General International 15-035DC M1 Use and Care Manual
Contents
1. Rotate the wheel half a turn and press the other half of the sanding disc into place as shown in A EMPTYING CLEANING THE COLLECTOR BAG 15 03500 ONLY TURN THE SWITCH TO THE OFF POSITION AND UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE EMPTYING OR REPLACING THE COLLECTOR BAG OR BEFORE PERFORMING ANY MAINTENANCE FINE PARTICULATE DUST IS A CARCINOGEN THAT CAN BE HAZARDOUS TO HEALTH WEAR EYE A RESPIRATO RY PROTECTION DEVICE WHEN EMPTYING CLEANING THE DUST COLLECTOR BAG Using a screwdriver loosen the clamp screw as much as needed C to loosen the belt clamp then unclamp it by pushing in opposite directions as shown in D and remove the bag from the machine Empty the bag or if it is too worn to be used again dis pose of the bag and it s contents and replace with a new bag disposing of the contents in a safe and responsible manner that complies with all local codes and regulations regarding waste disposal lf needed clean the bag by lightly tapping it to get rid of any build up of debris Re install the bag or install a new bag and use the bag clamp to hold the bag securely in place making sure that the clamp is sitting in the groove E 110V CONNECTION ON OFF MOTOR SWISH STARTING WIRING STARTING CAPACITOR ON OFF DUST COLLECTOR MOTOR GOUNDING ON OFF SWITCH DUST COLLECTOR E A Y O SWITCH O MAIN ASSEMBLY 19 035 MAIN ASSEMBLY 19 03900 P2. Lift the red stop switch panel C and remove the lock out pin Lower the stop panel and push the green ON button Wait for the sanding belt disc to reach full speed before sanding To stop the machine Push on the RED STOP panel and wait for the sanding belt disc to come to a complete stop WHEN YOU HAVE FINISHED USING THE MACHINE BE SURE TO RE INSTALL THE LOCK OUT PIN AND UNPLUG THE SANDER FROM THE POWER SOURCE TILTING THE SANDING BELT DISC TABLE BEFORE MAKING ANY ADJUSTMENTS MAKE SURE THAT THE SWITCH IS IN THE OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED To tilt the sanding belt table 1 Loosen table locking handle A 2 Tilt the table to the desired angle as indicated on the bevel scale B Turn the lock knob clockwise to secure the table in position To tilt the sanding disc table 1 Loosen table locking handles C 2 Tilt the table to the desired angle as indicated on the bevel scale D Turn the lock Knobs clockwise to secure the table in position HORIZONTAL VERTICAL SANDING BELT ADJUSTMENT To change the sanding belt from vertical to horizontal position Make sure the sander is turned off and unplugged Using a 10 mm wrench and the supplied 3 mm allen key loosen lock nut A then set screw B Set the sanding head to the horizontal position Re tighten set screw B and lock nut A to secure the sanding head in position Note Belt tracking adjustments may be ne
3. tion Wear protective hair covering to contain long hair and wear non slip footwear Be sure that adjusting wrenches tools drinks and other clutter are removed from the machine and or the feed table surface before operating Keep hands well away from the sanding belts and all moving parts Use a brush not hands to clear away sanding dust Be sure sanding belts are securely installed on the sanding drums Do not operate the sander if the sanding belts are damaged or badly worn Do not push or force the workpiece into the sander The machine will perform better and more safely when working at the feed rate for which it was designed Avoid working from awkward or off balance posi tions Do not overreach and keep both feet on floor Keep guards in place and in working order If a guard must be removed for maintenance or clea ning be sure it is properly re attached before using the tool again Never leave the machine unattended while it is run ning or with the power on Use of parts and accessories NOT recommended by GENERAL INTERNATIONAL may result in equip ment malfunction or risk of injury Never stand on the machine Serious injury could occur if the sander is tipped over or if the sanding drums are unintentionally contacted Always disconnect the tool from the power source before servicing changing accessories or sanding belts or before performing any maintenance or cleaning
4. INSTALL THE SANDER ONTO THE BASE CABINET The sander is mounted onto a base cabinet which provides stor age space for the miter gauge and replacement sanding discs and belts THE SANDER IS HEAVY DO NOT OVER EXERT THE HELP OF AN ASSIS TANT WILL BE NEEDED FOR THE FOLLOWING STEP Position the sanding head over the top of the base cabinet passing the dust collector wire through the hole on the stand A model 15 035DC only Insert the four supplied hex head bolts and flat washers B down through the holes in the base of the sanding head and into the base cabinet C Then open the door and from the inside secure the bolts with four hex nuts and washers using a 14 mm open end wrench and 14 mm sock et wrench ATTACH THE DOOR KNOB CONNECT DUST COLLECTOR WIRE MODEL 15 03506 1 ONLY From the inside insert the door bolt D through the Connect the power cord from the dust collector to the hole in the door into the door knob E as shown inlet plug on the switch in F Tighten the door bolt using a 17 mm open end wrench INSTALL DUST OUTLET MODEL 15 035 M1 ONLY 1 Using a 8 mm open end wrench loosen and remove the 4 nuts located on the left side of the base cabinet A Attach the 4 dust outlet B to the dust chute locat ed inside the cabinet C inserting screws D through the dust outlet mounting holes Secure with the nuts you just removed and firmly tighten the nuts CONNECTING TO A DUST COLLECTOR
5. or if the machine will be left unattended Make sure that switch is in the OFF position before plugging in the power cord Make sure the tool is properly grounded If equip ped with a 3 prong plug it should be used with a three pole receptacle Never remove the third prong Do not use the sander for any purpose other than its intended use If used for other purposes GENERAL INTERNATIONAL disclaims any real or implied war ranty and holds itself harmless for any injury which may result from that use GX ELECTRICAL REQUIREMENTS Z RESULT IN SERIOUS INJURY TO THE USER AS WELL AS DAMAGE TO THE MACHINE IF IN DOUBT CONTACT A QUALIFIED ELECTRICIAN BEFORE CONNECTING THE MACHINE TO THE POWER SOURCE VERIFY THAT THE VOLTAGE OF YOUR POWER SUPPLY CORRESPONDS N WITH THE VOLTAGE SPECIFIED ON THE MOTOR I D NAMEPLATE A POWER SOURCE WITH GREATER VOLTAGE THAN NEEDED CAN d BEFORE CONNECTING TO THE POWER SOURCE THIS TOOL IS FOR INDOOR USE ONLY DO NOT EXPOSE TO RAIN OR USE IN WET OR DAMP LOCATIONS GROUNDING INSTRUCTIONS In the event of an electrical malfunction or short circuit grounding reduces the risk of electric shock to the ope rator The motor of this machine is wired for 220V single phase operation and is equipped with a 3 conductor cord A and a 3 prong grounded plug B to fit a match ing grounding type receptacle C DO NOT MODIFY THE PLUG PROVIDED If it will not fit your recepta cle have the pro
6. Required maintenance Replacement of the sanding belt disc Belt replacement Sanding disc replacement Emptying cleaning the collector bag model 15 035DC only Wiring diagram Parts list a diagrams Contact information RULES FOR SAFE OPERATION To help ensure safe operation please take a moment to learn the machine s applications and limitations as well as poten tial hazards General International disclaims real or implied warranty and holds itself harmless for any injury that may result from improper use of its equipment Do not operate the sander when tired distracted or under the effects of drugs alcohol or any medi cation that impairs reflexes or alertness The working area should be well lit clean and free of debris Keep children and visitors at a safe distance when the sander is in operation do not permit them to operate the sander Childproof and tamper proof your shop and all machinery with locks master electrical switches and switch keys to prevent unauthorized or unsu pervised use Stay alert Give your work your undivided atten tion Even a momentary distraction can lead to seri ous injury Fine particulate dust is a carcinogen that can be hazardous to health Work in a well ventilated area and whenever possible use a dust collector and wear eye ear and respiratory protection devices Do not wear loose clothing gloves bracelets neck laces or other jewelry while the sander is in opera
7. cords that have 3 prong grounding plug and a matching 3 pole receptacle that accepts the tool s plug Repair or replace a damaged extension cord or plug immediately If you find it necessary to use an extension cord with your machine make sure the cord rating is suitable for the amperage listed on the motor I D plate An under sized cord will cause a drop in line voltage resulting in loss of power and overheating The accompanying chart shows the correct size extension cord to be used based on cord length and motor I D plate amp rating If in doubt use the next heavier gauge The smaller the number the heavier the gauge TABLE MINIMUM GAUGE FOR CORD TOTAL LENGTH OF CORD IN FEET AMPERE 110 VOLTS 25 FEET SOFEET 100 FEET 150 FEET RATING 220 VOLTS 50 FEET 100 FEET 200 FEET 300 FEET I NR Not Recommended 6 x 48 BELT amp 12 DISC SANDERS 15 035 15 035DC IDENTIFICATION OF MAIN PARTS AND COMPONENTS BELT TRACKING ADJUSTMENT SANDING BELT K STAND F SANDING DISC G BELT GUARD L DUST COLLECTOR SWITCH H MITER GAUGE DISC TABLE LOCK KNOB 1 BELT SANDER WORK TABLE M BELT TENSION LEVER DUST HOSE J MACHINE BASE MAIN ON OFF SWITCH 15 035DC ONLY The switch panel shown is for 15 035DC Model 15 035 is equipped with a large stop panel style switch see A on page 8 BASIC FUNCTIONS This machine has been designed for sanding or polishing removing kerf or pencil marks on small w
8. in the both the sanding belt and sand ing disc table slot as shown in A and can be set to any angle up to 30 to the left or right B To use a setting other than 90 loosen the handle C by turning it counterclockwise Rotate the miter head to the required angle shown on the angle indicator Then turn the handle clockwise to tighten it CENTER POINT A center point A is supplied with the sander for sanding cir cles B The center point slides into the miter slot that is perpendi cular to the sanding disc and must be positionned according to the radius of the workpiece Slide the center point along the miter slot C to the dis tance that matches the size of the workpiece Lock the center point in position by tightening the set screw D using the supplied 3 mm Allen key Place the center of the workpiece on the center point s pin E Turn the sander on and manually rotate the workpiece against the sanding disc until achieving desired results ADJUSTING THE 90 AND 45 BEVEL STOPS SANDING BELT TABLE BEFORE MAKING ANY ADJUSTMENTS MAKE SURE MN THAT THE SWITCH IS IN THE OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED The sanding belt operates at any angle from horizon tal to vertical with positive stops at 90 and 45 These stops are factory set However with use and vibration over time they evantually may need minor adjust ments 1 Make sure that the sander is turned off and
9. our commit ment fo quality and customer satisfaction General International agrees to repair or replace within a period of 24 months from date of purchase any genuine part or parts which upon examination prove to be defective in work manship or material In order to obtain this warranty all defective parts must be returned freight pre paid to General International Mfg Co Ltd Repairs attempted without our written authorization will void this warranty Disclaimer The information and specifications in this manual pertain to the unit as it was supplied from the factory at the time of printing Because we are committed to making constant improvements General International reserves the right to make changes to components parts or features of this unit as deemed necessary without prior notice and without obligation to install any such changes on previously delivered units Reasonable care is taken at the factory to ensure that the specifi cations and information in this manual corresponds with that of the unit with which it was supplied However special orders and after factory modifications may render some or all information in this manual inapplicable to your machine Further as several generations of this model of sander and several versions of this manual may be in circula tion if you own an earlier or later version of this unit this manual may not depict your machine exactly If you have any doubts or questions contact your
10. retailer or our support line with the model and serial num ber of your unit for clarification GENERAL amp GENERAL INTERNATIONAL WARRANTY All component parts of General General International and Excalibur by General International products are carefully inspected during all stages of production and each unit is thoroughly inspected upon completion of assembly Limited Lifetime Warranty Because of our commitment to quality and customer satisfaction General and General International agree to repair or replace any part or component which upon examination proves to be defective in either workmanship or material to the original purchaser for the life of the tool However the Limited Lifetime Warranty does not cover any product used for pro fessional or commercial production purposes nor for industrial or educational applications Such cases are covered by our Standard 2 year Limited Warranty only The Limited Lifetime Warranty is also subject to the Conditions and Exceptions as listed below Standard 2 Year Limited Warranty All products not covered by our lifetime warranty including products used in commercial industrial and educational applications are warranted for a period of 2 years 24 months from the date of purchase General and General International agree to repair or replace any part or component which upon examination proves to be defective in either workmanship or material to the original purchase
11. un plugged 2 Place a combination square on the table against the sanding belt as shown in A to verify the 90 angle of the table If needed loosen the table locking lever B then adjust the table to 90 to the sanding belt Tighten locking lever B to lock the table in position ADJUSTING THE 90 STOP SANDING DISC TABLE With the table set to 90 verify and if needed adjust the 90 stop as follows Loosen lock nut C using a 8 mm wrench Adjust set screw D using a 2 5 mm allen key uniil the screw sits on the stop E Re tighten lock nut C With the table set to 90 the bevel pointer might need to be adjusted Proceed as follows Loosen the screw F on the pointer mounting bra cket and manually align the pointer with the zero on the bevel scale G then re tighten the screw ADJUSTING THE 45 BEVEL STOP Verify the 45 setting by tilting the table down as far as possible and using a combination square check the angle If needed adjust as for the 90 stop this time using the lower stop screw H The sanding disc table can be tilted from 0 to 45 to the front and from 0 to 10 to the rear with a positive stop at 90 This stop is factory set However with use and vibration over time it evantually may need minor adjustments BEFORE MAKING ANY ADJUSTMENTS MAKE SURE THAT THE SWITCH IS IN THE OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED 1 Make sure that the sander is turned off
12. wrench loosen and re Using a large flat head screwdriver loosen and re move stud E then remove washer F and the table move pan head screw A and trunnion assembly G Note For stop installation the stud has to be re installed Re install the toothed nut D on the stud Slide the backstop holder J onto stud with toothed 5 Re install the washer F then re install the stud as nu a d secure in place using the previously re shown above threading its longer end in the sand moved handle C spring B and screw A with it s longer end threaded in as shown above Loosen and remove bolt K and washer L from the Loosen the locking handle and adjust the posi backstop M tionning of the workpiece stop up or down along i i the workpiece stop holder making sure it clears Place the workpiece stop against the workpiece y stop holder and use the washer and bolt to secure the sanding belt then re tighten the locking han in place as shown in N dle Tip Use 2 flat washers 3 mm thick approx placed under the workpiece stop O as a reference for appropriate clear ance hi For table installation the stud is installed with the For stop installation the stud has to be removed shorter end threaded in as shown above and re installed with the longer end threaded in as shown above BASIC ADJUSTMENTS amp CONTROLS CONNECTING TO A POWER SOURCE TO REDUCE THE RISK OF SHOCK OR FIRE DO NOT OPERATE THE U
13. 12 30 210 1x8x17L 12 5X17 35x23x10 M6 x10L 165x131 100x15 A3 1 CE 2 6x14 5 16x4 5 16x15x2T 5 16 3 8x1 1 4 3 8 3 8x19x2T 5 16x3 4 5 16x18x2T 5 16 16UF 350V 32MM 4P 3 16x3 8 ACC2 5 M6x25 M 7 16 X 3 371 5 X 159 M3x140L M4 J S S S J Jp I AT AT AT pol po p Ao AP ni a a a AP gt a In ini n al rm PARTS LIST 15 035 15 035DC M1 PART NO DESCRIPTION SPECIFICATION 15035DC 168 WASHER M5 15035DC 169 SPROCKET WASHER 15035DC 170 BELT POINTER 15035DC 171 SCREW 3 16 X 3 8 15035DC 172 FLAT WASHER 15035 173 SWITCH PLATE 15035 174 CLOSED STAND 15035 175 PHILLIPS HEAD SCREW 3 16 X 1 2 15035 176 PHILLIPS HEAD SCREW 3 16 X 1 4 15035 177 SWITCH ASS Y GENERAL STOPPER 15035 178 DUST CHUTE YW1075 15035 179 DUST HOSE 4 X 300 MM 15035 180 DUST HOSE CLAMP 4 X 1 4 15035 181 HEX NUT 3 16 15035 182 PHILLIPS HEAD SCREW 15035 183 HEX NUT 15035 184 STOP PLATE 15035 185 SWITCH COVER 15035 186 ON OFF SWITCH ni nia tro wo a a MODELS 15 035 15 035DC 8360 Champ d Eau Montreal Quebec Canada HIP 1Y3 Tel 514 326 1161 Fax 514 326 5565 Parts amp Service Fax 514 326 5555 Order Desk orderdesk general ca www general ca IMPORTANT
14. 150 Grit 15 039 12 Sanding Disc 150 Grit or depending on availability from your local tool abrasives or sharpening supply dealer These are standard sizes that should be readily available in most areas The use of any other size is not recommended and can lead to seri ous injury and or damage to the machine Replace an installed worn sanding belt disc as follows BELT REPLACEMENT Make sure the sander is turned off and unplugged Loosen and remove both bolts on the guard A and remove the upper guard B Loosen and remove both lower guard phillips head screws C and remove the lower guard D Push the belt tension lever E up to release the tension on the belt and remove the belt Tip To extend belt life and avoid premature breakage take note of the direction arrows F printed on the inside of the sanding belt to make sure you install the belt in the correct direction 5 Install a new sanding belt on the rollers paying atten tion to the direction of the arrows then pull the ten sion lever down G to tension the belt on the rollers and re install the upper and lower guards Note Belt tracking adjustments may be necessary after changing or replacing a sanding belt SANDING DISC REPLACEMENT 1 Make sure the sander is turned off and unplugged 2 Remove the worn sanding disc from the wheel 3 Remove the protective sheet from the new sanding disc and carefully adhere one half of the disc to the wheel
15. 5 035DC only are al ready installed ADDITIONAL REQUIREMENTS FOR SET UP Extra person for help with lifting Phillips head screwdriver Large flat head screwdriver 14mm Hex socket 14 mm open end wrench 17 mm open end wrench 10 mm open end wrench 8 mm open end wrench a 2 5 mm Allen key II Combination square vA Mf PLACEMENT WITHIN THE SHOP ESTABLISHING A SAFETY ZONE SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COM PLETED THE INSTALLATION AND ASSEMBLY STEPS DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO d PLACEMENT WITHIN THE SHOP This machine should be installed and operated only on a solid flat and stable floor that is able to support the weight of the machine and the operator Using the dimensions shown as a guide line plan for placement within your shop that will allow the operator to work unen cumbered and unobstructed by foot traf fic either passing shop visitors or other shop workers or other tools or machin ery ESTABLISHING A SAFETY ZONE For shops with frequent visitors or multiple operators it is advisable to establish a safety zone around shop machinery A clearly defined no go zone on the floor around each machine can help avoid accidents that could cause injury to either the operator or the shop visitor It is advisable to take a few moments to either paint
16. ART NO 15035DC 01 15035DC 02___ MOTOR COVER RH 15035DC 03___ MOTOR COVER LH 15035DC 04 15035DC 05 15035DC 06 15035DC 07 15035DC 08 15035DC 09 15035DC 10 15035DC 1 1 15035DC 12 15035DC 13 15035DC 14 15035DC 15 15035DC 16 15035DC 17 15035DC 18 15035DC 19 15035DC 20 15035DC 21 15035DC 22 15035DC 23 15035DC 24 15035DC 25 15035DC 26 15035DC 27 15035DC 28 PARTS LIST 15 035 15 035DC M1 DESCRIPTION MOTOR HOUSING STATOR ROTOR SHAFT DISC GUARD SANDING DISC PLATEN BELT FRAME BASE BELT PLATE BELT PLATE BRACKET UPPER WHEEL BRACKET BELT COVER UPPER WHEEL BRACKET UPPER WHEEL GUARD UPPER WHEEL SHAFT SHAFT BRACKET QUICK ADJUSTING BEARING UPPER WHEEL ALUM SHAFT BRACKET UPPER WHEEL ADJUSTING SPRING LOWER WHEEL GUARD LOWER WHEEL ALUM BELT TABLE BELT TABLE BRACKET DISC TABLE ANGLE SLIDE RH SPECIFICATION 4P 17x220 28x170 57 8x42x16 6203 3 1 2 70x26x8 4 5x30x60 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15035DC 29 ANGLE SLIDE LH 15035DC 30___ ANGLE BRACKET RH 15035DC 31___ ANGLE BRACKET LH HOLE _ 15035DC 32 15035DC 33 15035DC 34 15035DC 35 15035DC 36 15035DC 37 15035DC 38 15035DC 39 15035DC 40 15035DC 41 15035DC 42 15035DC 43 15035DC 44 15035DC 45 15035DC 46 15035DC 47 15035DC 48 15035DC 49 BALL RED 3 8 15035DC 50 15035DC 51 15035DC 52 15035DC 53 15035DC 54 15035DC 55 15035DC 56 KNOB 12 SANDI
17. C 139 15035DC 140 15035DC 141 15035DC 142 15035DC 143 15035DC 144 15035DC 145 15035DC 146 15035DC 147 15035DC 148 15035DC 149 15035DC 150 15035DC 151 15035DC 152 15035DC 153 15035DC 154 15035DC 155 15035DC 156 15035DC 157 15035DC 158 15035DC 159 15035DC 160 15035DC 161 15035DC 162 15035DC 163 15035DC 164 15035DC 165 15035DC 166 15035DC 167 PARTS LIST 15 035 15 035DC M1 DESCRIPTION PHILLIPS HEAD SCREW W WASHER CONDENSER FIXTURE PHILLIPS HEAD SCREW W WASHER DUST MOTOR SPRING PIN SPRING PIN SPRING FLAT DUST HOSE 6 x 48 SANDING BELT POWER CORD MALE POWER CORD FEMALE DOUBLE ROUND PIN DUST HOSE CLIP TERMINAL BLACK TERMINAL WHITE ROUND HEAD PIN INDICATOR FIXED BOLT DUST BAG CLAMP ADJUSTING SPRING SMALL WAVE WASHER BRACKET OF UPPER SHAFT STOP SCREW SWITCH LABEL ARROW LABEL TERMINAL TERMINAL SPRING PIN HEX SCREW FLAT WASHER HEX NUT TELESCOPIC HEX SCREW LOCK WASHER FLAT WASHER HEX SCREW FLAT WASHER LOCK WASHER CONDENSER CENTRIFUGAL SWITCH SET PHILLIPS HEAD SCREW W WASHER CLIP STOP SCREW HEX NUT BACKSTOP BACKSTOP HOLDER HEX HEAD BOLT GRAPHITE DUST MOTOR LABEL RUBBER SEAL ALLEN KEY ALLEN KEY SCALE BASE PIN L BRACKET SPECIFICATION 3 1 x1 4 300UF 125V 34MM MIDDLE OPEN 3 16x1 4 6x40 6x50 3 16 2 1 2x750 SEE PAGE 17 FOR COMPLETE LIST SJT16x3Cx1 75 SJT16x3Cx1 8 75 5x5x67 70 16Ax105 1 H 16 105 1 4 4 15
18. ING PIN HALF CIRCLE KEY DOUBLE ROUND HEAD PIN TOOTH NUT 6206 1 4x3 4 1 4x16x2 M5x10 3 16x1 4 M5 M5x30 4x12 5x5x32 15035DC 87 HANDLE 15035DC 88 HANDLE SPRING 15035DC 89 ALUM SCREW 15035DC 90 FLAT WASHER 5 16x18x2 15035DC 9 1 HEX SCREW 5 16x1 15035DC 92 TERMINAL 73B 15035DC 93 TELESCOPIC SCREW 1 4x1 2 15035DC 94 SWITCH BIG 4P 15035DC 95 SWITCH SMALL 4P 15035DC 9 BASE PLATE 15035DC 97 PHILLIPS HEAD SCREW W WASHER 3 16x3 8 15035DC 98 NYLON SCREW M10 15035DC 99 PHILLIPS HEAD SCREW W WASHER 3 16x1 2 15035DC 100 POWER CORD SJT14x3Cx2M 105 15035DC 101 ANGLE LABEL 15035DC 102 SLIDING BLOCK 15035DC 103 SCREW 1 4x1 2 15035DC 104 CENTER POINT 1 4x1 2 15035DC 105 MITRE GAUGE 15035DC 106 HEX ADJUSTING BOLT 15035DC 107 SPRING CLIP 15035DC 108 PHILLIPS HEAD SCREW 3 16x1 4 15035DC 109 SPECIAL BOLT 15035DC 110 ROUND HEAD KNOB 3 8 15035DC 111 WIRE PLATE MIDDLE 15035DC 112 WIRE RETAINER 8R 1 1 6 2 1 1 2 2 1 4 4 1 1 2 1 1 1 7 3 2 2 2 2 1 1 2 2 2 2 1 1 1 1 1 3 3 2 4 1 1 mmm J SS SS S P F PART NO 15035DC 113 15035DC 114 15035DC 115 15035DC 116 15035DC 117 15035DC 118 15035DC 119 15035DC 120 15035DC 121 15035DC 122 15035DC 123 15035DC 124 15035DC 125 15035DC 126 15035DC 127 15035DC 128 15035DC 129 15035DC 130 15035DC 131 15035DC 132 15035DC 133 15035DC 134 15035DC 135 15035DC 136 15035DC 137 15035DC 138 15035D
19. MODEL 15 035 M1 ONLY OPERATING THIS SANDER WITHOUT ADEQUATE DUST COLLECTION CAN LEAD TO EQUIPMENT MALFUNCTION OR DANGEROUS SITUATIONS FOR THE OPERATOR OR OTHER INDIVIDUALS IN THE WORKSHOP AN DO NOT OPERATE THIS SANDER WITHOUT AN ADEQUATE DUST COLLECTION SYSTEM PROPERLY INSTALLED AND RUNNING h The 4 diameter dust outlet allows for connection to q dust collector not included Be sure to use appropriate sized hose and fittings not included and check that all connections are sealed tightly to help minimize airborne dust Note Minimum recommended dust collection CFM require ments for this sander is 1100 CFM If you do not already own a dust collection system consid er contacting your General International distributor for information on our complete line of dust collection systems and accessories or visit our Web Site at www general ca ALWAYS TURN ON THE DUST COLLECTOR BEFORE STARTING THE SANDER AND ALWAYS STOP THE SANDER BEFORE TURNING OFF THE DUST COLLECTOR BUILT IN DUST COLLECTOR MODEL 15 035DC M1 ONLY Model 15 0035DC is equipped with a built in dust collector connected to the sanding head A to allow for direct dust extraction A collector bag is supplied and already installed inside the base cabinet B USING THE MITER GAUGE The supplied miter gauge allows for easier and safer sand ing by providing workpiece support when sanding straight 90 or angled ends 0 to 30 The miter gauge rides
20. NG DISC DUST CHUTE DISC GUARD SWITCH PLATE FIXING RING CLOSED STAND DOOR PLATE FAN HOUSING DUST BAG KNOB C RING QUICK ADJUSTING FIXED BOLT CRING SPRING PIN HANDLE LONG STOP SCREW HEX SCREW LOCK WASHER HEX SCREW LOCK WASHER TELESCOPIC SCREW FLANGE WASHER 7 16 SEE PAGE 17 FOR COMPLETE LIST 2 1 2 200x600x5 1 4x5 8 C 17 C 26 5x30 3 8x180 M8x25L 1 4x5 8 1 4 5 16x3 4 5 16 5 16x1 1 4 Ja S a 15035DC 57 15035DC 58 15035DC 59 15035DC 60 15035DC 61 PARTS LIST 15 035 15 035DC M1 DESCRIPTION HEX NUT PHILLIPS HEAD SCREW FLAT WASHER POINTER LOCK WASHER SPECIFICATION 1 1 4x1 M10x25 3 16 15035DC 62 PHILLIPS HEAD SCREW 3 16x1 4 15035DC 63 BRACKET ADJUSTING SCREW 15035DC 64 BRACKET ADJUSTING SCREW DITCH 15035DC 65 LOCK WASHER 5 16x18 15035DC 66 HEX SCREW 5 16x5 8 15035DC 67 PHILLIPS HEAD SCREW W WASHER 3 16x3 8 15035DC 68 BEARING 6003 15035DC 69 BALL 1 2 15035DC 70 LOCK KNOB 1 4x2 1 4 150350 71 HEX NUT 1 4 15035DC 72 BELT COVER BRACKET 15035DC 73 PHILLIPS HEAD SCREW W WASHER 3 16x3 8 15035DC 74 PHILLIPS HEAD SCREW W WASHER 3 16x3 8 15035DC 75 15035DC 76 15035DC 77 15035DC 78 15035DC 79 15035DC 80 15035DC 81 15035DC 82 15035DC 83 15035DC 84 15035DC 85 15035DC 86 BEARING HEX SCREW FLAT WASHER STOP SCREW ADJUSTING PLATE PHILLIPS HEAD SCREW W WASHER HEX NUT STOP SCREW SPR
21. NIT WITH A DAMAGED POWER CORD OR PLUG INTERRUPTEUR EN REPLACE DAMAGED CORD OR PLUG IMMEDIATELY POSITION D ARR T TO AVOID UNEXPECTED OR UNINTENTIONAL START UP MAKE SURE THAT THE POWER SWITCH IS IN THE OFF POSITION BEFORE CONNECTING TO A POWER SOURCE Once the assembly steps have been completed uncoil the power cord and plug into an appropriate outlet Refer back to the section entitled Electrical Requirements and make sure all requirements and ground ing instructions are followed When sanding operations have been completed turn off and unplug the sander from the power source ON OFF POWER SWITCH WITH SAFETY KEY MODEL 15 03500 ONLY el SAFETY KEY PREVENTS START UP WHEN REMOVED The 15 035DC is equipped with 2 ON OFF power switch start the machine insert the safety key 1 es with a removable lock out safety key one for the and lift the switch up 2 sanding belt disc motor A and one for the built in dust stop the machine push the switch down 3 collector motor B TO PREVENT UNWANTED OR UNAUTHORIZED START UP OR USAGE REMOVE THE LOCK OUT KEYS AND STORE THEM IN A SAFE PLACE OUT OF THE REACH OF CHILDREN WHENEVER THE SANDER IS NOT IN USE ON OFF SWITCH amp SAFETY PIN MODEL 15 035 ONLY The ON OFF switch assembly on the 15 035 is equipped with a lock out safety pin A When the pin is installed through the green on button B the machine cannot be started To start the machine
22. SETUP amp OPERATION MANUAL SANOS 6 X 48 BELT amp 12 DISC SANDERS Built in dust collector on model 15 035DC only Combination 6 x 48 belt sander Y and 12 disc sander Heavy duty enclosed cabinet pro tects motor from sanding dust Two large surface cast iron tilting tables for unlimited sanding opera tions Sanding belt operates at any angle from horizontal to vertical with posi tive stops at 90 and 45 Quick change belt tension lever for faster belt changes Handles all finishing operations including sanding polishing grind ing surfacing and cleaning Safety switch with key prevents unit from being started when key is removed Precision aluminum miter gauge included BELT SIZE 6 X 48 152 X 1220 MM DISC SIZE 12 305 MM BELT SPEED 2250 LIN FPM 686 LIN MPM DISC SPEED 1750 RPM BELT TABLE TILT 0 TO 45 DISC TABLE TILT 45 OUT amp 10 IN 15 0350 BELT POSITION HORIZONTAL VERTICAL DISC BACK PLATE CAST IRON q DUST CHUTE OUTLET BELT I nol FI5 035 BASE DIMENSIONS 15 3 4 X 22 400 X 559 MM 15 025DC Mi MOTOR PREWIRED 220V 1 1 2 HP 110 220 V 13 6 5 A MOTOR DUST COLLECTOR 15 035DC ONLY 1 4 HP 110 220 V 3A 1 5A WEIGHT 365 LBS 166 KG VERSION 2 REVISION 1 AUGUST 28 12 COPYRIGHT GENERAL INTERNATIONAL 08 2012 GENERAL INTERNATIONAL 8360 Champ d Eau Mon
23. and unplugged 2 Place a combination square on the table against the sanding disc as shown in A to verify the 90 angle of the table Note The square must not touch the wheel cover only the sanding disc 3 If needed loosen both lock Knobs then adjust the table to 90 to the sanding disc then re tighten both lock knobs to lock the table in position With the table set to 90 verify and if needed adjust the 90 stop as follows 1 Loosen lock nut using a 10 mm wrench 2 Adjust set screw D using the supplied 3 mm allen key until the screw sits on the table 3 Re tighten lock nut C ADJUSTING THE BEVEL POINTER With the table set to 90 the bevel pointer might need to be adjusted Proceed as follows Loosen the screw E on the pointer mounting bracket using the supplied 4 mm allen key and manually align the pointer with the zero on the bevel scale F then re tighten the screw INSTALLING SETTING THE WORKPIECE STOP The sanding belt table can be used as a fence when operating the sanding belt in the vertical position When sanding longer workpieces with the sanding head in the horizontal position the table can be replaced with a workpiece stop as follows BEFORE MAKING ANY ADJUSTMENTS MAKE SURE THAT THE SWITCH IS IN THE OFF POSITION AND THAT THE POWER CORD IS UNPLUGGED Make sure that the sander is turned off and un Remove spring B handle C and toothed nut D plugged Using a 10 mm open end
24. cessary after changing the position of the sanding head from vertical to horizontal position See Sanding belt tracking adjustment instructions below SANDING BELT TRACKING ADJUSTMENT DER BEFORE PERFORMING ANY ADJUSTMENTS A DO NOT ATTEMPT TO PERFORM ANY ADJUSTMENTS WHILE THE MACHINE IS RUNNING ALWAYS TURN OFF AND UNPLUG THE SAN a 7 KEEP HANDS WELL AWAY FROM THE SANDING BELT AND ALL MOVING PARTS WHEN THE SANDER IS RUNNING Though not essential proper belt tracking having the belt running straight and turning as evenly on the rollers as possible can prolong belt life and avoid having the belt slip off during operation This is done by tilting the idler roller upper roller ends slightly towards the front or rear so that the belt does not get uncentered but stays on the middle of the rollers Note Belt tracking adjustments may be necessary after changing or replacing a sanding belt to counterbalance for unevennesses between sanding belts 1 Make sure the sander is turned off and unplugged 2 Manually rotate the sanding belt by hand to visually confirm the belt tracking If the belt is tracking straight and evenly on the middle of the rollers you are ready to sand Proceed with normal operations If the belt is not tracking straight follow the instructions below before pro ceeding with normal sanding operations 3 Loosen lock nut A using a 10 mm wrench 4 Slightly turn the tracking adjustment knob B e Clockwis
25. e if the belt tracks to the right e Counterclockwise if the belt tracks to the left Turn on the machine on for a few seconds and check the position of the belt on the rollers As needed repeat this adjustment process until the belt is tracking evenly on the rollers MAINTENANCE AN MAKE SURE THE SANDER HAS BEEN TURNED OFF AND UNPLUGGED FROM THE POWER SOURCE BEFORE PERFORMING ANY MAINTENANCE PERIODIC MAINTENANCE Keep the machine CLEAN and FREE OF DUST Vacuum or brush off any loose debris and wipe down the machine and the tables occasionally with a damp rag Rollers must always be kept clean Dirt on rollers will cause poor tracking and belt slippage Periodically inspect the ON OFF switch power cord plug and other parts for damage P DO NOT OPERATE THE SANDER WITH A DAMAGED SWITCH POWER CORD PLUG OR OTHER PARTS REPLACE A DAMAGED PART IMMEDIATELY REQUIRED MAINTENANCE REPLACEMENT OF THE SANDING BELT DISC Sanding belt disc should be replaced when worn out Standard size 6 X 48 replacement belts discs can be purchased in a variety of grits from your General International dealer under the following part numbers 15 016 6 x 48 Sanding Belt 80 Grit 15 036 12 Sanding Disc 80 Grit 15 017 6 x 48 Sanding Belt 100 Grit 15 037 12 Sanding Disc 100 Grit 15 018 6 x 48 Sanding Belt 120 Grit 15 038 12 Sanding Disc 120 Grit 15 019 6 x 48 Sanding Belt
26. o have been directly or indirectly caused by or resulting from improper use or lack of or improper maintenance misuse or abuse negligence accidents damage in handling or transport or normal wear and tear of any generally considered con sumable parts or components Repairs made without the written consent of General International will void all warranty TABLE OF CONTENTS Rules for safe operation Electrical requirements Grounding instructions Circuit capacity Converting the motor to 110 V Extension cords Identification of main parts and components Basic Functions Unpacking Placement within the shop Establishing a safety zone Install the sander onto the base cabinet Attach the door knob Connect dust collector wire model 15 035DC M1 only Install dust outlet model 15 035 M1 only Connecting to a dust collector model 15 035 M1 only Built in dust collector model 15 035DC M1 only Using the miter gauge Center point Adjusting the 90 and 45 bevel stops sanding belt table Adjusting the 90 bevel stop sanding disc table Adjusting the bevel pointer Installing setting the backstop Basic adjustments amp controls Connecting to a power source On off power switch with safety key model 15 035DC M1 only On off power switch amp safety pin model 15 035 M1 only Tilting the sanding belt disc table Horizontal vertical sanding belt adjustment Sanding belt tracking adjustment Periodic maintenance
27. orkpieces such as chair legs or cabinet doors The sanding belt can be tilted at any angle between 90 and 180 for bevelled pieces Flat sanding with belt in hoizontal position 180 is easier and safer for longer workpieces The sanding disc can be used for sanding round or curved surfaces BASIC PRINCIPLES OF SANDING It is always preferable to remove less material per pass and take multiple passes This can extend sanding belt life place less strain on the motor and provide better workpiece finish quality SANDING BELT IN ANY SINGLE PASS TOO MUCH FRICTION WILL CAUSE BELTS TO OVERHEAT AND WEAR PREMATURELY AND IN N DO NOT USE THIS SANDER AS A THICKNESS PLANER NEVER ATTEMPT TO REMOVE MORE THAN THE DEPTH OF THE GRIT OF THE EXTREME CASES MAY CAUSE BURNS IN THE WORKPIECE Carefully unpack and remove the unit and its components from its shipping container and check for missing or damaged items as per the list of contents below NOTE Please report any damaged or missing items to your GENERALO INTERNATIONAL distributor immediately LIST OF CONTENTS SANDING HEAD 15 035 SANDING HEAD 15 035DC BASE 15 035 BASE 15 035DC MITER GAUGE 4 DUST OUTLET 15 035 only Door KNOB Door BOLT O Backstop BACKSTOP HOLDER Y Hex HEAD BOLT O FLAT WASHER nur O 4 ALLEN Key MM ALLEN KEY CENTER POINT The sanding belt sanding disc flexible hose and dust collection bag model 1
28. per receptacle installed by a quali fied electrician CHECK with a qualified electrician or service person if you do not completely understand these grounding instructions or if you are not sure the tool is properly grounded CIRCUIT CAPACITY Make sure that the wires in your circuit are capable of handling the amperage draw from your machine as well as any other machines that could be operating on the same circuit If you are unsure consult a qualified electrician If the circuit breaker trips or the fuse blows regularly your machine may be operating on a circuit that is close to its amperage draw capacity However if an unusual amperage draw does not exist and a power failure still occurs contact a qualified technician or our service department CONVERTING THE MOTOR TO 1104 Should you need to convert your machine s motor from 220 V to 110 V power Unless you are a qualified electri cian we do not recommend attempting this conversion on your own If you choose to do so you may risk seri ous personal injury damage to the motor and voiding the warranty of your machine We suggest you ask your local General International distributor to recommend qualified electricians in your area or perhaps one of their own technicians who can make this conversion properly and safely EXTENSION CORDS The use of an extension cord is not generally recom mended for 220V equipment If you find it necessary use only 3 wire extension
29. r during this 2 year warranty period subject to the conditions and exceptions as listed below To file a Claim To file a claim under our Standard 2 year Limited Warranty or under our Limited Lifetime Warranty all defective parts components or machinery must be returned freight or postage prepaid to General International or to a nearby distributor repair center or other location designated by General International For further details call our service department at 1 888 949 1161 or your local distributor for assistance when filing your claim Along with the return of the product being claimed for warranty a copy of the original proof of purchase and a letter of claim must be included a warranty claim form can also be used and can be obtained upon request from General International or an authorized distributor clearly stating the model and serial number of the unit if applicable and including an expla nation of the complaint or presumed defect in material or workmanship CONDITIONS AND EXCEPTIONS This coverage is extended to the original purchaser only Prior warranty registration is not required but documented proof of purchase i e a copy of original sales invoice or receipt showing the date and location of the purchase as well as the purchase price paid must be provided at the time of claim Warranty does not include failures breakage or defects deemed after inspection by GeneralO or General6 International t
30. treal Quebec Canada HIP 1Y3 Telephone 514 326 1161 Fax 514 326 5555 www general ca THAN K YOU for choosing this General International model 15 035 15 035DC 6 x 48 belt amp 12 disc sander This sander has been carefully tested and inspected before ship ment and if properly used and maintained will provide you with years of reliable service For your safety as well as to ensure optimum performance and trouble free operation and to get the most from your investment please take the time to read this manual before assembling installing and operating the unit The manual s purpose is to familiarize you with the safe operation basic function and features of this edge belt disc sander as well as the set up maintenance and identification of its parts and componenis This manual is not intended as a substitute for formal woodworking instruc tion nor to offer the user instruction in the craft of woodworking If you are not sure about the safety of performing a certain operation or procedure do not proceed until you can confirm from knowledgeable and qualified sources that it is safe to do so Once you ve read through these instructions keep this manual handy for future reference GENERAL INTERNATIONAL WARRANTY All component parts of General International machinery are carefully tested and inspected during all stages of production and each machine is thoroughly inspected upon completion of assembly Because of
31. using non slip paint or using tape define on the floor the limits or perimeter of each machines safety zone Take steps to ensure that all operators and shop visitors are aware that these areas are off limits whenever a machine is running for everyone but the individual operating the unit The protective coating on the sander table prevents rust from forming during shipping and storage Remove it by rubbing with a rag dipped in kerosene mineral spirits or paint thinner Dispose of potentially flammable solvent soaked rags according to manufacturer s safety recom mendations A putty knife held flat to avoid scratching the surface may also be used to scrape off the coating followed by clean up with solvent Avoid rubbing the sander s painted surfaces as many solvent based products will remove aint With screw driver push solvent saturated into To prevent rust apply a light coating of paste wax or use ATA regular applications of any aftermarket surface protec tant or rust inhibitor ASSEMBLY INSTRUCTIONS For your convenience this sander is shipped from the factory partially assembled and requires only minimal assem bly and set up before being put into service SERIOUS PERSONAL INJURY COULD OCCUR IF YOU CONNECT THE MACHINE TO THE POWER SOURCE BEFORE YOU HAVE COMPLE TED THE INSTALLATION AND ASSEMBLY STEPS DO NOT CONNECT THE MACHINE TO THE POWER SOURCE UNTIL INSTRUCTED TO DO SO
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