................................................................................... 38
13 Maintenance and Inspection........................................................................................................................ 39
13.1 Cleaning ................................................................................................................................................................ 39
13.2 Lubrication ............................................................................................................................................................ 39
13.3 Checking the Function of the Emergency Stop Button ......................................................................................... 39
13.4 Checking the Safety Labels.................................................................................................................................... 40
13.5 Readjusting the Turntable..................................................................................................................................... 40
13.6 Taking the Machine out of Operation / Storage ................................................................................................... 40
13.7 Average Situations / Emergencies ........................................................................................................................ 40
14 Electrical Circuit Diagram ............................................................................................................................. 41
15 Options and Accessories .............................................................................................................................. 42
15.1 Sanding Belts for KSM9-3000/200 ........................................................................................................................ 42
15.2 Sanding Belts for KSM9-3100/150 ........................................................................................................................ 42
15.3 Further Options..................................................................................................................................................... 42
16 Disassembly and Scrapping.......................................................................................................................... 43
EU - Declaration of Conformity............................................................................................................................. 44

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List of Figures
Figure 1: Veneer sanding device with sanding pad .................................................................................................................... 6
Figure 2: Name plate................................................................................................................................................................ 18
Figure 3: Working areas ........................................................................................................................................................... 19
Figure 4: Dimensions - KSM9-3000/200................................................................................................................................... 20
Figure 5: Dimensions - KSM9-3100/150................................................................................................................................... 20
Figure 6: Unload with Forklift truck.......................................................................................................................................... 21
Figure 7: Setting down with forklift truck................................................................................................................................. 21
Figure 8: Mobile base components.......................................................................................................................................... 22
Figure 9: Suction nozzle............................................................................................................................................................ 24
Figure 10: Main switch housing................................................................................................................................................ 25
Figure 11: Direction of rotation of the drive drum (top view).................................................................................................. 25
Figure 12: Machine overview - main components ................................................................................................................... 26
Figure 13: Control switches...................................................................................................................................................... 28
Figure 14: Fence locking springs............................................................................................................................................... 29
Figure 15: Lever receptacle (top view)..................................................................................................................................... 29
Figure 16: Tensioning sanding belt........................................................................................................................................... 29
Figure 17: Mounting, tensioning and replacing of the sanding belt......................................................................................... 29
Figure 18: Adjusting the table top and the sanding unit.......................................................................................................... 30
Figure 19: Scale and clamping lever......................................................................................................................................... 30
Figure 20: Handwheel .............................................................................................................................................................. 30
Figure 21: Aggregate inclined by 45°........................................................................................................................................ 30
Figure 22: Insert sanding pad................................................................................................................................................... 31
Figure 23: Receptable on sanding pad ..................................................................................................................................... 31
Figure 24: Centring pin in machine .......................................................................................................................................... 31
Figure 25: Calibrate veneer fences to zero position................................................................................................................. 32
Figure 26: Direction of rotation of the drive drum................................................................................................................... 32
Figure 27: Sanding cover .......................................................................................................................................................... 33
Figure 28: Side table height...................................................................................................................................................... 33
Figure 29: Side turntable height.............................................................................................................................................. 33
Figure 30: Cylindrical sanding components.............................................................................................................................. 33
Figure 31: Fold table to 45° ...................................................................................................................................................... 34
Figure 32: Change sanding drum.............................................................................................................................................. 34
Figure 33: Turret head engaged............................................................................................................................................... 34
Figure 34: Convert fence for flat workpieces ........................................................................................................................... 34
Figure 35: Remove left cover (B).............................................................................................................................................. 35
Figure 36: Open right cover (C) ................................................................................................................................................ 35
Figure 37: Sanding at right angles ............................................................................................................................................ 35
Figure 38: Sanding mitres......................................................................................................................................................... 35
Figure 39: Sanding an inner radius........................................................................................................................................... 36
Figure 40: Sanding an outer radius........................................................................................................................................... 36
Figure 41: Sanding angles on sanding pad ............................................................................................................................... 37
Figure 42: Sanding chamfers on sanding pad.......................................................................................................................... 37
Figure 43: Sanding off veneer protrusions .............................................................................................................................. 37
Figure 44: Align table top ......................................................................................................................................................... 40
Figure 45: Turntable locking pin............................................................................................................................................... 40
Figure 46: Locking bolt adjusting screw ................................................................................................................................... 40
Figure 47: Electrical circuit diagram ......................................................................................................................................... 41
Revisions:
Revision
Editor
Modification
Date
001
AG
Original manual translated
30.05.2022

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1Introduction
The purpose of this document is to acquaint the user with
the edge sanding machine and enable him to use it to the
full extent of its intended capabilities. Additionally it con-
tains important information to operate the machine safely,
properly and economically.
Observance of the manual helps to avoid hazards, reduce re-
pair costs and downtimes and increase the reliability and
service life of the machine.
Furthermore, this operating manual serves to supplement
instructions based on national regulations for accident pre-
vention and environmental protection.
Figure 1: Veneer sanding device with sanding pad
This operating manual must always be available at the place of use of the machine. It must be
read and followed by every person who is assigned to work on the machine, e.g.
•during operation, including set-up, troubleshooting in the work process, removal of pro-
duction waste and maintenance,
•during maintenance (servicing, inspection, repair)
•and/or during transport.)
Apart from the operating manual and the legally binding accident prevention provisions applicable in the country
and place of use, the recognized technical regulations for safe and proper work must also be observed.
1.1 Legal Notice
WOODPECKER is a brand of Hokubema Maschinenbau GmbH. All contents of these operating instructions are
subject to the rights of use and copyright of HOKUBEMA Maschinenbau GmbH. Any reproduction, modification,
further use and publication in other electronic or printed media, as well as their online publication, requires the
prior written consent of HOKUBEMA Maschinenbau GmbH.
1.2 Illustrations
All photos, figures and graphics contained in this document are for illustration and better understanding only
and may differ from the current state of the product. Title photos and general views may also include optional
components and special accessories.
2Symbols
2.1 General Symbols
Symbol
Meaning

Indicates passages within this operating manual that must be particularly observed in order to
prevent malfunctions or damage to the lift table.

Refers to chapters, sections, or figures within this document.

Refers to an external document or a third-party source.

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2.2 Symbols in Safety Instructions
Symbol
Safety Instruction
General danger symbol, which requires the highest attention!
Failure to observe may result in damage to the equipment, serious injury or even death.
Warning of possible danger from forklift traffic!
Non-observance may result in life-threatening injuries.
Warning indicates a possible hazard under suspended loads!
Non-observance may result in life-threatening injuries.
Warning indicates a possible fall hazard!
Non-observance of these instructions may result in serious injuries.
Warning indicates a possible cutting hazard!
Risk of personal injury and possibly additional damage to equipment.
Reference to the obligation to wear protective gloves!
Non-observance of these instructions may result in personal injury.
Reference to the obligation to wear hearing protection!
Non-observance of these instructions may result in personal injury.
Reference to the obligation to wear protective goggles!
Non-observance of these instructions may result in personal injury.
Reference to the obligation to wear a respiratory protection mask!
Non-observance of these instructions may cause breathing difficulties and lung damage.
Reference to the obligation to wear safety shoes!
Non-observance of these instructions may result in personal injury.
Possible dangerous crushing hazard in the area of stationary objects!
Risk of personal injury and possibly additional equipment damage.
Reference to a possible crushing hazard!
Non-observance increases the risk of injury to hands and fingers!
This symbol warns of the dangers of electric voltage!
Failure to observe may result in damage to the equipment, serious injury or even death.
Fire hazard! Do not smoke and do not ignite open fire.
Access for unauthorized persons prohibited!
Risk of personal injury and possibly additional equipment damage.
This safety notice indicates a possible dangerous pull-in hazard!
Wearing loose clothing, jewellery as well as long untied hair is prohibited!
Risk of personal injury and possibly additional damage to property.

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3General
The edge sanding machines KSM9-3000/200 and KSM9-3100/150 are produced according to the current state of
the art and placed on the market as a complete machine. All legal and normative regulations were observed. The
two models are identical in design and operation, but they differ in the following points:
•Version KSM9-3000/200 with a belt length of 3000 mm and belt width of 200 mm.
•Version KSM9-3100/150 with a belt length of 3100 mm and belt width of 150 mm. In addition, this
model has a revolving turret head with three different contact drums (Ø 60, 100 and 120 mm) for more
flexible working on the cylindrical sanding unit.
3.1 Target Group and Previous Experience
This operating manual is intended for the operating and maintenance personnel of the machine. The operating
personnel is to be determined by the operator and must further meet the following requirements:
•Basic technical knowledge (e.g. apprenticeship as carpenter, machine fitter, etc. and/or practice in operat-
ing woodworking machines)
•Reading and understanding these operating and maintenance instructions
In order to acquire the knowledge required to operate this machine, the operator must ensure the following
measures:
•Product training for every operator (also possible external personnel)
•Regular safety instruction
3.2 Requirements for the Operators
•The edge sanding machine may only be operated by trained personnel who have also read this manual.
•Inspection, maintenance, cleaning and repair may only be performed by technical specialists
with product-specific training and mechanical and/or electrical training.
•Specialists with product-specific training are to be commissioned and held responsible for
planning and checking the work.
•The national protective regulations for employees must be observed .
•The operator is responsible for the safe use of the machine.
•The legal minimum age must be observed.
3.3 Accident Prevention
To avoid accidents, the following rules must be observed for operation:
•Prevent unauthorized persons from gaining access to the machine.
•Keep unauthorized persons away from the danger areas.
•Repeatedly inform present other persons about existing residual risks (see section 4.1.3).
•Conduct and record regular training & instruction for persons who must be in the area of the machine.
•New employees must be trained internally to work on a thickener and this training must be documented.

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3.4 General Safety Regulations
In general, the following safety regulations and obligations apply when handling the edge sanding machine:
•The edge sanding machine may only be operated in a technically perfect and clean condition.
•It is prohibited to remove, modify or bypass any protective, safety or monitoring equipment.
•It is forbidden to modify or alter the machine without the written approval of the manufacturer / supplier.
•Faults or damage must be reported to the operator immediately, eliminated without delay and repaired if
necessary.
•For repairs, only original spare parts may be used.
•All protective, safety and monitoring devices must be regularly checked and maintained by the operator.
•Only instructed, trained or qualified persons may work on this machine.
•Maintenance work must be carried out and documented in accordance with the maintenance instruc-
tions.
•After maintenance or repair, the machine may only be started with all protective devices fitted. A respon-
sible person must be defined for this purpose, who checks that the guards have been properly installed.
•For the operation of edge sanding machine, the respective national safety regulations for employees as
well as the national safety and accident prevention regulations apply.
3.5 Standard Equipment
•Veneer sanding device with grooved infeed ruler for sanding overlapped veneers
•Powerful main motor with 4 kW and additional 0.25 kW motor for belt oscillation
•Cylindrical sanding unit with adjustable end table for concave or convex edges
•Revolving turret head
1
with 3 cylindrical sanding drums (ø 60, 100, 120 mm)
•Height adjustable workpiece table (maximum 230 mm)
•Extendable table widening with roller support
•Combined workpiece and mitre fence ± 60°
•Workpiece table with planed surface
•Inclinable sanding unit (maximum 45°)
•Rubber-coated sanding drums
3.6 Available Options
•Switching contact for automatic switching of the extraction system
•Matching sanding belts with different grits
•Mobile base with separate lifting rod
The article numbers can be found in chapter 15 “Options and Accessories”.
1
For constructional reasons, the rotary star turret is only available for model KSM9-3100/150.

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4Safety
4.1 Basic Safety Instructions
Woodworking machines can be dangerous if used improperly. Therefore, observe the safety instructions listed
in this chapter and the accident prevention regulations of your employer's liability insurance association!
The manufacturer accepts no liability for damage and malfunctions resulting from failure
to observe these operating instructions.
4.1.1 Application Area and Intended Use
The edge sanding machines are used exclusively for sanding wood and wood-like materials
(e. g.: fibreboard, chipboard, plywood, laminated and non-laminated boards, plastics, etc.).
This machine is not suitable for sanding metal, mineral materials as well as plastics and
waste wood in which nails, screws etc. may be contained.
The machine may only be operated on a level, firm surface with a minimum load-bearing
capacity of 1,000 kg/m².
Any processing of other materials requires prior consultation with the manufacturer and his approval.
Improper use can lead to danger to persons and to a defect or damage to the machine.
The machine is not suitable for operation outdoors or in potentially explosive environments.
•Permissible ambient temperature: +1 to +40° C
•Permissible humidity: max. 90 %
•Operating altitude: max. 1000 m above sea level
Intended use also includes connecting the machine to an adequately dimensioned extraction system and observ-
ing the operating, maintenance and servicing conditions specified in the operating manual. Any other use is con-
sidered improper and is prohibited.
4.1.2 Usable Sanding Belts
The machine is designed for operation with conventional paper sanding belts. To ensure the quality of the sand-
ing belt in the long term during storage and keeping, it should be stored or kept at a temperature of +5 … +25° C
and a humidity of 50 … 60 %.
•KSM9-3000/200 →belt length = 3000 mm | belt width = 200 mm
•KSM9-3100/150 →belt length = 3100 mm | belt width = 150 mm
You will find suitable sanding belts for your machine in chapter 15 “Options and Accessories”.
4.1.3 Modifications and Conversions to the Machine

Unauthorised conversions and modifications to the machine are strictly prohibited for safety
reasons. This will invalidate the CE declaration of conformity! The manufacturer is not liable
for any resulting damage. The risk for this is borne exclusively by the operator/user.