BORMANN PRO BBS1550 Bench Grinder Owner’s Manual

BORMANN PRO BBS1550 Bench Grinder Owner’s Manual

 Safety Instructions

Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference.

Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL.

Warning symbols and definitions

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Danger Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Warning Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Caution Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Notice Addresses practices not related to personal injury.
Caution

Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference.

IMPORTANT SAFETY INFORMATION

General Tool Safety Warnings

Warning

1. KEEP GUARDS IN PLACE and in working order.

2. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on.

3. KEEP WORK AREA CLEAN.
   Cluttered areas and benches invite accidents.

4. 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.

5. KEEP CHILDREN AWAY. All visitors should be kept safe distance from work area.

6. MAKE WORKSHOP KID PROOF with padlocks, master switches, or by removing starter keys.

7. DON’T FORCE TOOL. It will do the job better and safer at the rate for which it was designed.

8. USE RIGHT TOOL. Don’t force tool or attachment to do a job for which it was not designed.
   Table A: RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS
   (120 VOLT)

   NAMEPLATE AMPERES (at full load)| EXTENSION CORD LENGTH
   25′| 50′| 100′| 150′
   0 – 6| 18| 16| 16| 14
   6.1 10-| 18| 16| 14| 12
   10.| 16| 16| 14| 12
   12.1 16-| 14| 12| Do not use.

9. USE PROPER EXTENSION CORD. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating.
   Table A shows the correct size to use depending on cord length and nameplate ampere rating.
   If in doubt, use the next heavier gauge.
   The smaller the gauge number, the heavier the cord.

10. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Nonslip footwear is recommended.
    Wear protective hair covering to contain long hair.

11. ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

12. SECURE WORK. Use clamps or a vise to hold work when practical. It’s safer than using your hand and it frees both hands to operate tool.

13. DON’T OVERREACH. Keep proper footing and balance at all times.

14. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

15. DISCONNECT TOOLS before servicing; when changing accessories, such as blades, bits, cutters, and the like.

16. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off position before plugging in.

17. USE RECOMMENDED ACCESSORIES. Consult the owner’s manual for recommended accessories. The use of improper accessories may cause risk of injury to persons.

18. EVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted.

19. CHECK DAMAGED PARTS. Before further use of the tool, 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.

20. DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of the blade or cutter only.

21. EVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don’t leave tool until it comes to a complete stop.

Technical Data

Grounding Instructions

Warning

TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE CONNECTION READ AND FOLLOW THESE INSTRUCTIONS:

110-120 V~ Grounded Tools: Tools with Three Prong Plugs

1. In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

2. Do not modify the plug provided – if it will not fit the outlet, have the proper outlet installed by a qualified electrician.

3. Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor.
   If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.

4. Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

5. Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug.

6. Repair or replace damaged or worn cord immediately.

7. This tool is intended for use on a circuit that has an outlet that looks like the one illustrated above in 125 V~ 3-Prong Plug and Outlet. The tool has a grounding plug that looks like the plug illustrated above in 125 V~ 3-Prong Plug and Outlet.

8. The outlet must be properly installed and grounded in accordance with all codes and ordinances.

9. Do not use an adapter to connect this tool to a different outlet.

Sander Safety Warnings

For Your Own Safety Read Instruction Manual before Operating Sander

1. Wear eye protection.

2. Support work piece with miter gauge, backstop, or backstop, or backstop, or worktable.

3. Maintain 1/16 inch maximum clearance between table and sanding belt or disc.

4. Avoid kickback by sanding in accordance with the directional arrows.

5. The backstop is a fence near the surface that helps the operator maintain control of the work piece and prevents the work piece from being pulled into the machine. For safety, it must be adjusted very close to the sanding surface.

6. The worktable is the surface mounted close to the sanding surface that the operator rests the work piece against to prevent it from being pulled adjusted very close to the sanding surface.

7. The sanding belt is designed to rotate down towards the table while the disc rotates both up from the table and down towards the table. Sand on the belt with the workpiece in front of the backstop and/or table. Sand only on the downward moving surface of the disc – sanding on the upward moving surface may result in the workpiece being thrown up and towards the operator.

8. Remove Safety Key when the Switch is turned off. Do not leave the Safety Key in the Switch when the tool is not in use.

9. DO NOT OPERATE WITH ANY GUARD DISABLED, DAMAGED, OR REMOVED. Moving guards must move freely and close instantly.

10. The use of accessories or attachments not recommended by the manufacturer may result in a risk of injury to persons.

11. When servicing use only identical replacement parts.

12. Only use safety equipment that has been approved by an appropriate standards agency. Unapproved safety equipment may not provide adequate protection. Eye protection must be ANSI-approved and breathing protection must be NIOSH approved for the specific hazards in the work area.

13. Stay alert, watch what you are doing and use common sense when operating a power tool.
    Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.

14. Industrial applications must follow OSHA guidelines.

15. Maintain labels and nameplates on the tool.

16. Avoid unintentional starting.
    Prepare to begin work before turning on the tool.

17. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.

18. WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities, contains chemicals known [to the State of California] to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

    • Lead from lead-based paints
    • Crystalline silica from bricks and cement or other masonry products
    • Arsenic and chromium from chemically treated lumber

19. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals:
    Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

20. WARNING: Handling the cord on this product will expose you to lead, a chemical known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling.

21. The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

Vibration Safety
This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of vibration-related injury:

1. Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical check-ups to ensure medical problems are not being caused or worsened from use. Pregnant women or people who have impaired blood circulation to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud’s Disease should not use this tool. If you feel any medical or physical symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible.
2. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration related injury.
3. Use tools with the lowest vibration when there is a choice between different processes.
4. Include vibration-free periods each day of work.
5. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work.
6. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately.

SAVE THESE INSTRUCTIONS

Setup – Before Use:

****Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product.

Warning TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:

Turn the Power Switch of the tool off and unplug the tool from its electrical outlet before performing any procedure in this section.
Note: For additional information regarding the parts listed in the following pages, For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual.

Assembly/Mounting

Feet Placement

1. Carefully set the Belt/Disc Sander on its side.
2. Press Rubber Feet (28) over the four corner lips of the Base. See Figure A.
   

Mounting Backing Disc

1. Set the Belt/Disc Sander on its feet.
2. Slide the Backing Disc (5) onto the Drive Axle (54). The Set Screw (6) must face the flat surface of the Drive Axle (54). See Figure B.
   
   

Mounting Fence

1. The Fence (63) fits across the top of the sanding belt to prevent workpiece from moving to the rear when sanding.

2. Align two Tabs on the Fence (63) with two Holes on the top of the Belt End Guard (58). Place Fence tabs underneath the Belt End Guard (58).
   Insert two Machine Screws through Flat Washers and into Holes. Thread Machine Screws into the Tabs on the Fence (63). Note: Use Flat Washers between screw heads and Belt End Guard (58). See Figure C.
   

3. Bolt the Fence (63) to the Belt Support Housing (52) using Bolt (32), Flat Washer (26), and Lock Washer (27).

Functions

Safety Switch
Insert the Safety Key into the Switch. This “Key” is a safety precaution and should remain in the Switch during use and be removed after Switch (31) is turned off and/or any time the Belt/Disc Sander is left unattended or in storage.

Operating Instructions

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product.

Tool Set Up

Warning  TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch of the tool off and unplug the tool from its electrical outlet before performing any procedure in this section.

TO PREVENT SERIOUS INJURREVENT INJURY:
DO NOT OPERATE WITH ANY GUARD DISABLED, DAMAGED, OR REMOVED. 

Mounting Table for Use as Disc Sander
NOTE: The Table (69) may be used as support for both horizontal and vertical applications.

1. Insert the end of Table Bar (72) with Pivot Indicator (70) into the Bar Holder (74). See Figure E.

2. Insert free end of Table Bar (72) into two Mounting Supports on bottom of Table (69). Tighten the two Set Screws. See Figure E

3. Mount the Pivot Indicator (70) tab to the Table (69) using a Hex Bolt (71), Flat Washer (26) and Lock Washer (27). See Figure F.
   

4. Mount Pivot Indicator (70) to the Bar Holder (74) using the Angle Adjusting Knob (75) and Flat Washer (26). Finger tighten. See Figure E and Figure F.

5. Tighten all fasteners. Make sure the Pivot Indicator (70) operates smoothly when the Angle Adjusting Knob (75) is loosened.

6. Slide the Supporting Shaft (76) into Bar Holder (74). Align the flat face of the Supporting Shaft with Set Screws and tighten securely. See Figure G.
   

7. Slide the Supporting Shaft (76) into the hole on side of Machine Body (33) and tighten Bolt (32). See Figure D on page 7.

Mounting Table for Use as Belt Sander

NOTE: The Table (69) may be used for both horizontal and vertical operations.

1. Remove Table from Machine Body (33) by loosening Bolt (32) and sliding Supporting Shaft (76) out.

2. Set the Belt/Disc Sander in vertical position by loosening both Nuts (22). Raise the Belt Support Housing (52).
   When it is vertical, wrench tighten both Nuts (22) securely to prevent the Belt Support Housing (52) from slipping. See Figure H.
   

3. Insert Supporting Shaft (76) into the hole facing the belts and tighten Bolt (32) against flat side of Supporting Shaft (76). See **Figure I.

**

Leveling the table

NOTE: For these instructions and “General Operating Instructions” on following pages, refer to Figure C on page 7 of this manual.

1. Loosen the Angle Adjusting Knob (75) on the Pivot Indicator (70). Place a combination square (not supplied) on the Table (69) so that the combination square touches the sanding disc. If the Table is 90° to the sanding disc, the table is level. Always maintain a maximum of 1/16″ clearance between the Table and the Sanding Disc. Tighten the Angle Adjusting Knob.
2. If the Table is not 90° to the sanding disc pad, loosen the Angle Adjusting Knob and tilt the Table until it is square with the sanding disc. Tighten the Angle Adjusting Knob.
3. Loosen Screw (29) holding the Angle Pointer (73) and adjust it to point to 90°. Tighten the Screw.

Adjusting the Sanding Belt Tracking

1. With the Belt/Disc Sander turned off, manually move the Sanding Belt.
2. If the belt starts moving to the side of either roller, it needs to be adjusted.
3. Turn the Belt Adjustment Knob (49) until the belt rides the centre of the Rear Roller (56) and the Front Roller (44).
4. Move the Sanding Belt manually after adjustment to assure proper alignment.

Mounting Sanding Discs
NOTE: Before using the Sanding Disc the first time, wipe down the Backing Disc with denatured alcohol (shellac thinner). This will clean the surface, leave no residue and assure a secure bond.

1. Remove the Table (69) if it is mounted in front of the Sanding Disc.
2. Peel off old Sanding Disc.
3. Align perimeter of new Sanding Disc over the Backing Disc (5) and press firmly onto the Backing Disc.

Work piece and Work Area Set Up

1. Designate a work area that is clean and well lit. The work area must not allow access by children or pets to prevent distraction and injury.
2. Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing the power cord to possible damage. The power cord must reach the work area with enough extra length to allow free movement while working.
3. Secure loose work pieces using a vice or clamps (not included) to prevent movement while working.
4. There must not be objects, such as utility lines, nearby that will present a hazard while working.

General Operating Instructions

1. Make sure that the Switch is in the off position, then plug in the tool.
2. Insert Safety Key into Switch.
3. Make sure nothing is contacting the Sanding Disc or Belt, then turn on the Switch.
4. When using the Disc Sander, only use the LEFT side of the Sanding Disc (as you face it) to sand. The Sanding Disc turns counter-clockwise and using the right side could cause kickback.
5. Use two hands and hold work piece securely against the fence/table at all times. Press the work piece against the belt/disc to start sanding. Keep the workpiece moving for a better finish.
6. After use, turn off the tool, remove the Safety Key from the Switch, and disconnect from the power supply.
   Clean and store the tool indoors out of children’s reach.

Maintenance and Servicing

****Procedures not specifically explained in this manual must be performed only by a qualified technician.

Warning TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:

Turn the Power Switch of the tool off and unplug the tool from its electrical outlet before performing any procedure in this section.

TO PREVENT SERIOUS INJURY FROM TOOL FAILURE:
Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use.

Cleaning, Maintenance, and Lubrication

1. BEFORE EACH USE, inspect the general condition of the tool. Check for:
   • loose hardware, misalignment or binding of moving parts, cracked or broken parts, damaged electrical wiring, and any other condition that may affect its safe operation.
2. AFTER USE, turn off the tool, remove the Safety Key from the Switch, and disconnect its power supply. Then, wipe external surfaces of the tool with clean cloth.
3. A Dust Port (59) is located on the bottom of the Lower Guard Plate (60). It is held in place with a Screw (61) and can be removed for vacuuming collected dust and sanding residue. Replace the Dust Port after cleaning and tighten Screw.
4. Apply a light coat of paste wax to the Table to make feeding material easier.
5. Use compressed air to blow dust and debris from the Sander and Motor.
6. The Bearings on this Sander are sealed and do not require lubrication.

WARNING! If the supply cord of this power tool is damaged, it must be replaced only by a qualified service technician.

Sanding Belt Replacement

1. Push the Belt Tension Handle (50) forward to loosen the belt.
2. Remove Upper Guard Plate (58) by unscrewing four Screws (7).
3. Remove the Lower Guard Plate (60) by unscrewing the four Screws (7) that hold it to the Belt Support Housing (52).
4. Slide the old Sanding Belt off the Rear Roller (56) and Front Roller (44).
5. Replace with a 4″ X 36″ Sanding Belt with the correct grit for the project you are working on. Note: The larger the grit number, the smaller the grain. Use small numbered grits for cutting and larger for smoothing and finishing.
6. Slide a new Sanding Belt onto Front and Rear Rollers.
7. Replace the Lower Guard Plate and tighten the four Screws securely.
8. Replace the Upper Guard Plate and tighten the four Screws.
9. Push the Belt Tension Handle to the rear to tighten the belt.
10. Before using, manually check the new belt for alignment. See instructions in the “General Operating” section of this manual.

V-Belt Replacement

1. Remove Set Screws (6) and pull off Backing Disc (5).
2. Remove four Screws (11) and Washers (10) from Outer Pulley Cover (9).
3. Once the Outer Pulley Cover is removed, the V-Belt (12) is accessible.
4. Remove the V-Belt using a flat screwdriver (not supplied). Place the tip of the screwdriver between the Motor Pulley (13) and the V-Belt while turning the V-Belt by hand. As it turns, the V-Belt will ride up and out of the Motor Pulley groove. Once off the Motor Pulley, lift the V-Belt off of the Spindle Pulley (14).
5. Place the new V-Belt (12) onto the Spindle Pulley, by using a flat screwdriver (not supplied) as a wedge. Turn the Spindle Pulley and ride the new V-Belt onto the Motor Pulley.
6. Replace Outer Pulley Cover.
   WARNING! If the supply cord of this power tool is damaged, it must be replaced only by a qualified service technician.

V-Belt Tensioning

1. Remove Set Screws (6) and pull off Backing Disc (5).

2. Remove four Screws (11) and Washers (10) from Outer Pulley Cover (9).

3. Loosen four motor mount Nuts (22) and slide the Motor (40) further forward towards Front Roller (44), making sure to pull evenly on the motor.
   While holding the Motor in its current position, tighten the Nuts.

4. Place a straight edge on the faces of the two pulleys to ascertain alignment. Contact surfaces of the pulleys and the straight edge must fully touch. Fully tighten the Nuts.

5. Replace Outer Pulley Cover and tighten Screws and Washers.
   Replace Backing Disc and tighten Set Screws.

Troubleshooting

1. Not plugged in
2. No power at outlet.
3. Safety Key not inserted into Switch.
4. Switch is not turned “ON”.

|

1. Plug in Sander.
2. Check power at outlet and/or circuit breaker.
3. Insert Safety Key into Switch.
4. Turn on the Switch.

Motor slows when sanding|

1. V-Belt too tight.
2. Applying too much pressure while sanding

|

1. Have the V-Belt adjusted by a qualified technician.
2. Use less pressure.

Wood burns while sanding|

1. Sanding disc or belt may be loaded with dirt or debris.
2. Too much pressure.

|

1. Clean or replace disc or belt using instructions in this manual.
2. Use less pressure.

****Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect power supply before service.

Parts List

DISPOSE OF PACKAGING RESPONSIBLY

DO NOT DISPOSE OF ELECTRICAL GOODS IN HOUSEHOLD WASTE

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