User Manual - SuperMax Tools
Contents
1. ST 48085 137 FAE Le SO unas 48085 138 Meer P 48085 139 180 Grit Abrasive Strip ET 40 48085 140 180 Grit Arbasive Strip 4mm 41 48085 141 Carriage BOM M8X1 25X30 esten rn 42 48085 142 1 47 280 1 47 zc 48085 143 EE EN I 44 480BS 144 Drom AA LS 45 480BS 1495 Flat Washer UT 46 48085 146 Round Socket Head Screw VENDT 48085 147 FANN t rA 48 iocus 480BS 148 JUNC OM ET SUPERBRUSH HEAD ASSEMBLY PARTS LIST 25 Hex Screw w Washer 110 24 X IB etas 2 Dust Cover 1 PU ME 4 Tension Roller Bracket Inner 027 222 0002 1 Spring 4 Tension Roller Bracket Inner2. 1 Pad Bracket Tension 2 5150 EEE EEE 2 PTE ned 1 PENT 1 12011240 51110 lke RE cm 1 Round Socket Head Cap Screw 4 Lock VVaSTIBT O 4 Nylon Insert Lock Nut UTD 1 Signal Cord Interver tO Control M 1 Hex Nut w o M 4 Hex Cap SAUEN used MX 2 RES ETEN 1 Hex Cap O16 T10X I 2 1 MOUNDINO lt ROTE 1 Me 1 Tension Roller Bracket Outer Right 2 2 1 Tension Roller Bracket Outer 1 Height Direction Label RR 1 Maimtenance 9 1 VEE 1 26 19 38 DnuM BRusH OwNER S MANUAL e C KE XB ENE e 3 k E QUUM 9 V 5 4 Kr 2 F 2 4 19 38 Owner s MANUAL 27 Part List Conveyor and Motor Assembly Index Part No No Description Size 480 5 201 Gear
3. 6 32 1 2 13 22 480BS 219 Switch ON ORP une 20 248055 220 ENE Z T iuis 480 5 113 Set Screw 1 4 20 1 4 22 480 5 222 Bracket Base 23 280 5 221 Cover Base Control HOUSING 24 480 5 224 Hex Cap 1 4 20 3 4 7 5 400BS 225 rine xinh Washer Wave UT RT 26 480BS 145 Washer UT m 480 5 227 Bracket Take 51 202 480 5 154 PT ME 29 na 480BS 229 Roler 480655230 Suns 280B5 231 Hex 14 20 nere 480 5 232 Washer Lock Int Tooth S DO os 480 5 233 02 Screw Round Head Slotted 1 4 20 1 3 4 480 5 234 2 24 lt lt Bracket Take OO 480 5 167
4. Lock Washer oett orte rna orn xung s eee 36 480 5 236 Roller Sy 480 5 237 Bracket Support Drive Roller 38 480 5 238 Bed CONVEYOTF E 39 48085 239 Hex Cap 5 16 18x3 A 480 5 240 Belt Conveyor Rubber Not Shown 480 5 241 Fiat NE 42 NM 480 5 242 HEN udi 5 16 24 43 480 5 243 Slotted Set Screw 8 369 5 1 6 44 480 5 244 Strain Relief Gear Motor 6 4 AB 48065 24595 FO CNU es n e a E STO 18 Luma 46 480 5 246 Receptacle Signal AT 480BS 247 Hex 1 4 20x1 2 T 4 28 SUPERBRUSH CONVEYOR 8 MOTOR 19 38 Drum BrusH OWNER s MANUAL 29 19 38 COMBO SPECIFICATIONS Warranty Two years on parts and labor limited Manufacturer s warranties on conveyor belts brush heads and abrasives Sanding Ca
5. DEPTH GAUGE OPERATION The depth gauge see Fig 5 measures the distance 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 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 h
6. eR Gauge 48085 119 Depth Gauge 48085 120 Mir 2 480BS 121 rn Height Adjustment Hanale rt drea dv nra rre rera eia 22 08 48085 122 Nylon Insert Lock Nut BIB TT 5 103 5 Height Adjustment SENGA 24 480BS 124 mino MEN EN cO LORS 2312 480 5 125 Thrust Bearing OTTO TER 26 48085 126 sno 21 48085 127 vido 26 EM 480 5 128 Hex Cap 3 8 16 1 1 4 29 48085 129 Flat OD 48085 130 mo 48085 131 DN seine 48085 132 NE 55 480 5 133 Pan Head Machine Screw FO EEUU 480 5 134 Strain Relief inverter TN eese 48085 135 DC Ne 36 400 5 13 ient
7. 90 gt 480 5 202 Strain Relief Power Cord OP 3 4 PE 48085 203 Pr Flat SITO o PNE 480 5 205 Socket Head 10 32 1 2 Omen 48085 206 Tracker Kit optional m P f iion 480 5 207 fins ata see 48085 208 Speed Adjustment JE 48085 209 Wining Guard 480 5 210 5 Er vu EE 2009 21 1 Contr l Housing BET svever 2 480 5 212 Pan Head Self Tapping Screw 9 902 KZ EG 480 5 213 Receptacle Main 14 480 5 214 Pan Head Machine Screw 10 32 1 2 15 45 44 48085 215 Washer Lock Int Tooth x41 480 5 216 10 32 UT eens 480 5 217 Screw Head Slotted 10 32 3 8 18 480 5 218 Screw Phil Pan
8. Any operating problems with the will likely occur most often during the period that you are becoming familiar with its components and their adjustments If you are experiencing 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 motor 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 SUPE
9. eneren P 102 Strain Relief Pen 480 5 103 Main Cord Inverter to Control BOox seem 4 480BS 104 916 SONA 48085 105 Nylon Insert Lock Nut 5 16 24 Ds 48085 106 Flat Washer cm DID ene 48085 107 ME TOR 8 48085 108 Motor Slide Plate EET 48085 109 STEN PD 10 uos 400BS 110 ee Hex Cap SClOW 9 16 160X 11 4 48085 111 Lock WY ASOD OE E EE T2 48085 112 Socket Head Screw 3 8 16x1 1 4 40085 1 47 20 1 4 48085 114 Lom 48085 115 OPIS Bez o o TO ns 48085 116 Height Plate Depth Tf ge 48085 117 MM 11 I8 0 116 sparen Lapel
10. YOUR SUPERBRUSH Adjusting Height Controls 7 Lol 210 7 Brush Speed Adjustment 8 Changing Brush or Drum 12 Flatter 14 Replacing Conveyor csset 19 Hen LP 29 SUPERBRUSH TECHNICAL DATA Parts List For Head Assembly 24 Parts List For Conveyor MSDN 27 SUPERBRUSH Specifications 29 Vee 30 SUPERBRUSH Accessories amp Supplies 31 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 BOUT SUPERBRUSH SYSTEM Ihis manual is designed to help familiarize you with your SuperMax sander and to help you take advantage of its exclusive features By understanding its major components and how they work together you will be able to get the most from your investment The SuperBrush system is basically made up of 1 height adjustment handle which raises and lowers the sanding head 2 brush speed control knob which controls brush speed from 200 to 1000 RPM and drum speed to 1750 RPM 3 motor starter switch which starts and stops the drive motor and sanding brush and 4 a feed rate control knob which starts feed conveyor and selects feed rate from 0 10 feet per minute Fig I SuPERBRUSH nomenclature UNPACKING YOUR SU
11. 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 the bronze bushings or conveyor belt 1 M Fig 17 Inboard conveyor attachment bolts OPERATING YOUR SUPERBRUSH 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 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 OwNER S MANUAL TROUBLESHOOTING YOUR SUPERBRUSH
12. 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 position 5 The take up fastener is designed to automatically take up any slack caused by stretching 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 101 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 A 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 protect
13. rate and slow brush speed may produce the same result as a fast feed rate and fast brush speed The 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 AS Fig 11A Tension roller height and depth gauge adjustment performance A faster feed rate allows faster brushing but fewer revolutions of the brush per inch of sanding A slower feed rate provides more revolutions of the brush per inch of sanding Fig 10 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 inch 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 c
14. the machine familiarize yourself with its components features and basic adjustments by reviewing the following pages You will find it an invaluable aid in setting up operating and servicing your machine If after reviewing this manual you still have problem you cant solve please call your SuperMax Tools dealer ABOUT THE SUPERBRUSH SYSTEM SUPERBRUSH Nomenclature 4 Unpacking Your dren 5 SETTING UP YOUR SUPERBRUSH Connecting Dust Collectors 6 Checking For Machine Level 6 Checking Height 7 Checking Brush Alignment 7 Checking Drum Alignment y Drum Brush Speed Adjustment 7 EG cu 9 Checking Conveyor Belt Tracking 8 OPERATING YOUR SUPERBRUSH Basic Operating Procedures cape 9 Adjusting OR y Selecting Stock Feed 10 10 Setting Brush Depth of Cut 11 Setting Drum Depth of Cut 11 Using Ibe Depth 11 Monthly Morn 12 Tirs For MAXIMUM PERFORMANCE 12 ABRASIVE SELECTION GUIDE 16 Wrapping Abrasive Strips 17 TROUBLESHOOTING YOUR SUPERBRUSH Troubleshooting Guide Motors 20 Troubleshooting Guide Conveyor 21 Troubleshooting Guide Machine 27 MANUAL CONTENTS 3 SERVICING
15. 4 1 2 for most applications The rollers can be adjusted closer to the sanding drum when sanding 19 38 Drum BrusH OwNERS MANUAL short flat stock only adjust remove the four tension adjusting screws 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 See page 26 Flat Surfaced Stock Loosen the four socket head screws 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 1 8 to 14 into the deepest part of the profile being sanded Nylon brushes should be set to penetrate approximately 1 16 into the deepest part of the profile being sanded Wire brushes should be set to penetrate 1 32 to 1 16 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 A slower feed rate allows more brushing to occur In some instances a slow feed
16. Drum WWW Drum 71938 CL Closed Stand includes locking wheels 71938 Open Stand 98 08130 Caster Set Heavy duty roll amp swivel lock used with open stand 71938 7 Infeed Outfeed Tables 0000000000000 Outfeed Tables 71938 DRO DRO digital read out depth gauge ee eaae a a a a o CONVEYOR BELTS 60 0322 Type 1 100 grit abrasive surface with reinforced backing 61 1003 2 Polyurethane textured surface with monofilament backing DRUM ABRASIVES 60 19 100 100 Grit SuperMax 19 38 Combo 3 WrapsinBox 6919120 120 Gris SuperMax 19 38 Combo 3 WiapsinBox 601950 150 Grit SuperMax 19 38 Combo 3 WiapsinBox For information on the SuperBrush and supplies call SuperMax Tools 888 454 3401 or visit www supermaxtools com CAUTION IMPORTANT SAFETY INFORMATION Keep Tuis MANUAL HANDY QUICK REFERENCE For SAFE SANDING OPERATION FOLLOW HESE GUIDELINES BECOME FAMILIAR WITH THE PROPER OPERATIONAL PROCEDURES FOR USING THIS MACHINE ALWAYS BE SAFETY CONSCIOUS WHEN OPERATING THE MACHINE B ALWAYS WEAR EYE PROTECTION WHILE OPERATING THE SANDER ALWAYS FEED STOCK AGAINST THE ROTATION OF THE BRUSH OR 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 K
17. ICKBACK KNOW HOW TO PREVENT IT B ALWAYS DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICING OR ADJUSTMENT OF THE MACHINE DO MODIFY THIS MACHINE MODIFICATIONS ARE DONE AT THE OWNER S 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 SUPERMAX DEALER IMPORTANT BEFORE OPERATING YOUR SUPERBRUSH READ THE INSTRUCTIONS IN THIS MANUAL FOR UNPACKING AND SETTING UP YOUR MACHINE PART NO 92 1938 COPYRIGHT 2012 PRINTED IN USA
18. Keep Ihis Manual Handy For Quick Reference SUPERBRUSH OWNERS MANUAL 19 38 Drum BrusH IMPORTANT BEFORE OPERATING YOUR SUPERBRUSH READ THE INSTRUCTIONS IN THIS MANUAL FOR UNPACKING AND SETTING UP YOUR MACHINE TOOLS Improving Your Greatest Asset Time 2 19 38 Drum BrusH Owner s MANUAL 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 youve purchased was to bring a new dimension of productivity to your shop be it large or small Right from the start our goal at SuperMax Tools has been 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 All SuperMax Tools brush sanders feature 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 SuperMax Tools and its dealers are committed to providing you with innovative solutions from selecting the right machine to helping you get top performance when you put it to work in your shop Regardless of how yo
19. PERBRUSH Your 19 38 Combo sander has been shipped mostly assembled from the factory If any damage has occurred as 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 See enclosed Warranty Statement 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 2 Tighten nut against handwheel Fig 2 Open plastic remove liner cut box 7 10 ABOUT HE SUPERBRUSH 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 m
20. RBRUSH 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 misaligned 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 OwNER S 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 m
21. able allowing the conveyor belt to carry the stock into the brush Once the stock 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 Fig 11 amp page 26 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 1 8 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 much tension can cause snipe when drum sanding or not enough lift when sanding profiled material To increase tension turn the tension adjusting screw clockwise 4 revolution at a time To decrease tension turn the adjusting screw counter clockwise 14 revolution at a time See fig 11 TENSION ROLLER PRESSURE The tension rollers are factory set for the most versatile use and longest minimum length approximately
22. ain motor and depth gauge Install two lock washers and two flat washers on studs on outboard side of conveyor Install lock washer and flat washer onto two socket head or hex 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 4A 11 Tighten all bolts and nuts Fig 4 Secure to stand remove packing block 6 19 38 Drum BrusH Owner s MANUAL SETTING Your SUPERBRUSH 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 4 diameter dust exhaust port at the top of the cover To attach to your collection system install 4 hose from your collector See Tips For Maximum Performance page 12 of this manual The minimum recommended dust collector capacities is 600 cfm For best results follow the recommendati
23. ander Replace end caps of brush head and install four screws Reinstall bearing and tighten the two 3 8 carriage bolts Tighten the two set screws in the bearing to the brush shaft Close dust cover Plug in sander Fig 14A Fig 14B NOTES 15 16 19 38 Drum BrusH OwNERS MANUAL BRASIVE SELECTION GUIDE GRIT PPLICATION 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 Note When using Pre Marked or Pre Cut abrasives not all of the steps below are necessary Proper attachment of the abrasive strip to the drum is critical to achieving top performance from your SuperMax Tools 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 o
24. angle perpendicular to the brush However even a slight oftset 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 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 WARNING Do Not Re wire machine to 220 volt MAINTAINING YOUR SUPERBRUSH 13 I4 19 38 DnuM 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 Remove two 3 8 carriage bolts from outboard brush support bearing Remove outboard bearing from shaft of brush Remove four screws from end caps of outboard side of brush head 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 Note Abrasive side of strips must be oriented so abrasive side contacts top of stock as it passes through s
25. apacity and least noticeable scratch pattern Please note when drum 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 wil come on when INTELLISAND operating Fig 11 a 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 When 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 SuperMax Tools 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 fladder 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 giv
26. e the best finish and longest brush life When using a wire brush on metal it is 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 1 2 thick flat wood surface Strips of narrow sandpaper can also be used Lower the brush so the tips of the bristles contact the sandpaper by 1 32 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 as a drum sander It may take some experimentation to determine the proper depth of cut given the variables OPERATING YOUR SUPERBRUSH 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 I e 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 16
27. ead Install bearings on shaft with set screws loose Install coupler 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 a 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 allo
28. elting 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 Reduce depth of cut decrease brush RPM Use alternate feeding procedure WIRING DIAGRAM 23 GM TO GEAR MOTOR RAD WIRE BLACK WIRE WHITE WIRE GREEN WIRE a MEETS DRUM MOTOR POWER OUTLET 24 19 38 DruM BrusH 5 MANUAL Part List Drum Head Assembly Index Part No No Description Size Qty 48085 101 MIT 480BS 101MF M Otor Fan not 480BS 101MFC Motor Fan Cover not 480BS 101JB JUNCt ON BOX NOt SDOWII n iain hid pana a 480BS 101JBC Junction Box Cover not SNOWN 2
29. f 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 16a 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 through 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 The 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 SANDPAPER STRIP ABRASIVE SIDE UP Also see Fig 16 b and Fig 16 c OPERATING YOUR SUPERBRUSH 17 4 With the trailing edge of the strip
30. ion 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 Fig 16 Marking and cutting taper on strip Ee Approx 3 18 19 38 Owner s 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 amp 17 Remove the two nuts and washers outboard side Fig 7 amp 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
31. lts and type of brush CHECKING CONVEYOR BELT RACKING Conveyor 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 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 of 2 for tracking conveyor OPERATING YOUR SUPERBRUSH 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 SuperBrush offe
32. ons of the manufacturer of your dust collection equipment NOTE Some applications will require more dust collection than the recommended minimum CFM CHECKING MACHINE For LEVEL Proper leveling of the machine is important to achieve continued maximum performance from the 19 38 Combo Fig 5 SuPERBRUSH 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 ADJUSTMENT 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 16 of an inch Before operating height adjustment be sure the packing block is removed It is located under the outboard end of the carriage arm Fig 3 Raise drum brush to remove BrusH ALIGNMENT 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 on the outboard edge of the conveyor and turning the 7 16 adjustment nut to bring the conveyor parallel to the br
33. pacity Maximum Width Minimum Length Maximum Thickness Minimum Thickness Dimensions Brush Brush Speed Dust Hood Height Adjustment Conveyor Motor Drive Motor TEFC Power Requirements Shipping Weight 38 two passes 2 1 4 to 3 1 2 varies with application 4 typical varies with brush drum style amp application 1 32 typical varies with applications Length 36 Width 42 Height 24 without stand 5 diameter typical Typical bristle length 1 1 2 varies Infinitely variable 200 to 1000 RPM Brush 1750 RPM Drum Hinged back with 4 vacuum port 1 16 per revolution Depth Gauge included 43 torque Direct drive D C motor Infinitely variable 0 10 feet per minute 1 3 4 HP Continuous duty 110 Volt Single Phase 20 amp service 242165 weight varies on how equipped 2 boxes 30 WARRANTY 2 YEAR WARRANTY Limited warranty We will provide all replacement parts which are found to be defective in materials or workmanship Manufacturers warranties on conveyor belts and brush heads BRUSHES amp SUPPLY CHECKLIST 31 BRUSHES amp SUPPLY CHECKLIST SUPERBRUSH OPTIONS 802520 1 2 impregnated brush configurations in variousgis Wirebrishconfguations pp Please contact SuperMax Tools for complete listing of brushes and brush material available ACCESSORIES ITEM E 71938 1 Sanding
34. rs considerable control and versatility through variable brush speed 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 aggressive brush or setting Ihe 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 SuperBrush The basic operating procedure for the SuperBrush models 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 SuperBrush rest and hold the stock to be sanded on the conveyor t
35. u take advantage of these innovations we are confident our equipment will help bring you a giant step forward in precision shop productivity CAUTION SAFETY FIRST When maintaining and operating this machine always put safety first For your own safety read and understand this owners manual before operating this machine Always heed and follow all normal safety precautions including the following Always wear eye protection while operating the sander Always feed stock against the brush rotation Never place hands or fingers under the brush or dust cover Keep hands and clothing away from operating brush and drum Never operate sander without its dust cover or guarding in place Always maintain control of stock to avoid kickback know how to prevent it Always disconnect electrical power before doing any servicing or adjusting of the machine MODEL IDENTIFICATION Your 19 38 Combo sander is one of a family of machines from SuperMax Tools designed to help you achieve results comparable to industrial size sanders at fraction of the cost For future reference find the model stock and serial numbers on the back of machine base and write them in below Model Stock Number Serial Number Date Purchased Dealer IMPORTANT MANUAL HANDY Please read this manual first It was designed to help you get the most from your 19 38 Combo sander Before unpacking or using
36. ush or drum See Fig 7 SETTING UP YOUR SUPERBRUSH 7 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 5 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 7 16 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 resu
37. w you to fine tune the machine for maximum results regardless of the 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 a 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 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 Stock Feeding Angle Some pieces because of their dimensions will need to be fed into the machine at 90
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