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1. A 1 DS T 48085 223 Cover Base Control Housing pp 1 PA ete 48085 224 Cap ocre 17 5220 05 7 Let 4 480 5 225 Washer Wave 4 48085 145 Flat Washer ba Ar nc 4 PA E 48085 227 Bracket Up Slide 4 2 BO radon 48085 154 4 29 48085 229 RUE ee ee A A IA 1 SO AS 48085 230 UTC 2 A 48085 231 Hex UIT WA Q 2 6 48085 232 Washer Lock Int NT VAE I A ETS 2 OO ER 48085 233 Screw Round Head Slotted 1 4 20x1 3 4 2 S scan 48085 234 Bracket Take ae an 2 48085 167 Lock lt 4 48085 236 BOP Driver vr 1 A 48085 237 Bracket Support Drive 1 48085 238 BEA CON GO 1 9 63505 132 Round Socket Head Cap Screw 5 16 18 3 4 2 402. C CM EUN 8 48085 130 FUMING Sada 2 Olas 480BS 131A BEG EE VE anni oda 1 OZ 48085 132 Handle mener E 1 OO cias 48085 133 Pan Head Machine BXI 2 nes 2 34 48085 195 Warning 2 480BS 135 DUSE Cover Uem 1 SO 48085 196 Height Direction Label o a 1 gt TA 48005 137 Sanding Drum el 1 48085 198 Warne ROW 48085 199 Rotating Direction Label 1 40 48085 183 Motor Cord Motor to 00 1 41 48085 141 Carriage Bolt 1 25 30 4 42 48085 142 Sel SCIEW ee 1 4 285014 4 43 48085 143 Bog SOL octo t oai ien A 2 44 48085 144 Drum Carnage ap NE 1 45 48085 145 Washer dd ooo E d 5 46 48085 146 Round Socket Head 5 2 iaa 48085 147 SENERE LU cre
3. A 4 48085 205 Socket Head Cap Screw 110 32x 1 2 ne 4 Dicens 48085 206 TRACKS AAA PA 2 480BS 207 OU 1 lt A 48085 208 Speed Adjustment Label pp 1 48085 209 Winnog Guard ET 1 480BS 210A CO 1 A sacha 480BS 211A GOntrol 1 9 lt Seed 1 AA 48085 212 Pan Head Self Tapping Screw DSL NIZ nee 2 48085 213 Receptacle Main 1 eos 48085 214 SOOW ee passe 1 48085 215 Washer Lock Int A 2 ica 48085 216 FEN 2 jp PER 480BS 217 Screw Hex Head Slotted 10 32 3 8 5 ua 48085 218 Screw Phil FO BOX 2 2 19 48085 219 A ba 1 e ee 48085 220 Soule Na 1 48085 113 Set Screw V4 20Xx1 4 en 2 BO 480BS 222 Bracket
4. VEE RE EE 48085 189 A MSDS 1 85 48085 190 e ee asien 86 48085 1103 Hex Cap Screw 10 24 1 480BS 1104 HON Aro M 88 48085 1105 Lock Was Neri 89 480 5 1106 fol cc 90 635DS 200 i nins F stener TOO RM NM 48005 13834 alada A OG dos 48005 136 Phillips Flat Head Screw M3SX0 510 ane 48005 138 Flex NU ee WIS Oi ee 2 94 48005 139 Inboard Abrasive Fastener pp 48005 140 Outboard Abrasive Fastener aa ds 96 48085 136 EIGEN anne 4280BS 137 sd A DONC 98 48085 138 STOW EN 4 7 25 26 AX 8 Part List Conveyor And Motor Assembly Index Part No No Description Size Qty AA 48085 201 Gear o dia 190 WG aaa 1 PERDE 48085 194 Strain Relief Signal Cord PO mu 1 aca 48085 203 Pen 1 5 480BS 204
5. E ei perd 48 48085 148 lt siae CREE da 49 480BS 149 Hex Cap Screw w Washer 10 24 3 8 BO 48085 150 DUST COVER asia 48085 151 Sees O2 48085 152 SDIING PR 48085 153 Tension BONE un 54 48085 154 BUSING OMG sad SNE Dcus A80B5 155 eiae Tension Roller Bracket Inner 48085 156 JS FET se Men 480BS 157 Spring Tension POE is a dn DO m de 480BS 158 Tension Roller Bracket Inner 48085 159 Pad Braeket TensiomRholler sois ade 60 48085 160 Packer NN 61 48085 161 Pl scr 62 48085 162 Eae u cc cin cA LR MA A MIRI MA IM MID A LM EE 63 48085 163 PIJTE aS da 64 48085 164 o A a re eon oe ne ER wee eee 65 48085 165 900 AGI ascii ee 48085 166 Round Socket Head Cap LO LOMO ea 48085 167
6. Lock tat tea 68 48085 168 SPANG CEDE 69 48085 169 Nylon Insert Lock Nut VA 2Q rio P 480BS 170 Signal Cord Inverter to Control ig pore 48085 171 Hex Nut w ME 28 n ads ZG0BO 172 Screw Phil Pan Head UA AE aa 48085 173 A o A T4 ss 480BS 174 Hex Cap 516 19X1 1 2 ae ENS 48085 175 Mo nting TCR TO ss 48085 176 TT sse 48085 177 Hex 93 8 4 raa Ji MEM 48085 178 SN id mE 480BS 179 Tension Roller Bracket Outer Right 80 48085 180 Tension Roller Bracket Outer Left Od es 48085 181 EAN 48085 182 oran Signal om on 48085 188 Washer
7. 7 Lol Table 7 Brush Speed Adjustment 8 Changing Brush or Drum 12 Replacing Flatter Strips 14 Replacing Conveyor 19 Hen LP 2 Combo Sander TECHNICAL DATA Parts List For Head Assembly 24 Parts List For Conveyor DC Motor Asse rn 27 Combo Sander Specifications 32 FOR YOUR SAFETY Read all instructions carefully and note the safety cautions on the opposite page and on the back cover of this manual 4 19 38 Drum BrusH OWNERS MANUAL ABOUT THE Combo Sander System This manual is designed to help familiarize you sanding head 2 brush speed control knob which with your Combo sander and to help you take controls brush speed from 200 to 1000 RPM and advantage of exclusive features By understanding drum speed to 1750 RPM 3 a motor starter switch its major components and how they work together which starts and stops the drive motor and sanding you will be able to get the most from your investment brush and 4 a feed rate control knob which starts The Combo sander is basically made up of 1 a feed conveyor and selects feed rate from 0 3 meter per height adjustment handle which raises and lowers the minute Fig 1 Combo sander nomenclature UNPACKING Combo Sander Your 19 38 Combo sander has been shipped mostly assembled from the factory any
8. Rear A 1 48085 308 Fonera 1 9 doses 480BS 309 1 ASOBS223 innan ee V T Pre 2 Vlade 48085 311 Screw ee VMS 2 Viss 480 5 312 NS 1 A 48085 313 EC 1 ER 480BS 314 SOLON e alt ine WA ZOX 2 48085 315 Hex Head 3 8 16 2 1 2 4 is 48085 316 al 4 29 Part List Infeed Outfeed Tables Assembly Optional Index Part No No Description Size Qty A 48085 401 Brack Ob no HUI reto 2 48085 402 Cartage Boll WA 2082 rad 8 48085 403 Hex 3 8 16x1 4 Aca 48085 231 aaa 14 20 8 48085 145 1E E AE 8 Ded 48085 406 TE 2 48085 129 Flat Washer Cj gm ET E 4 31 32 19 38 Combo Owner s MANUAL 19 3
9. 48085 240 Conveyor Rubber Not SHOWN 4 1 41 480BS 204 Flat Washer SAO Mr 1 480 5 242 Flex UL SION DA sten ae 1 48085 243 Slotted Set Screw 8 36 5 16 1 442222 480 5 249 Strain Relief Signal Cord 1 AS o oss 480BS 245 Ss er ue PES eee 2 46 480BS 2406 Hecepidcle Signal Garda 1 A 48085 247 Hex STEN nere 8 48 48085 248 EMG Fio ia LOL TM 1 27 28 Part List Closed Stand Assembly Index Part No No Description Size Qty A 48085 301 Slade s tb Et 2 gatus 480BS 302 Nylon Insert Lock Nut 3 8 4 E PEN 480BS 303 4 480BS 304 Hex 51651 12 SER 48085 204 Washer DI nies E 12 Dnus 480BS 306 BOLOM 1 ER 48085 307
10. SWISS tec Since 1865 Operating Instructions and Parts Manual Combo Brush Drum Sander Model ST 480 BDS M Revision A 1 2012 CE Conformity Declaration Product Brush Drum Sander ST 480 BDS M Article Number 77 830 83001 11 Brand SWISSTEC Manufacturer DKSH Hong Kong Limited 23 F Tower A Southmark 11 Yip Hing Street Wong Chuk Hang Hong Kong On our own responsibility we hereby declare that this product complies with the regulations 2006 42 Machinery Directive 2004 108 EC EMC Directive Electro Magnetic Compatibility 2006 95 EC Low Voltage Directive 2002 95 EC RoHS Directive Reduction of Hazardous Substances designed with consideration of the standards EN ISO 12100 1 ISO 12100 2 EN ISO 13857 349 EN 953 EN 60204 1 EN ISO 13849 1 ISO 11202 EN ISO 14121 1 Technical file compiled by Marcel Baumgartner General Manager Sourcing Technology 2012 1 5 Marcel Baumgartner General Manager Sourcing Technology DKSH Hong Kong Limited 23 F Tower A Southmark 11 Yip Hing Street Wong Chuk Hang Hong Kong Safety Authorized Use The machine is not suitable for wet sanding The proper use also includes compliance with the operating and maintenance instructions given in this manual The machine must be operated only by persons familiar with its operation and maintenance and who are familiar with its hazards The required minimum age must be observed
11. Drum ALIGNMENT Check alignment when using sanding drum After installing sanding drum remove abrasive from drum Using a flat piece of wood or aluminum as a thickness gauge insert it between the conveyor belt and the drum on the right inboard side of the machine Fig GA Lower the sanding head so the drum just contacts the thickness gauge Then holding up the front tension roller check both sides of the drum using the thickness gauge If the drum is not parallel loosen the four socket head cap screws along the outboard edge of the conveyor and raise or lower the conveyor with the adjustment nut to achieve parallel alignment Tighten the four socket head cap screws Fig 6 Checking brush alignment and table height adjustment outboard side Fig 7 Adjusting brush alignment 8 19 38 Drum BrusH OWNERS MANUAL IMPORTANT When using the sanding drum accessory adjust RPM Gauge to drum sanding highest setting turned fully clockwise Only use drum sander at this setting RPM GAUGE The RPM gauge or readout Fig 8 displays the brush speed or rotation The label under the control knob is a guide IMPORTANT The brush heads are to be run between 200 1000 RPM only The sanding drum is to be run at max 1750 RPM only Damage to the machine brush or drum can result from not following this guide Choose proper brush RPM for the best results and type of brush CHECKING CONVEYOR BELT TRACKING Conveyor
12. The machine must only be used in a technically perfect condition When working on the machine all safety mechanisms and covers must be mounted In addition to the safety requirements contained in these operating instructions and your country s applicable regulations you should observe the generally recognized technical rules concerning the operation of machines Any other use exceeds authorization In the event of unauthorized use of the machine the manufacturer renounces all liability and the responsibility is transferred exclusively to the operator Safety General Safety Notes Machines can be dangerous if not used properly Therefore the appropriate general technical rules as well as the following notes must be observed 1 Read and understand the entire instruction manual before attempting assembly operation Keep this operating instruction close by the machine protected from dirt and humidity and pass it over to the new owner if you part with the tool No changes to the machine may be made Daily inspect the function and existence of the safety appliances before you start the machine Do not attempt operating in this case protect the machine by unplugging the main cord Remove all loose clothing and confine long hair Before operating the machine remove tie rings watches other jewelry and roll up sleeves above the elbows 10 11 12 13 14 15 16 17 18 19 2
13. 24 Grit 36 Grit 50 Grit 60 Grit 80 Grit 100 Grit 120 Grit 150 Grit 180 Grit 220 Grit Abrasive planing surfacing rough sawn boards maximum stock removal glue removal Abrasive planing surfacing rough sawn boards maximum stock removal glue removal Surfacing and dimensioning boards trueing warped boards Surfacing and dimensioning boards trueing warped boards Light dimensioning removal of planer ripples Light surfacing removal of planer ripples Light surfacing minimal stock removal Finish sanding minimal stock removal Finish sanding only not for stock removal Finish sanding only not for stock removal Fig 15 Accessing inboard abrasive fastener WRAPPING ABRASIVE STRIPS Proper attachment of the abrasive strip to the drum is critical to achieving top performance from your 19 38 Combo drum sander Abrasive strips do not have to be pre measured end of the roll is first tapered and attached to the left outboard side of the drum Then the strip is wrapped around the drum and the second taper is made for attachment to the right inboard side of the drum To attach a strip to the drum follow the procedure below 1 Mark and cut a taper at one end of the roll as shown in Fig 16 Because the tapered end should use most of the left outboard slot width its end must be trimmed Fig 16B and 16C Raise the clip lever on the left outboard side of the drum Fig 16D Insert the tapered end throug
14. belt tracking adjustments may occasionally be necessary during break in and normal operation to compensate for belt stretching If adjustments are necessary follow the instructions below Belt tracking adjustments are made while the conveyor belt is running With the conveyor unit on and set at the fastest speed setting watch for a tendency of the conveyor belt to drift to one side of the conveyor To adjust the belt tracking tighten the take up screw nut A Fig 9 on the side the belt is drifting toward and loosen the take up screw nut on the opposite Fig 8 Brush RPM gauge side Adjusting the take up screw nuts on both sides of the conveyor allows belt tracking adjustments to be made without affecting belt tension Adjust the takeup screw nuts only 1 4 turn at a time Then allow time for the belt to react to the adjustments before proceeding further to avoid over adjustments NOTE Make sure wrench is below surface when brushing or sanding Fig 9 Hanging wrench 1 012 for tracking conveyor OPERATING Your Combo Sander 9 OPERATING YOUR 19 38 Drum BRrusH Before using your Brush review the previous pages in this manual on initial set up and adjustment In this section you will learn how to operate the machine Note that connecting the machine to an adequate dust collection system is necessary before operating the unit The Brush offers considerable control and versatility through variable brush speed
15. with key on inboard side Tighten set screws in coupler half of head Install rubber spider in coupler half of head Make certain no spider is in coupler half on motor Pivot new head into place by first aligning couplers When pivoting new head in place lower head Tapping on the outboard end of the shaft with a rubber hammer can help seat coupler Caution do not damage bearing when tapping When head is in place install bolts into both bearings and tighten Make sure head is centered in housing and couplers seated If needed slide motor coupler half into new head and tighten set screws Tighten two set screws in each bearing inboard and outboard Make sure all bolts and screws are tight MONTHLY MAINTENANCE For best results perform the following recommended maintenance procedures on monthly basis Lubricate conveyor bushings and check for wear Fig 13 Offset stock feeding angle Lubricate all moving parts such as threaded rods and washers Clean dust from the conveyor belt Blow dust from the motors Check all set screws for tightness Clean brush or drum and abrasives if applicable Tirs For MAXIMUM PERFORMANCE The versatility designed into the 19 38 Combo allows it to be used for wide ranging variety of tasks that will boost the return on your investment Learning to use its multiple adjustments and controls will allow you to fine tune the machine for maximum results regardless of t
16. you get top performance when you put it to work in your shop Regardless of how you take advantage of these innovations we are confident our equipment will help bring you a giant step forward in precision shop productivity ABOUT THE Combo Sander SYSTEM Combo Sander Nomenclature 4 Viper 5 SETTING Your Combo Sander Connecting Dust Collectors 6 Checking For Machine Level 6 Checking Height Adjustment 7 Checking Brush Alignment 7 Checking Drum Alignment y Drum Brush Speed Adjustment 7 EG Cu T A 8 Checking Conveyor Belt Tracking 8 OPERATING YOUR Combo Sander Basic Operating 9 Adjusting Tension y Selecting Stock Feed 10 10 Setting Brush Depth of Cut 11 Setting Drum Depth of 11 Using The Depth 11 Monthly monas 12 Tirs For MAXIMUM PERFORMANCE 12 ABRASIVE SELECTION GUIDE 16 Wrapping Abrasive Strips 17 TROUBLESHOOTING YOUR Combo Sander Troubleshooting Guide Motors 20 Troubleshooting Guide Conveyor 21 Troubleshooting Guide Machine 22 MANUAL CONTENTS 3 SERVICING YOUR Combo Sander Adjusting Height Controls
17. 0 21 22 23 24 Always wear eye protection while operating the sander Wear safety shoes never wear leisure shoes or sandals Always wear the approved working outfit Do not wear gloves Remove jammed work pieces only when motors are turned off and the machine is at a complete standstill Install the machine so that there is sufficient space for safe operation and work piece handling Keep work area well lighted The machine 15 designed to operate in closed rooms and must be placed stable on firm and leveled ground Make sure that the power cord does not impede work and cause people to trip Keep the floor around the machine clean and free of scrap material oil and grease Stay alert Give your work undivided attention Use common sense Do not operate the machine when you are tired Do not operate the machine under the influence of drugs alcohol or any medication Be aware that medication can change your behavior Never reach into the machine while it is operating or running down Never leave a running machine unattended Before you leave the workplace switch off the machine Keep children and visitors a safe distance from the work area Do not operate the electric tool near inflammable liquids or gases Observe the fire fighting and fire alert options for example the fire extinguisher operation and place Dont use in a dangerous environment Dont use the machine in damp or wet locatio
18. 8 Combo Sander Specifications Sanding Capacity Maximum Width Minimum Length Maximum Thickness Minimum Thickness Dimensions Brush Brush Speed Dust Hood Height Adjustment Conveyor Motor Drive Motor Power Requirements Reference Current 960mm two passes 60 to 90mm varies with application 100mm typical varies with brush style amp application 0 8mm typical varies with applications 1070 mm Lx 635 mm W x 1320 mm H 127mm diameter typical Typical bristle length 38mm varies Infinitely variable 200 to 1000 RPM Brush 1750 RPM Drum Hinged back with 100mm vacuum port 1 6mm per revolution Depth Gauge included 50 kg cm torque Direct drive D C motor Infinitely variable 0 3 m min 1 1kW 1 5HP 51 100 230V 1 N PE 50Hz 4 2 1 5 Extension Cord HO7RN F Installation Fuse Protection 10 Net Weight 155 kg Noise Emission Acoustic pressure level EN 11202 Idling In operation 69 7 dB A 84 4 dB The specified values are emission levels and are not necessarily to be seen as safe operating levels As workplace conditions vary this information is intended to allow the user to make a better estimation of the hazards and risks involved only NOTES CAUTION IMPORTANT SAFETY INFORMATION KEEP Tuis MANUAL HANDY For QUICK REFERENCE FOR SAFE SANDING OPERATION FOLLOW THESE GUIDELINES BECOME FAMILIAR WITH THE PROPER OPERATIONAL PROCED
19. 8085 111 LOCK WaSHBE 4 12 48085 112 Socket Head Cap Screw 9 8 16X1 12 i acad tents 4 TO siete 48085 113 SELSCHEW E 14 20014 ana 5 14 48085 114 2 ria 48085 115 GUN SNE NNN 1 TO cc 480BS 116 2116 Pale A 1 Vet 480BS117 iii Screw Phil Pan Head MIO aciei eue oia 11 480 5 118 Label Gauge MNM ad 1 48085 119 Pepin Gauge ESN 1 20 dus 48085 120 KNOB ee a m 1 ZA RT 48085 121 Height Adjustment Handle spend atodos 1 22 ss 48085 122 Nylon Insert Lock Nut A 1 28 48085 123 Height Adjustment Screw pp 1 24 480BS 124 ERINO bete E 1 48085 125 Thrust Bearing pp BTTO sortase 1 2 48085 126 A 1 2f 48085 127 A 4 Pour 48085 128 Hex JE TX 15 1 4 ne 4 29 48085 129
20. ERS MANUAL Fig 16H Allow room inside slot for strip to move Fig 161 Reset take up as needed as strip stretches REPLACING CONVEYOR BELTS To replace the conveyor belt the conveyor assembly must be removed from the machine Raise the drum brush carriage to its highest position using the height adjustment handle Turn off power source to machine Unplug main drive motor and inverter from receptacle in gear motor assembly Loosen the conveyor take up screws Fig 9 to relieve belt tension and slide the driven roller fully inward Remove the two bolts inboard side that attach the conveyor assembly to the base see A Fig 17 Remove the two nuts and washers outboard side B Fig 18 Lift the conveyor and remove it from the sander Stand conveyor on motor side Avoid tearing the belt on any edges underneath the conveyor bed during removal Reverse the procedure for re installation Re install the conveyor bed to sander Conveyor Belt Tension To adjust the tension of the conveyor belt first adjust the take up screw nut Fig 9 on both sides of the conveyor to obtain approximately equal tension on both sides of the belt when taut Insufficient belt tension will cause slippage of conveyor belt on the drive roller during sanding operation The conveyor belt is too loose if it can be stopped by hand pressure applied directly to the top of the conveyor belt Excessive belt tension can result in bent rollers premature wearing of th
21. URES FOR USING THIS MACHINE m ALWAYS BE SAFETY CONSCIOUS WHEN OPERATING THE MACHINE ALWAYS WEAR EYE PROTECTION WHILE OPERATING THE SANDER ALWAYS FEED STOCK AGAINST THE ROTATION OF THE BRUSH DRUM NEVER PLACE HANDS UNDER THE BRUSH DRUM OR DUST COVER NEVER OPERATE WITHOUT ITS DUST COVER OR GUARDS IN PLACE KEEP HANDS AND CLOTHING AWAY FROM OPERATING BRUSH DRUM AND COUPLER ALWAYS MAINTAIN CONTROL OF STOCK TO AVOID KICKBACK KNOW HOW TO PREVENT TT ALWAYS DISCONNECT ELECTRICAL POWER BEFORE PERFORMING SERVICING OR ADJUSTMENT OF THE MACHINE DO MODIFY THIS MACHINE MODIFICATIONS ARE DONE AT THE OWNERS RISK AND ALSO WILL VOID THE MANUFACTURER S WARRANTY FOR CUSTOMER SERVICE AND QUESTIONS ABOUT THE OPERATION OR MAINTENANCE OF THIS MACHINE PLEASE CALL YOUR AUTHORIZED DEALER IMPORTANT BEFORE OPERATING YOUR COMBO SANDER READ THE INSTRUCTIONS IN THIS MANUAL FOR UNPACKING AND SETTING UP YOUR MACHINE
22. and feed rate Experiment with both to find the proper sander performance for a given application Varying the brush speed makes the brush more or less aggressive Too aggressive on the brush may tend to raise the grain or excessively round edges Sometimes it may be better to make two or more passes with a less ageressive brush or setting The brush is rotating against the direction of feed therefore the leading edges of contours will receive more sanding than trailing edges Stock should be reversed on subsequent passes to sand all surfaces Stock may also be fed at an angle to allow more brush penetration on the sides BASIC OPERATING PROCEDURES After you have connected the machine to a dust collection system you are ready to begin to use the sander basic operating procedure for the brush sander is as follows Fig 10 1 Set depth of cut bristle contact page 10 2 Set tension rollers to type of stock being sanded See Tension Roller Adjustment below and Fig 11 Fig 10 Operating controls 3 Start sanding brush and select slow brush speed page 8 Start conveyor and select feed rate page 10 Start dust collector system Feed stock through unit Gradually increase brush speed RPM until the desired finish is achieved Fig 8 To feed stock through the sander rest and hold the stock to be sanded on the conveyor table allowing the conveyor belt to carry the stock into the brush Once the stoc
23. are removed from the machine before turning it on Stand to one side of the conveyor and make sure no one else 15 standing in line with the conveyor while feeding stock into the machine Should a part slip while being fed it may exit the machine at a high rate of speed and can cause injuries to anyone standing directly front of the infeed 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 Use recommended accessories accessories may be hazardous improper Always feed stock against the rotation of the drum or brush Keep your hands clear when feeding parts onto the conveyor The part will be forced down as it begins to feed causing a pinching action between the part and the conveyor bed Never reach into a running machine Turn off sander and disconnect from power before attempting to retrieve parts from within the machine Always maintain control of stock to avoid kickback know how to prevent it 42 Turn off the machine and disconnect from power before cleaning Use a brush compressed air to remove chips or debris do not use your hands 43 Do not stand on the machine Serious injury could occur if the machine tips over Remaining Hazards When using the machine according to regulations some remaining hazards may still exist 1 The moving sanding drum or brush i
24. ce between the conveyor table and the bottom of the sanding brush or drum The sanding head must be parallel to the conveyor bed surface To calibrate the depth gauge loosen the two screws holding the scale Lower the brush or sanding head with abrasive installed until the head touches the conveyor belt Slide the scale to align with the pointer at the 0 mark Tighten the two screws holding the scale An optional DRO digital read out for depth is available Fig 12 This offers the most precise reading of sanded thickness and allows for accurate repeatability of a thickness Great when making parts that must be an exact thickness or when matching a thickness To operate turn ON and select standard inch in or metric millimeter mm Lower drum with abrasive installed until it touches the conveyor belt Press zero button to calibrate smi Fig 12 Depth Gauge and optional DRO 12 19 38 DRUM BRUSH OWNERS MANUAL CHANGING BRUSH HEADS OR DRUM To remove head Unplug sander Loosen two set screws in motor coupler half Loosen two set screws in outboard left bearing Loosen two set screws in inboard right bearing Remove two bolts from outboard bearing and two bolts from inboard bearing Lift and pivot brush or drum from outboard side and pull from motor coupler Use gloves when handling wire brush To install head Install bearings on shaft with set screws loose Install coupler
25. ching of the abrasive strip Important Position the abrasive strip in the slot with sufficient room between the inside of the slot and the tapered end of the strip to allow it to be pulled into the drum as needed Fig 16H Note that not leaving enough space between the strip and the inside of the slot will prevent the take up fastener from operating properly 6 The abrasive strip may stretch enough in use to allow the take up lever to reach its lowest position so it no longer is able to maintain tension on the strip Fig 161 If this occurs it will be necessary to reset the take up lever by raising it pushing the strip end into the slot and then releasing the clip lever Note sandpaper cleaning stick may be used to remove deposits and help extend sandpaper life To use operate the sanding drum with the dust cover open Caution For your own safety always wear eye protection while performing sandpaper cleaning and take all precautions to avoid any contact of hands or clothing with uncovered drums Hold the cleaning stick against the rotating drum and move it along the drum surface It is good procedure to use a shop brush to remove any cleaning stick crumbs from the drums before resuming sanding operations 1 SANDPAPER STRIP ABRASIVE SIDE UP Also see Fig 16 b and Fig 16 c Fig 16 Marking and cutting taper on strip 18 19 38 DRUM BRUSH OWN
26. ck If a line ridge is still visible after adjusting Fast Lever additional adjustments can be made to the initial drum alignment Page 7 T o sand stock narrower than the drum reverse the previous steps making sure the Fast Lever isin the U P position Fig 4B and bolts aretight in flange of conveyor bed on inboard side 15 I4 19 38 Drum BrusH OWNERS MANUAL CHANGING FLATTER STRIPS 19 38 Combo Flatter abrasive strip changing Unplug sander Loosen two set screws from outboard left brush support bearing Fig 14A Remove two carriage bolts from outboard brush support bearing Fig 14B Remove outboard bearing from shaft of brush Remove four screws from end caps of outboard side of brush head Fig 14C Remove two end caps Pull strips of abrasive from outboard side of brush head Remove one strip at a time Replace strips by sliding them into brush head Abrasive side must face up on infeed or front of brush head Fig 14D Note Abrasive side of strips must be oriented so abrasive side contacts top of stock as it passes through sander Replace end caps of brush head and install four screws Reinstall bearing and tighten the two carriage bolts Tighten the two set screws in the bearing to the brush shaft Close dust cover Plug in sander Fig 14A NOTES 15 16 19 38 DRUM BRUSH OWNERS MANUAL ABRASIVE SELECTION GUIDE GRIT COMMON APPLICATION
27. damage has occurred as a result of shipment notify the transportation company as soon as possible and ask them to make an immediate inspection Ask for a damage or loss report Also notify your dealer of any loss or damage during shipment Important To avoid problems and potential damage to the machine please read through the unpacking instructions below before proceeding to set up the machine in your shop Assemble stand or prepare dedicated bench for sander attachment Open Box 1 with main sanding unit Remove cardboard liner Open plastic bag Cut each corner of Box 1 to fold sides flat providing access to sanding unit Fig 2 Remove two wood packing plates from bottom of sanding unit Fig 3 With one or two helpers place sanding unit on stand or bench and attach securely Use bolts from packing plates Install knob to height adjustment handle finger tighten nut to knob Thread stud from knob into hand wheel Fig 4A Tighten nut against handwheel Fig 2 Open plastic remove liner cut box 7 10 ABOUT The Combo Sander System 5 Using handle raise sanding head to high position and remove packing block from under carriage arm and motor if so equipped Fig 4 Remove conveyor from packaging and place on sanding unit The conveyor motor should be near main motor and depth gauge Install two lock washers and two flat washers on studs on outboard side o
28. e bronze bushings or conveyor belt OPERATING Your Combo Sander 19 Conveyor Belt Tracking Belt tracking adjustments are made while the conveyor belt is running After the proper belt tension is obtained see above turn the conveyor unit on and set it at the fastest speed setting Watch for a tendency of the conveyor belt to drift to one side of the conveyor To adjust the belt tracking tighten the take up screw nut Fig 9 on the side the belt is drifting toward and loosen the take up screw nut on the opposite side Adjusting the take up screw nuts on either side of the conveyor allows belt tracking adjustments to be made without affecting belt tension Note Adjust the take up screw nuts only 1 4 turn at a time Then allow time for the belt to react to the adjustments before proceeding further Avoid over adjustments 20 19 38 DRUM BRUSH OWNERS MANUAL TROUBLESHOOTING Any operating problems with the sander will likely occur most often during the period that you are becoming familiar with its components and their adjustments If you are experiencing a problem affecting the machine s brushing performance check the following listings for potential causes and solutions it may also pay to review the previous sections in this manual on setting up and operating your machine TROUBLESHOOTING GUIDE MOTORS PROBLEM Motors do not start Brush motor overloads Conveyor motor oscillates Brush moto
29. e depth of cut decrease brush RPM Use alternate feeding procedure 23 ELECTRIC TO GEAR MOTOR BLACK WIRE BLUE WIRE BROWN WIRE GREEN WIRE PANEL DRUM MOTOR POWER OUTLET 24 Part List Drum Head Assembly Index Part No No Description Size Qty dios 48085 101 GIF 1 5HP 4P 230V 60HZ 3PH 1 ER 480B5 101ME FAN not SHOWN seen 480 5 101 Motor Fan Cover not 1 2 c JUNCUON Box SNOW ae ee 480 5 101 Junction Box Cover not shown 48085 194 Strain Relief Signal Cord 48085 103 Main Cord Inverter to Control 1 4 48085 104 KW SOXSIA iin 2 tociens 48085 105 Nylon Insert Lock Nut A 4 48085 106 F Washer 2 cA a 9 Jones 480BS 107 ONE P 8 o MNT 48085 108 Motor IB 2 1 48085 109 SEC HO 1 seeks 48085 110 Hex Gap STEN shui 5 16 18 1 1 4 6 did estin 4
30. f conveyor Install lock washer and flat washer onto two socket head bolts and install into flange of conveyor bed on inboard motor side Keep support plate in place on inboard side and make sure fast lever is positioned up Fig 4B Tighten all bolts and nuts Fig 4 Secure to stand remove packing block 6 19 38 Drum BrusH OWNERS MANUAL SETTING YOUR Combo Your 19 38 Combo sander was adjusted and aligned at the factory and it has been carefully packed for shipment However because of possible stress during transit the unit should be thoroughly checked before being put to use This section covers the preoperational checks you should make after unpacking and final assembly Unnecessary problems can be avoided if these essential checks are performed before operating Likewise performing the recommended monthly maintenance procedures page 12 will help assure trouble free service CONNECTING Dust COLLECTORS Dust collection is necessary for all models The 19 38 Combo is equipped with one 100 mm diameter dust exhaust port at the top of the cover To attach to your collection system install hose from your collector See Tips For Maximum Performance page 12 of this manual The minimum recommended dust collector capacities is 560m3 h For best results follow the recommendations of the manufacturer of your dust collection equipment NOTE Some applications will require a suitable dust collec
31. g 19 38 DRUM BRUSH OWNERS MANUAL short flat stock only adjust remove the four tension adjusting screws A Fig 11 keeping track of screw penetration into retaining nut Slide rollers in toward drum using retaining nut closest to drum Reinstall four adjusting screws with the same tension or penetration into retaining nut Flat Surfaced Stock Loosen the four socket head screws A Fig 11A holding the tension roller brackets Place stock under brush Lower brush to proper bristle penetration Raise brush two to three revolutions Tighten the four socket head screws Remove stock lower brush head to previous setting when adjusting and brush material Bristle Contact Proper bristle penetration is critical for the best finish and longest brush life Flatter brushes should be set to penetrate between 3 to 6mm into the deepest part of the profile being sanded Nylon brushes should be set to penetrate approximately 1 6mm into the deepest part of the profile being sanded Wire brushes should be set to penetrate 0 8 to 1 6mm into the material being brushed SELECTING BRUSH STOCK FEED RATES Selecting the proper feed rate is essential to proper Brushing and sanding Feed rate controls the duration or dwell time of brushing on the contact area slower feed rate allows more brushing to occur In some instances a slow feed rate and slow brush speed may produce the same result as a fast feed rate and fast br
32. h However even slight offset angle of the stock can provide for more effective sanding brushing on some stock Fig 13 Keeping the Machine Clean For best results make cleaning the machine a regular shop procedure Allowing excess build up of dust and debris can adversely affect performance slippage on the conveyor belt and or the accumulation of material on the brush which can throw off the center of balance Leave the dust collector on when cleaning dust from the drum or brush Also sweep the conveyor belt after cleaning operations If not cleaned the conveyor belt could allow stock to slip during operation Sanding Stock wider than drum T he Fast Lever is very useful when sanding stock wider than the drum Sanding stock wider than the drum may require extra space between the drum and the conveyor along the outboard edge T he extra space helps prevent an overlap line or ridge from developing along the sanded part when it extends beyond the sanding drum The 19 38 sander is equipped with a Fast Lever adjuster mechanism that allows easy changing of the drum alignment in relationship to the conveyor without changing the initial drum alignment operate loosen the two bolts through the flange of the conveyor on the inboard side motor side of the conveyor bed Flip Fast Lever down Fig 4B Tighten the two bolts through theflange of the conveyor bed It is a good idea to test a scrap piece before sanding good sto
33. h the slot and into the fastener so that it uses most of the width of the slot Release the clip lever to securely hold the strip end in the fastener 2 Wrap the strip around the drum being careful not to overlap the windings tapered cut of the strip end should follow the edge of the drum Continue to wrap the abrasive in a spiral fashion by rotating the drum with your left hand and guiding the strip with your right hand Fig 16E Successive windings of the strip should be flush with previous windings without any overlap 3 Mark the trailing end of the strip where it crosses the right inboard end of the drum Fig 16F From this point cut a taper as was done with the starting edge of the strip taper on the remaining roll can be used as the taper for the starting edge of the next strip to be cut OPERATING Your Combo Sander 17 4 With the trailing edge of the strip properly cut rewrap the drum and insert the tapered end through the slot in the right inboard end of the drum Insert the tapered end into the inboard take up fastener Pull up on the clip lever to open the clip and pull the take up lever to the top as shown Fig 16G After inserting the strip end release the clip lever by moving your index finger toward the drum slot This allows the clip to retain the abrasive while holding the take up lever in an up position 5 The take up fastener is designed to automatically take up any slack caused by stret
34. he job to be done best results come from experimenting with different machine adjustments to fit the job at hand Following is listing of useful tips which can help you improve performance of your brush sander Dust Collection When connecting dust collectors remember that straight pipe will not restrict airflow as much as flexible tubing Also Ys and elbows will restrict airflow less than Ts Brushing Multiple Pieces At Once When brushing multiple pieces simultaneously make sure to stagger step the pieces across the width of the conveyor belt This provides better contact with the tension rollers Try to only process multiple pieces of similar thickness If there is significant thickness difference the thinner pieces can slip on the conveyor belt if they do not contact the tension rollers When brushing high stock special care is needed to prevent tipping Brushing Imperfect Stock To avoid personal injury take special care when sanding brushing stock that is twisted bowed or otherwise varies in thickness from end to end If possible support such stock as it is being brushed to keep it from slipping or tipping Use extra roller stands help from another person or hand pressure on the stock to minimize potentially hazardous situations OPERATING Your Combo Stock Feeding Angle Some pieces because of their dimensions will need to be fed into the machine at 90 angle perpendicular to the brus
35. k is halfway through reposition yourself to the outfeed side of the machine to receive and control the stock as it exits the unit NG A TENSION ROLLER ADJUSTMENT Spring loaded infeed and outfeed Tension Rollers B Fig 11 are provided to maintain downward pressure on stock being sanded and to prevent slippage of the stock on the conveyor When properly set the Tension Rollers should engage or raise up about 3mm to accommodate the stock being brushed The Tension Rollers can and must be adjusted to accommodate flat surfaced stock vs highly contoured surface stock Tension Roller height is adjusted as follows Note Make sure brush head is appropriate for application and contact TENSION ROLLER PRESSURE The tension roller pressure is factory set for most applications However the pressure of each roller can be adjusted Caution too little pressure can result in slippage of stock on conveyor belt or kick back Too much tension can cause snipe when drum sanding or not enough lift when sanding profiled material To increase tension turn the tension adjusting screw Fig 11 clockwise revolution at a time To decrease tension turn the adjusting screw counter clockwise 4 revolution at a time TENSION ROLLER PRESSURE The tension rollers are factory set for the most versatile use and longest minimum length approximately 115mm for most applications The rollers can be adjusted closer to the sanding drum when sandin
36. n the work area can cause injury 2 Drawing in trapping hazard by power feed mechanism 3 Squeezing hazard by work piece power outfeed Thrown workpieces can lead to injury Sanding dust and noise can be health hazards Be sure to wear personal protection gear such as safety goggles ear plugs and dust mask Use a suitable dust exhaust system 6 The use of incorrect main supply or a damaged power cord can lead to injuries caused by electricity Congratulations You have made a wise purchasing decision by adding this machine to your tool line up The main purpose in inventing and developing the combo machine you ve purchased was to bring a new dimension of productivity to your shop be it large or small Right from the start our goal is to design and manufacture equipment that is capable of providing you with maximum economy maximum utility and maximum performance Your 19 38 Combo will pay you back many fold in the years ahead by helping you get better results in less time start to finish This tool incorporates a bundle of exclusive features which you will appreciate more every time you use it This Combo sander features a variable brush speed RPM and the exclusive variable speed power feed conveyor system Together they provide you with ultra precise control for a variety of applications Swisstec and 15 dealers are committed to providing you with innovative solutions from selecting the right machine to helping
37. ned 3 Conveyor table not flat and square 4 Conveyor belt worn 5 Drive roller worn or damaged 6 Roller bushings elongated due to excessive weat SOLUTION Align shaft flats of gear motor and drive roller tighten shaft coupling set screws Adjust belt tension page 8 Reduce depth of cut reduce feed rate Reduce depth of cut Lower tension rollers page 9 Reduce feed rate Clean or replace conveyor belt Readjust belt page 8 Readjust Readjust by leveling machine Replace conveyor belt page 19 Replace drive roller Replace bushings 22 19 38 DRUM BRUSH OWNERS MANUAL TROUBLESHOOTING GUIDE MACHINE PROBLEM POSSIBLE CAUSE Brush height adjustment 1 works improperly Knocking sound 1 while running Sniping of wood 1 gouging near end of board 2 Burning of wood 1 melting of finish Gouging of wood 1 Improper adjustment of height control Bearing worn Inadequate support of stock Conveyor drive or driven rollers higher than conveyor bed Feed rate too slow Excessive depth of cut Conveyor belt is too loose Excessive depth of cut Wood slipping on conveyor due to lack of contact SOLUTION Readjust height control Replace bearing Use roller stands to support stock Readjust rollers Increase feed rate Reduce depth of cut decrease brush RPM Adjust belt tension Reduc
38. ns or expose it to rain Wood dust is explosive and can also represent a risk to health Dust from some typical woods particular and from hardwoods like beach and oak 15 classified as a carcinogenic substance Always use a Suitable dust extraction device To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipment such as face or dust masks that are specifically designed to filter out microscopic particles 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Before machining remove any nails and other foreign bodies from the work piece Never operate with the guards not in place serious risk of injury Use a feeding aid if you want to feed short stock into the machine Machine only stock which rests securely on the table Specifications regarding the maximum minimum size of the work piece must be observed Do not machine more than two work pieces at the same time Connection and repair work on the electrical installation may be carried out by a qualified electrician only Have a damaged or cord replaced immediately worn power Replace any torn or worn sanding paper immediately Make machine adjustments maintenance with the machine unplugged from the power source Remove adjusting keys and wrenches Form a habit of checking to see that keys and adjusting wrenches
39. r or conveyor gear motor stalls PossIBLE CAUSE 1 Main power cord unplugged from receptacle 2 Brush motor cord unplugged from receptacle near power feed motor 3 Circuit fuse blown or circuit breaker tripped 1 Inadequate circuit 2 Machine overloaded 1 Motor not properly aligned 2 Shaft collar or bushing worn 3 Drive roller bent 1 Excessive depth of cut SOLUTION Plug in primary power cord Plug in brush motor and inverter cord at receptacle on machine if so equipped Fig 5 Replace fuse or retrip breaker after determining cause Check electrical requirements Use slower feed rate slower brush RPM reduce depth of cut Loosen housing bolts run motor retighten bolts Replace shaft collar or bushing Replace drive roller Reduce depth of cut decrease brush speed reduce feed rate TROUBLESHOOTING Your Combo Sander 21 TROUBLESHOOTING GUIDE CONVEYOR PROBLEM Conveyor rollers run intermittently Conveyor belt slips on drive roller Stock slips on conveyor belt Conveyor belt tracks to one side or oscillates from side to side POSSIBLE CAUSE 1 Shaft coupling loose 1 Improper conveyor belt tension 2 Excessive depth of cut 1 Excessive depth of cut 2 Tension rollers too high 3 Excessive feed rate 4 Dirty or worn conveyor belt 1 Belt out of adjustment 2 Drive or driven conveyor belt rollers misalig
40. s important to use a light contact of the bristle tips Nylon Brushes If a nylon brush brush becomes uneven dressing the tips of bristle brush to maintain uniform brush wear will be a benefit Dressing Instructions Staple or glue a wide sheet of 60 grit sandpaper to a 12mm thick flat wood surface Strips of narrow f sandpaper can also be used Lower the brush so the tips of the bristles contact the sandpaper by 0 8mm Set the conveyor speed to approximately 50 feed rate Pass the abrasive loaded board through the machine until the brush fibers are sharp and even SETTING Drum DEPTH OF CUT Determining the depth of cut is the most IMPORTANT set up procedure before operating a drum sander It may take some experimentation to determine the proper depth of cut given the variables OPERATING Your Combo Sander 11 of abrasive grit type of wood and conveyor feed rate Practicing on scrap before sanding a project can be beneficial A good rule of thumb when sanding is to place the workpiece under the drum and lower the sanding head until the workpiece contacts the drum but the drum can still be rotated by hand When making successive passes lower the sanding head no more than the thickness of the grit abrasive 1 8 1 16 of a turn for 80 grit and less for finer grits Note one revolution of the height adjustment handle moves the sanding head 1 6mm DEPTH GAUGE OPERATION The depth gauge A Fig 12 measures the distan
41. tion equipment ex minimum capacity different sanding materials CHECKING MACHINE For LEVEL Proper leveling of the machine is important to achieve continued maximum performance from the 19 38 Combo Fig 4B FAST Lever UP Fig 5 Sander Components 1 Height Adjustment Handle 2 Brush Speed Knob RPM 3 Depth Gauge 4 Conveyor Adjustment 5 Drum Brush ON OFF Switch 6 Conveyor Table 7 Tension Rollers 8 Drum Brush Carriage Fig 5 HEIGHT DJUSTMENT The brush drum height is controlled by the height adjustment handle Fig 5 Turning the handle raises or lowers the sanding head One revolution of the handle raises or lowers the table 1 6 mm Before operating height adjustment be sure the packing block is removed It is located under the outboard end of the carriage arm Fig 4 Raise drum brush to remove BrusH LIGNMENT The brush must be parallel to the conveyor bed surface Brush alignment can be visually checked by raising the tension rollers Fig 6 to their highest position See Tension Roller Adjustment page 9 and lowering the head so the brush just contacts the conveyor surface Brush contact should be equal across the width of the conveyor Brush misalignment can be corrected by loosening the four cap screws A Fig 7 on the outboard edge of the conveyor and turning the adjustment nut B Fig 7 to bring the conveyor parallel to the brush or drum SETTING Your Combo Sander 7
42. um sanding with RPM adjusted to fastest speed INTELLISAND will automatically adjust the conveyor feed rate if an excess load is detected This prevents excessive gouging reduces the risk of burning and it protects the machine from overload or stalling The red light by the adjustment knob will come on when INTELLISAND 15 operating C Fig 11A When the load is decreased INTELLISAND will automatically increase the feed rate to the pre selected speed INTELLISAND does not engage when brush sanding or if drum sanding at a slower RPM than recommended SETTING BRUSH DEPTH OF CuT CONTACT When a nylon or wire brush is worn and needs changing the bristles will either have fractured and the brush head looks bald or the bristle length has worn and the bristles are too short for effective brushing When an abrasive or cloth brush is worn the brushing material will become smooth or the brush will be considerably smaller in diameter as compared to new Please call your dealer if you have any questions Brush life can vary considerably due to RPM contact type of brush and material being brushed Some types of brush heads some flatter brushes for example will allow changing of the brush material by the operator When using a wire brush for distressing wood slowing brush RPM using light contact and a moderate feed rate generally will give the best finish and longest brush life When using a wire brush on metal it i
43. ush speed variable feed rate control of the conveyor belt adjusts the load on the machine it can be infinitely adjusted for maximum operating Fig 11 Tension rollers and adjustment bracket Fig 11A Tension roller height and depth gauge adjustment performance A faster feed rate allows faster brushing but fewer revolutions of the brush per centimeter of sanding A slower feed rate provides more revolutions of the brush per centimeter of sanding B Fig 114 The best feed rate will depend on a number of factors including type of stock brush depth of cut used and whether the stock is fed directly in line with the conveyor bed or at an angle When testing feed rates begin with a mid range 50 setting and adjust faster or slower depending on conditions and performance Drum SANDING FEED RATES Selecting the proper feed rate is essential to proper finish sanding For finish sanding the best finish is usually achieved with a slow to moderate feed rate after the proper depth of cut has been determined This allows for the most revolutions of the drum per centimeter of sanding When abrasive planning faster feed rates can be used as long as the machine is not over stressed Please note angling stock as it is sanded will allow the most effective stock removal and least loading of the abrasives Feeding stock straight through yields the widest sanding capacity and least noticeable scratch pattern Please note when dr
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