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User Manual - SuperMax Tools

1. Ref Description Part Number Qty Number SM25x2 Both SM37x2 Unit Models l DUST COVER 40 1525 40 3237 l 2 DUST COVER HANDLE 80 2841 l 3 8x1 2 SELF TAPPING SCREW 10 3904 2 4 1 4 20x1 2 ROUND HEAD MACH SCREW 10 3205 8 5 1 4 INTERNAL TOOTH LOCK WASHER 11 0504 8 6 DUST COVER MOUNT 40 0240 40 4243 l f HINGE 40 0225 2 8 1 4 SAE WASHER 11 0205 8 3 1 4 20 HEX NUT 12 0001 8 10 3 8 16 x1 HEX HEAD BOLTS 10 9205 8 11 5116 WROUGHT WASHER 11 9103 8 12 3 8 16 FLANGED LOCK NUT 12 0209 8 13 1 4 28x1 4 SOCKET HEAD SET SCREW BEARING 10 8602 8 14 5 16 18x1 CARRIAGE HEAD BOLT 10 1204 6 15 5 16 18x1 1 4 HEX HEAD BOLT 10 9106 2 16 5 16 SAE WASHER 11 0206 10 17 5 16 LD SPACER 30 1305 2 18 DRUM BEARING 50 3067 4 19 OUTBOARD DRUM MOUNT BKT 40 0519 l 20 5 16 18 HEX NUT 12 0003 8 21 SECONDARY DRUM ADJ KNOB 80 3135 2 22 5 16 I D SHAFT COLLAR WITH SET SCREW 20 1102 2 23 OUTBOARD SECONDARY DRUM ADJ BKT 40 0527 l 24 5 16 LOCK WASHER 11 0010 2 25 OUTBOARD SECONDARY DRUM INDICATOR 95 1659 l 26 BRASS SPACER 30 1303 2 21 3 8 SPRING WASHER 20 1165 2 28 EXTENSION SPRING 20 3210 2 29 1 4 x 1 KEY STOCK 20 0762 2 30 OUTBOARD INDICATOR NEEDLE 40 0531 l 31 OUTBOARD ABRASIVE FASTENER 21 1173 2 32 6 32x3 8 FLAT HEAD PHILLIPS SCREW 10 3003 4 33 SANDING DRUM 30 1200 30 3100 2 34 INBOARD ABRASIVE TAKEUP FASTENER 21 1172 2 35 INBOARD INDICATOR NEEDLE 40 0530 l 36 INBOARD SECONDARY DRU
2. Fig 6 Intellisand Controller Using a flat piece of wood or metal as a thickness gauge insert it between the conveyor table and the primary front drum on the left outboard side of the machine see Fig 26 Raise the table up so the drum just contacts the thickness gauge Then holding up the front tension roller check at out board side Fig 7 of the drum to see that the drum is parallel to the table If it is not disengage Fig 7 Checking drum alignment inboard side 8 SUPERMAX OWNER S MANUAL Fig 8 Adjusting primary drum alignment the right inboard miter gear see Fig 8 finely raise or lower the right inboard side of the table to achieve parallel alignment of the front primary drum The distance between the conveyor table and both sides of the front drum should be the same Reinstall the miter gear aligning the set screw to the flat of the shaft Dual Drum Models Before altering this con veyor table position also check to see that the rear drum dual drum models only is likewise parallel to the conveyor table with both sides at the same height above the table Using the same thickness gauge check both sides of the rear drum from the rear of the machine while holding up the rear ten sion roller Adjustment of the rear drum is done by using the right and left drum adjustment knobs see Fig 9 After the rear drum is adjusted it is important to reset the rear drum adjustment indi
3. TROUBLESHOOTING GUIDE OPERATIONS Continued Problem Sniping of wood gouging near end of board Burning of wood Gouging of wood Unsanded ridge along length of piece sandpaper appears clean Possible Cause Tension rollers set too far down 2 Stock not supported properly during infeed or outfeed 3 Conveyor drive or driven rollers higher than conveyor bed Feed rate too slow 2 Excessive depth of cut for grit used 3 Excess build up on abrasive strips 4 Abrasive is too fine Ua Abrasive strips overlapped 6 Drum out of alignment Conveyor belt is too loose 2 Excessive depth of cut 3 Wood slipping on conveyor due to lack of contact 4 Abrasive is too fine Grit has been removed from backing Solution Reset tension rollers page 28 Support stock with roller stands tables or benches Readjust rollers page 28 Increase feed rate Reduce depth of cut or increase grit coarseness Reduce depth of cut clean strips or replace Replace with abrasive of coarser grit Rewrap strip without overlap Realign drum page 26 Adjust belt tension page 8 Reduce depth of cut Use alternate feeding procedure page 17 Replace with coarser grit Avoid this area of drum or change abrasive strips 24 SUPERMAX OWNER S MANUAL SERVICING YOUR SUPERMAX The basic adjustment proced
4. To attach the SUPERMAX to your collection sys tem install 4 hose from your collector See Tips For Maximum Performance page 17 of this man ual The minimum recommended dust collector capacities at the dust port s are SUPERMAX 25 and SUPERMAX 25x2 600 CFM SUPERMAX 37 and SUPERMAX 37x2 1 200 CFM For best results fol low the recommendations of the manufacturer of your dust collection equipment CHECKING MACHINE FOR LEVEL Proper leveling of the machine is essential to achieve continued maximum performance from the SUPERMAX Before making fine adjustments place the unit where it will be used in the shop Then adjust the four leveling feet using a carpen ter s level both across the machine and in line with the machine placing the level on the conveyor bed If you have equipped your SUPERMAX with the caster set do the same after positioning the machine where it will be operated most often Mark the position of the legs on the floor with tape so it can be returned to the same position CHECKING DRUM ALIGNMENT Your SUPERMAX was shipped from the factory preadjusted with the drum s aligned to the con veyor table Unless the machine was stressed dur ing shipment only fine adjustment should be nec essary Minor alignment corrections can be done without relieving V belt tension or adjusting the tension rollers but should be done without any abrasive strips attached SETTING UP YOUR SUPERMAX 7 INTELLISAND CONTROLLER
5. page 31 Replace bushings page 31 Readjust height control pages 9 24 26 Increase drive belt tension Realign bearing page 33 Replace V belt page 32 Glue weight back in place Replace pulley page 34 Retighten or replace set screws Insert abrasive paper or replace fastener page 10 Replace bearing page 33 22 SUPERMAX OWNER S MANUAL TROUBLESHOOTING GUIDE OPERATIONS Problem Rippled sanded surface non uniform ripples Rippled sanded surface uniformly spaced ripples Possible Cause 1 Uneven feed rate 1 Excessive feed rate 2 Excessive depth of cut 3 Sander vibration Solution Check for these conditions and refer to previous section Troubleshooting Machine See Selecting Intellisand Feed Rates page 14 Conveyor belt slipping on drive roller Board slipping on conveyor belt e Conveyor gear motor stalling Excessive V belt tension page 5 Set screw loose on shaft coupler between gear motor and conveyor Conveyor bushings dry lubricate Reduce depth of cut or reduce feed rate Reduce depth of cut or reduce feed rate Check for these conditions Loose bolts or bearing and pulley set screws retighten Dirty drum clean inside Excessive V belt tension reduce tension page 5 Worn V belt replace page 32 Warped driven pulley replace page 34 TROUBLESHOOTING YOUR SUPERMAX 23
6. 1 Loosen the set screws located at the front of the table support castings Fig 19 2 Lubricate thoroughly by applying penetrating lubricant to the table support castings where they contact the column tubes and to all contact points of adjusting screws and cross bar Fig 20 Also apply oil or grease to the miter gears 3 If the height adjustment feels stift check for misalignment of adjusting screw supports and the drum support castings which could cause binding on the adjusting screw rods Fig 19 These cast ings can be adjusted by loosening the set screws which secure them to the column tubes Realign the adjusting screw supports by loosening the two set screws that hold them to the column tubes and rotate to the proper position 4 The adjusting screw supports located immedi ately below the height adjustment handle and the Fig 20 Adjusting miter gears for proper mesh at r i s x l I 2 t 7 LE Ve K J ti l h pe F i j Rra CHEE EHHH HEH HHIHH p 9 M Fig 21 Miter gear below adjusting screw support left outboard drum supporting casting Fig 19 must both be set at the proper height along the column tubes so the height adjusting screws pro vide for proper miter gear alignment Before adjusting these parts tighten one set screw in the table support castings Fig 19 to hold the height adjusting screw in position during adjustment Also check to se
7. 60 0324 60 0337 l SUPERMAX TECHNICAL DATA 47 SUPERMAX ACCESSORY amp SUPPLY CHECKLIST ITEM DESCRIPTION QTY SUPERMAX OPTIONS 98 0130 CASTER SET Heavy duty roll amp swivel lock Set of 4 98 0070 RACK N ROLL Abrasive storage system ABRASIVES Resin bond non adhesive abrasive cloth strips Pre Marked 60 grit and finer covers 25 drum 12 times 37 drum 8 times Pre Marked 36 grit covers 25 drum 9 times 37 drum 6 times Pre Cut grit includes 3 strips for 25 drum 2 strips for 37 drum Pre Cut Pre 25 37 Marked Size and Description 60 5024 60 7024 24 GRIT Surface rough sawn boards stock amp glue removal 60 5036 60 7036 60 9036 36 GRIT Surface rough sawn boards stock amp glue removal 60 5060 60 7060 60 9060 60 GRIT Surfacing and dimensioning boards trueing warped boards 60 5080 60 7080 60 9080 80 GRIT Surfacing light dimensioning remove planer ripples 60 5100 60 7100 60 9100 100 GRIT Light surfacing remove planer ripples 60 5120 60 7120 60 9120 120 GRIT Light surfacing minimal stock removal 60 5150 60 7150 60 9150 150 GRIT Finish sanding minimal stock removal 60 5180 60 7180 60 9180 180 GRIT Finish sanding not for stock removal 60 5220 60 7220 60 9220 220 GRIT Finish sanding not for stock removal 60 5000 n a n a Assortment 1 strip each of 36 80 120 grit 60 0505 ABRASIVE CLEANING STICK Specialty abrasives are
8. NOT SHOWN 41 1010 l SUPERMAX CONVEYOR amp MOTOR PARTS LIST Ref Description Part Number Qty Number SM25 Both SM37 Unit Models DRIVEN ROLLER 30 3103 30 3104 l 2 1 2 LD SQUARE OILITE BUSHING 50 3109 4 3 TAKEUP SLIDE 40 4108 2 4 5 16 SAE WASHER 11 0206 2 5 5 16 24 FLANGED NUT 12 0308 6 6 WRENCH 40 0375 vg 8 TAKEUP BASE BRACKET 40 4107 2 9 3 8 16x1 CARRIAGE BOLT 10 1302 16 10 5 16 24x3 STUD 30 1306 2 11 3 8 16 NYLON INSERT LOCK NUT 12 8005 4 12 3 8 SPRING WASHER 20 1165 8 13 SIDE RAIL 40 4105 l 14 ROLLER SUPPORT BRACKET 40 4109 15 RUBBER COVERED DRIVE ROLLER 30 3106 30 3107 l 16 3 8 16x3 4 CARRIAGE BOLT 10 1301 4 17 3 8 FLANGED LOCK NUT 12 0209 16 18 CONVEYOR BED 40 4101 40 4201 19 SIDE RAIL 40 4106 Continued on page 46 SUPERMAX CONVEYOR amp MOTOR 45 46 SUPERMAX OWNER S MANUAL SUPERMAX CONVEYOR amp MOTOR Parts LIST Cont d Ref Description Part Number Qty Number SM25 Both SM37 Unit Models 20 BOTTOM COVER 40 4116 l 21 10 24 RETAINING NUT 20 1155 2 22 10 24x3 8 SLOTTED HEX HEAD SCREW 10 3803 2 23 CONTROL BOX BASE BRACKET 40 4115 i 24 1 4 20x1 2 ROUND HEAD MACH SCREW 10 3205 3 25 SWITCH BRACKET SINGLE PHASE 40 5005 l 25 SWITCH BRACKET THREE PHASE 40 0124 i 26 SWITCH BOX 72 5400 2 i 27 ON OFF SWITCH DRUM SINGLE PHASE 72 5400 1
9. When used in this way the secondary drum gener ally is positioned just slightly lower than the pri mary drum so it removes the scratches left by the coarser grit on the primary drum Fig 14 However the exact depth of cut of the secondary drum will depend on the specific abrasive grits on each of the drums The chart on page 14 shows grit combinations and rear drum settings can also be found under the dust cover of your machine It suggests settings for various abrasive grit combinations try these to start and make adjustments as necessary for your work When adjusting the secondary drum turn FRONT DRUM CD CONVEYOR BELT Fig 14 Relative positions of dual drums 14 SUPERMAX OWNER S MANUAL DUAL DRUM GRIT COMBINATIONS amp SETTINGS BRASIVE GRIT GRADES FRONT REAR REAR DRUM DRUM GRIT DRUM GRIT SETTING 36 36 2 0 36 60 2 5 36 80 2 5 60 80 2 0 60 100 1 5 80 100 1 0 80 120 1 0 100 150 0 5 120 150 0 5 120 180 0 5 150 220 0 5 Note The grits and settings shown are starting sugges tions only Other combinations and settings are possi ble depending on your particular circumstances both adjustment knobs so that the indicator nee dles move to the desired setting at the plus end of the scale See Fig 9 page 8 The depth of cut of the secondary drum should be rechecked each time a different grit combination is used On dual drum machines fine tuning the rear drum settings can help improve perfor
10. SCREWS Fig 3 Table support casting and set screws 6 SUPERMAX OWNER S MANUAL SETTING UP YOUR SUPERMAX Your SUPERMAX drum 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 cov ers the pre operational checks you should make after unpacking and final assembly Unnecessary problems can be avoided if these essential checks are performed before operating the sander Likewise performing the recommended monthly maintenance procedures listed at the end of this section will help assure trouble free service MAKING ELECTRICAL CONNECTIONS The neutral wire white in the power cord to the sander is not used and does not need to be con nected on four wire 220V single phase angle con nector or five wire 220V three phase power con nections Please see wiring diagrams on pages 36 and 37 for details Single Phase The drum s of all SUPERMAX single phase sanders are powered by a 5 HP 208 230 volt single phase motor A NEMA 14 30 plug and cord is supplied Included with the sander is a NEMA 14 30 flush mount receptacle to use with the sander Single phase SUPERMAX sanders require a minimum dedicated circuit of re 10 gauge wire protected by a 30 amp fuse or breaker Extension cords are not recommended but if used should be of at least 10 gauge wire for len
11. also available SUPERMAX POWER FEED CONVEYOR BELTS TYPE 1 100 grit abrasive surface with reinforced film backing TYPE 2 Polyurethane roughtop surface with monofilament backing TYPE 1 TYPE 2 60 0324 61 1004 24 Power Feed Bed with 2 diameter Drive Roller 60 0337 61 1007 36 Power Feed Bed with 2 diameter Drive Roller Note It is our policy to not sell direct in an DEALER NEAREST YOU area that is served by a SuperMax Tools dealer For information on the dealer nearest you call 651 454 3401 or email sales supermaxtools com or visit our website at www supermaxtools com 3 YEAR WARRANTY Limited warranty We will provide replacement parts which are found to be defective in materials or workmanship CAUTION IMPORTANT SAFETY INFORMATION FOR SAFE SANDING OPERATION FOLLOW THESE GUIDELINES E BECOME FAMILIAR WITH THE PROPER OPERATIONAL PROCE DURES FOR USING THIS MACHINE ALWAYS BE SAFETY CONSCIOUS WHEN OPERATING THE MACHINE ALWAYS WEAR EYE PROTECTION WHILE OPERATING THE SANDER ALWAYS FEED STOCK AGAINST THE ROTATION OF THE DRUM S NEVER PLACE HANDS UNDER THE DRUM S OR DUST COVER NEVER OPERATE SANDER WITHOUT ITS DUST COVER OR DRUM AND BELT GUARDING IN PLACE E KEEP HANDS AND CLOTHING AWAY FROM OPERATING DRUM S BELT AND PULLEYS m ALWAYS MAINTAIN CONTROL OF STOCK TO AVOID KICKBACK KNOW HOW TO PREVENT IT m ALWAYS DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICING OR ADJUSTMENT OF THE M
12. improve performance of your sander Dust Collection When connecting dust collec tors remember that straight pipe will not restrict airflow as much as flexible tubing Also Ys and elbows will restrict airflow less that Ts When con necting to the dual ports of the SUPERMAX 37 or 37x2 use a larger diameter pipe to the machine and then split to two 4 hoses connected to the ports An alternative is to use two separate 4 lines running to the ports do not use only one 4 line and split it by the machine Multiple Piece Sanding Runs When abrasive planing or thickness sanding a run of similar pieces that you want to have the same thickness it is best to determine the thickness of the thinnest piece and process all pieces to that same thickness Be aware that the sander will remove cups and crowns in the work piece consider this when mea suring and processing stock to the same thickness Sanding Multiple Pieces At Once When sanding multiple pieces simultaneously make sure to stag ger step the pieces across the width of the con veyor belt This provides better contact with the tension rollers Try to only process multiple pieces of similar thickness If there is a significant thick ness difference the thinner pieces can slip on the conveyor belt if they do not contact the tension rollers Also note that pieces thicker than 3 4 should be longer than the minimum normally re commended to prevent tipping of the stock see OP
13. indicators located on both sides of the drum The drum adjustment knobs allow proper depth of cut with virtually any abrasive grit combinations on the drums The two drums are normally both used during sanding operations but either the primary or secondary drum can be used alone Single or Primary Drum To adjust the drum of single drum models or to adjust the primary drum of dual drum models set the drum height equal to the thickness of the piece to be processed This is most easily done as follows Lower the con veyor table to a depth greater than the thickness of the board Do not start the drum at this time Start the conveyor and feed the board until it is OPERATING YOUR SUPERMAX 13 beneath the drum s Raise the conveyor table so the drum s contact the board but the drum s can still be rotated by hand Continue to run the board through the machine This is the setting for the first sanding pass The depth of cut can be measured on the depth gauge or by fractions of a revolution of the height adjustment handle Note One revolution of the handle will raise the table 3 32 of an inch 1 3 of a turn will equal 1 32 of an inch etc Secondary Drum On dual drum models sanding with a different abrasive grit on each drum is pos sible in a single pass The coarser abrasive is wrapped on the primary front drum for dimen sioning and surfacing of the wood while the finer abrasive is wrapped on the secondary rear drum
14. 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 12 e 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 12 f From this point cut a taper as was done with the starting edge of the strip The taper on the remaining roll can be used as the taper for the starting edge of the next strip to be cut n 2 12 4 SANDPAPER STRIP ABRASIVE SIDE Up A A N x v Also see Fig 12 b and Fig 12 c Fig 12 a Marking and cutting taper on strip 4 With the trailing edge of the strip properly cut rewrap the drum and insert the tapered end through the slot in the right inboard end of the drum Insert the tapered end into the inboard take up fastener Pull up on the clip lever to open the clip and pull the take up lever to the top as shown Fig 12 g After inserting the strip end release the clip lever by moving your index finger toward the drum slot This allows the clip to retain the abrasive while holding the take up lever in an up
15. load ing of the abrasives slippage on the conveyor table and or the accumulation of material inside the drums which can throw off the center of bal ance Leave the dust collector on when cleaning dust from the drums Also brush the conveyor belt after cleaning operations If not cleaned the con veyor belt could allow stock to slip during sanding operations WSS 4 aA Fig 18 Cleaning abrasive strips TROUBLESHOOTING YOUR SUPERMAX 19 TROUBLESHOOTING YOUR SUPERMAX Any operating problems with the SUPERMAX drum sander will likely occur most often during the period that you are becoming familiar with its components and their adjustments If you are experiencing a problem affecting the machine s Problem Motors do not start Drum motor overloads Conveyor motor oscillates Drum motor or conveyor gear motor stalls Possible Cause Main power cord unplugged from receptacle Circuit fuse blown or circuit breaker tripped Drum motor thermal overload protector tripped single phase only Magnetic starter thermal overload protector tripped SUPERMAX SE single and three phase models Inadequate circuit Machine overloaded Motor not properly aligned Shaft collar worn Drive roller bent Excessive depth of cut sanding performance check the following listings for potential causes and solutions it may also pay to review the previous section
16. models do not loosen the set screws on the upper drum support castings 3 Install the power feed gear motor Rotate the drive roller on the conveyor system so the flat part of the shaft is down If necessary plug the gear motor into an appropriate 220V AC outlet to rotate the motor output shaft coupling so the set screws face downward Unplug the gear motor Slide the power feed motor assembly onto the drive roller shaft aligning the shaft coupling and four mounting holes Start the four 5 16 hex head bolts on the power feed motor mounting bracket but do not tighten yet Next tighten the set screws in the coupling on the drive roller shaft making sure they are on the flat of the shaft Rock the drive roller while tight ening the set screws to make sure they are centered properly on the flat Install the safety shield on the bottom of the assembly with two screws Then plug in the cord and turn conveyor on full speed While it is running tighten the four 5 16 bolts to secure the motor assembly in place 4 If necessary adjust the tension of the V belt between the primary motor and driven pulleys To do this loosen the two screws in lower belt guard and loosen the pinch bolt located at the back of the motor support casting Slide the motor sup port casting down the column tube until the V belt is taut Tighten the two screws in lower belt guard Retighten the motor support pinch bolt TABLE SUPPORT CASTING HEX NUT amp SET
17. need to be changed to eliminate noise or excessive play in the drum 1 With the drums resting on the conveyor bed proceed as follows Remove the four 3 8 x 1 1 4 bolts from the drum support casting on the right side remove the on off switch and depth gauge with the bolts 2 Next remove the upper two 3 8 x 1 1 4 bolts from the drum support casting on the left out board side of the sander Loosen the bottom two 3 8 x 1 1 4 bolts from the left drum support casting but do not remove them 3 Lift the right inboard side of drums and place a 2x6 on edge under the drums Loosen and remove the V belt pulleys from drum shafts see Fig 39 Important Make sure to note the loca tion of the pulleys Also measure the distance from CSE i PR V 3 J PL Z gt Fig 43 Removing rear bearing inboard side pulley edge to the drum support casting to use as a reference when reinstalling pulleys so they will be properly aligned 4 Replace bearings by following Steps I through 4 under Bearing Replacement Left Side above Fig 41 44 5 Reinstall V belt pulleys on the drum shafts making sure they are located in the same position as before Doublecheck this alignment after the drums have been bolted back in place using the measurement from Step 3 above 6 Lower the drums by removing the 2x6 Reinstall the six 3 8 x I 1 4 bolts in the drum support castings and tighten them Install the on off sw
18. of the height adjusting screw on the left outboard side and under the height adjustment handle on the right inboard side of the machine On both sides the washer and E clip or washer only should be snug on the casting just below the wash er If there is a space between the washer and the casting tighten one set screw in each of the table support castings If one height adjusting screw is loose remove the miter gear from the cross bar on that side Turn down the threaded height adjusting screw rod until it is snug with the washer Make sure both sides are snug on top Reinstall the miter gear and tighten Loosen the set screws in the table support castings and test for smooth operation ADJUSTING TABLE SUPPORT CASTINGS If the conveyor table does not raise and lower easi ly measure the distance between the top of the base column support and the bottom of the table 26 SUPERMAX OWNER S MANUAL ag a ae X ES Fig 23 Adjusting table support castings support casting Fig 23 on both the right inboard side and the left outboard side of the machine Compare these measurements they should be within 1 16 If not disengage the miter gear on the right inboard side of the cross bar Adjust the conveyor bed height using the height adjustment handle to get the same measure ment on both sides Then re engage the miter gear on the cross bar If the conveyor table is still difficult to raise or lower the table s
19. pro ceeding further Try to avoid over adjustments Make sure wrench is below surface when sanding CHECKING TABLE HEIGHT CONTROLS The table height and depth of cut is controlled by the height adjustment handle see Fig 11 Turning the handle raises or lowers both sides of the table simultaneously by transferring the handle rotation through the miter gear and cross bar assembly Important Before using the height adjustment be sure to loosen both the set screws located on the front of both table support castings see Fig 3 and Fig 11 to allow the table support to slide on both column tubes These set screws are tightened for shipping and must be loosened and readjusted to SETTING UP YOUR SUPERMAX 9 a HEIGHT ADJ HANDLE DRUM ORT SET SCREW Fig 11 Table height adjustment mechanism allow the table support castings to move freely on the column support tubes Readjust the set screws just so they eliminate free play between the table support casting and the column tube To properly adjust tighten the set screws see Fig 3 only finger tight so they lightly touch the column tubes Then hold each set screw in position with an Allen wrench and tighten the hex nut Check the operation of the height adjustment mechanism If it does not operate smoothly or eas ily further adjustments may be necessary Refer to the servicing section of this manual which begins on page 24 for further adjustment procedures MONTHLY
20. step procedure Step 1 With the sanding drums properly aligned loosen all four tension roller suspension bolts Raise the table to the bottom of the sanding drum s The tension rollers should be resting firmly on the conveyor bed Tighten only the two rear outfeed tension roller suspension bolts Step 2 Lower the conveyor table by one full turn of the height adjustment handle At this point press down on the front infeed tension roller so it is resting on the table Now tighten the front infeed tension roller suspension bolts If there still is a snipe mark left on pieces being sanded repeat Step 1 and Step 2 but in Step 2 lower the conveyor bed a half turn instead of a full turn Warning Improperly adjusted tension rollers i e those set too high rendering them non functional could allow kick back slippage of pieces being sanded SERVICING YOUR SUPERMAX 29 REPLACING SANDING DRUMS Changing drums on the SUPERMAX is a relatively rare procedure most often the result of external damage or damage resulting from improper set tings for the stock being sanded To begin disconnect power to sander Remove the sandpaper on the drums and level the sanding drums to each other Next loosen the pinch bolt of the motor support casting loosen two screws in lower belt guard raise the motor and retighten the pinch bolt With this done follow the steps below for dual drum sanders The procedure is basically the same for singl
21. ACHINE m DO NOT MODIFY THIS MACHINE MODIFICATIONS ARE DONE AT THE OWNER S RISK AND ALSO WILL VOID THE MANUFACTURER S WARRANTY E FOR CUSTOMER SERVICE AND QUESTIONS ABOUT THE OPERA TION OR MAINTENANCE OF THIS MACHINE PLEASE CALL YOUR AUTHORIZED PERFORMAX DEALERSHIP PART NO 92 3700D COPYRIGHT 2006 PRINTED IN USA
22. DJUSTMENT SETTING THE DEPTH OF CUT Adjusting the SUPERMAX for the proper contact between the abrasive and the stock determines the mechanical depth of cut Determining the depth of cut is the most important set up procedure before operating the SUPERMAX sander It may take some experimentation to determine the prop er depth of cut given the variables of abrasive grit type of wood and feed rate For best results use scrap wood to practice sanding and to develop skill and familiarity with the machine before doing fin ish work good rule of thumb when sanding with grits finer than 80 is to raise the conveyor table so the drum s contacts the workpiece but still can be rotated by hand When using grits coarser than 80 grit you can raise the conveyor table slightly more However a combination of several variables will determine the proper depth of cut to use includ ing the following 1 Abrasive type and grit size 2 Width of the piece being processed 3 Hardness of the piece 4 Feed rate of the conveyor belt If your SUPERMAX is a single drum model the depth of cut is controlled by the table height adjustment handle which raises or lowers the con veyor table under the drum If your machine is a dual drum version the depth of cut of the primary drum is also adjusted by the table height adjust ment handle On dual drum units the depth of cut of the sec ondary drum is controlled by the two adjustment knobs analog
23. ERATING YOUR SUPERMAX 17 Specifications page 37 Going to longer pieces 1s especially important when sanding boxes or other tall short or light stock Edge Sanding When edge sanding the Performax sander will mimic the opposite edge of the stock which is laying on the conveyor belt Because of this it is important for the stock edge to have been ripped at the proper angle to the face before the sanding process When edge sanding stock that is less than 3 4 wide or more than 2 high it is good procedure to stack and clamp sev eral pieces together to prevent them from slipping or tipping on the conveyor belt Sanding Imperfect Stock When sanding stock with a cup or crown place the crown up This will stabilize the stock to help prevent tipping or rock ing during sanding After the crown has been removed and the top is flat turn the stock over and sand the opposite side To avoid personal injury take special care when sanding stock that is twisted bowed or otherwise varies in thickness from end to end If possible support such stock as it is being sanded to keep it from slipping or tip ping Use extra roller stands help from another person or hand pressure on the stock to minimize potentially hazardous situations Face Frames amp Raised Panel Doors It is very important to have the proper abrasive contact when doing this type of sanding If the machine is set to take an excessive depth of cut the result can be a go
24. Keep This Manual Handy For Quick Reference OWNER S MANUAL For SUPERMAX 25 and SUPERMAX 37 Single Drum SUPERMAX 25x2 and SUPERMAX 37x2 Dual Drum SHOWN WITH OPTIONAL CASTERS 25 IMPORTANT BEFORE OPERATING YOUR SUPERMAX READ THE INSTRUCTIONS IN THIS MANUAL FOR UNPACKING AND SETTING UP YOUR MACHINE SM SuperMax Tools 2 SUPERMAX OWNER S MANUAL CONGRATULATIONS You have made a wise purchasing decision by adding this Made In USA machine to your tool line up The main purpose in inventing and devel oping the machine you ve purchased was to bring a new dimension of productivity to your workshop be it large or small Right from the start our goal at SuperMax Tools has been to manufacture equipment that is capable of providing you with maximum economy maximum utility and maxi mum performance Your SuperMax Tools drum sander 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 drum sanders feature patented self cooling drums and spring tension abrasive take up fasteners as well as sealed and permanently lubricated bearings The exclusive SuperMax Tools variable speed power feed conveyor system provides you with ultra precise control whether you are surfacing rough sawn lumber dimensioning otherwise unusable stock cleanin
25. M INDICATOR 95 1660 1 37 INBOARD SECONDARY DRUM ADJ BKT 40 0526 l 38 1 2 13x2 HEX HEAD BOLT 10 0407 1 39 1 2 INTERNAL TOOTH LOCK WASHER 11 0508 l 40 INBOARD DRUM MOUNT BKT 40 0520 l 41 5 16 18 RETAINING NUT 20 1159 2 42 1 2 LD SPACER 30 1304 1 43 IDLER PULLEY 50 1258 l 44 1 2 SAE WASHER 11 0209 l 45 1 2 LOCK WASHER 11 0013 l Continued on page 44 SUPERMAX DUAL DRUM HEAD ASSEMBLY 43 44 SUPERMAX OWNER S MANUAL SUPERMAX DUAL DRUM HEAD ASSEMBLY PARTS LIST Cont d Ref Description Part Number Qty Number SM25x2 Both SM37x2 Unit Models 46 1 2 13 HEX NUT 12 0009 l 47 DRIVEN PULLEY 50 0502 2 48 5 16 18x1 2 HEX HEAD BOLT 10 9101 2 49 BELT GUARD COVER 80 1028 80 1038 l 50 8 32x1 PHILLIPS FILLISTER HEAD SCREW 10 3107 6 51 COMPRESSION SPRING 20 3268 6 32 5 16 18x3 4 CARRIAGE HEAD BOLT 10 1203 4 53 8 32 SQUARE NUT 12 0102 6 54 TENSION ROLLER BASE BKT 40 0306 2 55 TENSION ROLLER SUSPENSION BKT RIGHT 40 0302 3 56 TENSION ROLLER SUSPENSION BKT LEFT 40 0303 3 57 5 16 LD OILITE BUSHING 50 3105 6 58 TENSION ROLLER 30 1205 30 3119 3 59 MIDDLE INNER BELT GUARD 41 1028 l 60 10 24 RETAINING NUT 20 1155 2 61 10 24x3 8 SLOTTED HEX HEAD SCREW 10 3803 4 62 5 16 18 FLANGED LOCK NUT 12 0207 6 63 5 16 18x3 8 SET SCREW PULLEY 10 8903 2 64 BELT GUARD PLATE
26. MAINTENANCE For best results perform the following recommend ed maintenance procedures on a monthly basis Lubricate conveyor bushings and check for wear Lubricate all moving parts such as threaded rods washers and column tubes Clean sawdust from the sandpaper and the con veyor belt Blow dust from the inside of sanding drum s and the motors e Check all set screws for tightness on parts such as table support castings bearings conveyor coupler castings pulleys and miter gears 10 SUPERMAX OWNER S MANUAL WRAPPING ABRASIVE STRIPS Note When using Pre Marked or Pre Cut abrasives not all of the steps below are neces sary 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 The end of the roll is first tapered and attached to the left out board side of the drum Then the strip is wrapped around the drum and the second taper is made for attachment to the right inboard side of the drum To attach a strip to the drum follow the procedure below 1 Mark and cut a taper at one end of the roll as shown in Fig 12a Because the tapered end should use most of the left outboard slot width its end must be trimmed Fig 12 b and 12 c Raise the clip lever on the left outboard side of the drum Fig 12 d Insert the tapered end through the slot and into the fastener so that
27. PERMAX 11 g i Fig 12 h Allow room inside slot for strip to move Fig 12 i Reset take up as needed as strip stretches 12 SUPERMAX OWNER S MANUAL OPERATING YOUR SUPERMAX Before using your SUPERMAX drum sander 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 BASIC OPERATING PROCEDURES After you have selected and installed abrasive strips and connected the machine to a dust collec tion system you are ready to begin to use the SUPERMAX The basic operating procedure for all of the SUPERMAX models is as follows 1 Set depth of cut 2 Start drum s 3 Start conveyor and select feed rate 4 Start dust collector system 5 Feed stock through unit To feed stock through the SUPERMAX rest and hold the board to be sanded on the conveyor table allowing the conveyor belt to carry the board into the drum s Once the stock is halfway through reposition yourself to the outfeed side of the machine to receive and control the board as it exits the unit FEED RATE CONTROL a SECONDARY b DRUM ae ny ADJUSTMENT LE KNoB DR EE _ lt i 23e Am er 5 ung gt 3 Moe ds KP dr EG om om HAS r oo a Fig 13 SUPERMAX operating controls KNOB HEIGHT A
28. REPLACING V BELT To change the V belt on the SUPERMAX first unplug machine from the outlet Remove two screws in lower section of belt guard and loosen the pinch bolt of the motor support casting Raise the motor and retighten the pinch bolt The pro cedure is the same for single drum sanders except that there is one driven pulley instead of two V Belt Removal 1 Remove the lower outer belt cover by removing the four 10 32 screws holding it in place see Fig 29 and 37 Remove the two 5 16 x 1 2 hex head bolts holding it in place pull the middle cover to the left Take the V belt off the pulley Fig 38 2 Loosen the pinch bolt of the motor support casting raise the motor and re tighten pinch bolt Fig 38 Removing main motor V belt drive 3 Remove the miter gear from the right inboard side of the transfer rod Loosen the shaft collar on the left outboard side of the rod and pull the rod back enough so the V belt can be removed Note the routing of the old V belt now remove the old V belt and replace it with the new V belt Machine Reassembly 1 To reassemble the unit after replacing the V belt first place the transfer rod back through the machine Tighten the shaft collar Reinstall the miter gear on the transfer rod making sure the set screw is centered on the flat of the rod 2 Adjust the tension on the V belt by sliding the motor down and then tightening the pinch bolt in the motor support casting A
29. TIPPED SET SCREW 10 9906 4 18 LOCKING KNOB 81 3132 2 19 OUTBOARD TABLE SUPPORT CASTING SINGLE 30 5105 l DUAL 30 5205 1 20 TABLE MOUNT BRACKET 40 0025 40 4242 2 21 3 8 16x1 HEX HEAD BOLT 10 0205 18 22 5 16 WROUGHT WASHER 11 9103 37 25 3 8 16 FLANGE LOCK NUT 12 0209 24 24 INBOARD HEIGHT ADJ SCREW 30 1212 30 1212HR l 29 MITER GEAR 20 1101 4 26 1 2 I D OILITE BUSHING 50 3107 4 21 COLUMN TUBE 30 1236 2 27 COLUMN TUBE 30 3044 2 28 1 2 13x1 2 SOCKET HEAD SET SCREW 10 8905 2 29 SHAFT COLLAR 1 2 I D 20 1103 2 30 TRANSFER ROD 30 1213 30 3117 l 31 MOTOR MOUNT 40 0106 32 MOTOR SUPPORT CASTING 30 5107 1 35 3 8 16x1 1 2 HEX HEAD BOLT 10 9207 9 34 LEG CASTING 30 1102 4 34 LEG CASTING 30 1103 4 35 COLUMN BASE CASTING 30 1101 2 36 LEVELING FEET 20 0655 4 P 3 8 16 HEX NUT 12 0005 8 38 BASE SUPPORT BRACKET 40 0230 40 4241 l 39 RETAINING RING 20 0752 l 40 OUTBOARD HEIGHT ADJ SCREW 30 1211 30 1211HR l SUPERMAX SE STAND ASSEMBLY 39 40 SUPERMAX OWNER S MANUAL SUPERMAX SINGLE DRUM HEAD ASSEMBLY PARTS LIST Ref Description Part Number Qty Number SM25 Both SM37 Unit Models l DUST COVER 40 0525 40 4237 l 2 DUST COVER HANDLE 80 2841 l 3 8x1 2 HEX HEAD SELF TAPPING SCREW 10 3904 2 4 1 4 20x1 2 ROUND HEAD MACH SCREW 10 3205 8 5 1 4 INTERNAL TOOTH LOCK WASHER 11 0504 8 6 DUST COVER MO
30. UNT 40 0240 40 4243 l 7 HINGE 40 0225 2 8 1 4 SAE WASHER 11 0205 8 9 1 4 20 HEX NUT 12 0001 8 10 3 8 16x1 HEX HEAD BOLT 10 9205 8 11 5 16 WROUGHT WASHER 11 9103 8 12 DRUM MOUNTING BRACKET 40 0210 2 13 3 8 16 FLANGED LOCK NUT 12 0209 8 14 5 16 18x1 CARRIAGE HEAD BOLT 10 1204 4 15 DRUM BEARING 50 3057 2 16 1 4 28x1 4 SET SCREW BEARING 10 8602 4 17 8 32x1 PHILLIPS FILLISTER HEAD SCREW 10 3107 4 18 COMPRESSION SPRING 20 3268 4 19 RIGHT TENSION ROLLER SUSPENSION BKT 40 0302 2 20 LEFT TENSION ROLLER SUSPENSION BKT 40 0303 2 21 TENSION ROLLER BASE BKT 40 0304 2 22 8 32 SQUARE NUT 12 0102 4 29 5 16 SAE WASHER 11 0206 4 24 5116 18 HEX NUT 12 0003 4 25 5 16 1 D OILITE BUSHING 50 3105 4 26 TENSION ROLLER 30 1205 30 3119 2 27 OUTBOARD ABRASIVE FASTENER 21 1175 l 28 6 32x3 8 FLAT HEAD PHILLIPS SCREW 10 3003 2 29 SANDING DRUM 30 1200 30 3100 i 30 INBOARD ABRASIVE TAKEUP FASTENER 21 1172 l 31 1 4 x1 KEY STOCK 20 0762 l 32 UPPER INNER BELT GUARD 40 3050 l 33 10 24 RETAINING NUT 20 1155 4 34 DRIVEN PULLEY 50 0502 l 35 5 16 18x3 8 SET SCREW PULLEY 10 8903 l 36 MIDDLE INNER BELT GUARD 40 3061 l 37 BELT GUARD COVER 40 3060 l 38 10 24x3 8 SLOTTED HEX HEAD SCREW 10 3803 4 SUPERMAX SINGLE HEAD DRUM ASSEMBLY 41 42 SUPERMAX OWNER S MANUAL SUPERMAX DUAL DRUM HEAD ASSEMBLY PARTS LIST
31. able cleaning sticks following the manufac turer s directions See Fig 18 Cleaning sticks are available from your dealer or from SuperMax Tools When cleaning also brush the stick crumbs from the drum while it is still rotating Important Wear eye protection tight fitting clothes and keep alert during this operation to avoid injury Cloth backed abrasives can be cleaned by soaking in paint thinner or mineral spirits for 20 minutes to 1 hour then using a brush to remove any build up or burns Dry the abrasive strips completely before reuse In some cases build ups resulting from burns can be removed with Plexiglas held on edge Fig 17 Offset stock feeding angle over a rotating drum Have dust collection turned on when cleaning Stretching Abrasive Life When sanding metal or solid surface MDF or particle board ceramic abra sive RegaliteTM will last longer than aluminum oxide and also allow a more uniform finish Abrasive life can also be increased on SUPERMAX machines by removing the abrasive strip from the drum and reversing it To do this remove the strip and use what was the trailing end as the starting end on the left outboard side of the drum Reversing the strip will provide a fresh set of cut ting edges on the drum Keeping The Machine Clean For best results make cleaning the machine a regular shop proce dure Allowing excess build up of dust and debris can adversely affect performance through the
32. as detected too great a depth of cut and or too fast a feed rate This change in conveyor speed may leave a detectable mark on finish surfaces If a mark is vis ible make adjustments by slowing conveyor and or lessening the depth of cut and run the stock through again Begin experimenting with the feed rate set at about 40 to 50 of maximum The best feed rate will depend on a number of factors including type of stock grit and depth of cut used and whether the stock is feed directly in line with the conveyor bed or at an angle If you observe a ripple effect on the stock slow down the feed rate If the finish is smooth and the machine is not overworking you can experiment with using a faster feed rate Also try a faster feed rate if the stock you are working begins to show burn marks With cherry hard maple and some other hardwoods using a shallower depth of cut and a faster feed rate will help minimize burn marks Slightly angling the stock as it is fed into the machine may also help pre vent burning the stock Because of the wide range of variables it is impor tant to experiment with your specific conditions and make adjustments to achieve the optimum feed rate If problems occur first check the depth of cut and or adjust the feed rate Refer to Troubleshoot ing Your SUPERMAX in this manual page 19 USING THE DEPTH GAUGE The depth gauge see Fig 16 measures the distance between the conveyor table and the sanding drum
33. cators to zero on both sides Set the secondary drum adjustment indicators by loosening hex nut then moving the indicator scale so that the zero mark is directly under the needle and retightening the hex nut see Fig 9 Likewise zero the indicator for other side of drum Take care not to overtighten the hex nut of the indicator This can flare the brass bush ing and render the indicator inoperable Also check that the secondary drum adjustment knobs turn with a slight resistance to avoid any _ INDICATOR m NEEDLE NON xk MEANN e INDICATOR SCALE INDICATOR HEX NUT Fig 9 Rear drum adjustment indicator movement during operation To adjust knob resis tance turn the knob clockwise to reveal the set screw on the shaft collar below the bracket then loosen the screw Making sure the adjustment knob is tightly seated on top of the bracket raise the shaft collar up against the bracket from below and retighten the set screw Note The nut of the rear bolt on the rear secondary drum bearing bracket should be backed off a quarter turn from being fully tightened This allows the lock washer to be depressed slightly but not complete ly This is the pivot point for the rear drum CHECKING THE CONVEYOR BELT Conveyor belt tension and tracking adjustments may occasionally be necessary during break in and normal operation to compensate for belt stretching Install Ceramic Guides at this time See the Ceramic Guides instru
34. conveyor belt continually tracks to one side of the machine first try reversing the belt on the conveyor bed If this doesn t remedy the problem place a level on the conveyor bed to make sure the conveyor bed is not twisted If it is twisted see page 7 for instructions on squaring up the bed If squaring up the bed does not remedy the problem proceed with the steps below SERVICING YOUR SUPERMAX 31 Fig 35 Conveyor belt replacement Step 1 Check the conveyor drive and driven roller to make sure they are parallel to the surface of the conveyor bed To do this first center the conveyor belt on the bed Then lay a straight edge on the exposed edge of the conveyor table on the left out board side extending it over the drive roller then driven roller Note the distance between the drive roller then driven roller and the straight edge 3 w a gt a ae JS gt op ERE CONVEYOR MOUNTING BOLT ADA Fig 36 Tensioning and tracking conveyor belt 32 SUPERMAX OWNER S MANUAL TRANSFER Rop Fig 37 Removing belt guard and transfer rod Step 2 Now repeat Step 1 on the right inboard side of the conveyor Compare the measurements from side to side If they are not equal loosen one of the brackets that hold the drive or driven roller in place Tip this bracket until the distance between the drive or driven roller and the straight edge are equal from side to side then tighten the bracket
35. ction sheet inside Ceramic Guides box for details Ceramic Guides are pack aged separate on sander Belt Tension To adjust the tension of the convey or belt first adjust the take up screw nut see Fig 10 on both sides of the conveyor to obtain approxi mately 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 r Fig 10 Adjusting conveyor belt tracking result in bent rollers premature wearing of the bronze bushings or belt Belt Tracking Belt tracking adjustments are made while the conveyor belt is running After the proper belt tension is obtained see above turn the convey or unit on and set it at the fastest speed setting Watch for a tendency of the conveyor belt to drift to one side of the conveyor To adjust the belt tracking tighten the take up screw nut see Fig 10 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
36. djust so the belt deflects about 1 2 between the pulleys when pressed Excessive tension can increase motor load and decrease bearing life while a loose belt can reduce operating efficiency and shorten belt life 3 Reinstall the outer and middle belt guard using the two 5 16 x 1 2 hex head bolts and the four 10 32 screws 4 Make sure that the pulleys are in alignment by holding a straightedge across their flat sides and adjusting to it Also check that all bolts are tight before using the sander ROTATING REPLACING DRUM BEARINGS Replacing the permanently lubricated drum bear ings on the SUPERMAX sander is a relatively straight forward procedure Bearings should be replaced when they allow excessive play of the drum make excessive noise or otherwise indicate failure Note that if clicking noises in the bearings are a problem rotating may be a solution instead of replacement as follows See Fig 40 Rotating Bearings Step 1 Loosen the set screws in the bearing collar Leave the allen wrench in one of the set screws Then rotate the drum within the bearing and tighten the set screws Step 2 If the clicking persists or if the drum shaft is tight in the bearing and cannot rotate then loosen the two bolts holding the bearing and the flange for the bearing Now repeat Step 1 After the drum is rotated within the bearing tighten the flanges first and then the set screws Note After tightening the rear bolt in the flange l
37. e The nut of the rear bolt on the rear secondary drum bearing bracket should be backed off a quarter turn from being fully tight ened This allows the lock washer under the rear bolt on the rear bracket to be depressed slightly but not completely After alignment is completed lower the motor mount to re establish V belt ten sion Tighten two screws in belt guard ADJUSTING TENSION ROLLERS With the sanding drums properly aligned raise the table to the bottom of the sanding drums Loosen all four tension roller suspension bolts see 1 Fig 28 Lower the table by one full turn of the height adjustment handle At this position the tension roller assembly should be resting on the table with the drums suspended slightly above the table Then retighten the tension roller suspension bolts Note Too much tension roller pressure can cause snipe marks which are identified as a visible line running across the width of the board approxi mately 2 1 4 from the end of the board If a snipe mark occurs on the trailing end of the board adjust the infeed tension roller Tension roller pres Fig 28 Tension roller adjustment Tension Roller Suspension Bolts Tension Roller Spring Retaining Screws sure can be adjusted two ways either by loosening the tension roller spring retaining screws see 3 Fig 28 or by raising the height of the tension rollers To adjust the tension rollers to eliminate snipe marks use this two
38. e drum sanders except there is only one driven pulley and drum Disassembly Procedure 1 Disengage the outer belt guard cover by remov ing the four 10 32 screws and the two 5 16 x 1 2 bolts holding it in place Fig 29 Take the V belt off driven pulleys 2 Level the drums to each other see pages 7 and 8 in this manual Then raise the conveyor bed until the drum s rest on the conveyor bed 3 Remove the four 3 8 x 2 1 4 bolts from the drum support casting on the right side see Fig Fig 29 Removing outer belt guard 30 Remove on off switch bracket and depth gauge 4 Remove the top two 3 8 x 2 1 4 bolts from the drum support casting on the left outboard side of the sander Loosen the bottom two 3 8 x 2 1 4 bolts from the left drum support casting but do not remove them 5 Lift the right inboard side of drums and place a 2x6 on edge under the drums Fig 32 Loosen and remove the V belt pulleys from drum shafts Important Make sure to note the location of the pulleys Also measure the distance from pulley edge to the drum support casting to use as a refer ence when reinstalling pulleys so they will be prop erly aligned 6 Loosen the set screws in the two V belt pulleys and remove the pulleys Next loosen the two set screws in each of the four bearing collars Fig 33 Now remove the sanding drum support brackets that hold the bearings Fig 34 Remove the sanding drums at this time and ins
39. e that the column tubes are cen tered inside the bore of the table support castings Fig 19 If not loosen the casting bolts and tight en the set screws at the front of table support cast ing to center the tube Retighten the bolts and loosen the set screws 5 If the height adjustment mechanism feels rough check the miter gear Fig 20 alignment The miter gears can be adjusted on their shafts by loosening the set screws on the gears Check and adjust so that the gear mesh is not too tight or too loose and that the gear teeth align with the opposing gear Note that the shaft collars located on the cross bar Fig 21 should be adjusted to control the lateral movement of the cross bar to maintain accurate miter gear alignment and mesh The mesh of the miter gears should be smooth and even If not adjust the gears for good mesh Fig 20 Measure the space between the miter gear and the adjusting screw support that holds the height adjusting screw in place Fig 21 The SERVICING YOUR SUPERMAX 25 Fig 22 Height controls on outboard side distance should be 1 32 or less If there is exces sive space move the adjusting screw support to the proper distance above the miter gear and retighten Loosen the set screws in the table support castings Fig 19 and test for smooth operation 6 Next check the position of the height adjusting screw rods First raise the conveyor table Then check the E clip and washer at the top
40. ear drum on dual drum sanders Follow Steps 1 through 3 for the bearing on the left side of single drum sanders but do not loosen the rear bolt as instructed in Step 3 1 Begin by removing the outer half of the bearing flange Loosen the set screws in the bearing collars and remove the bearing Fig 41 2 If the shaft of the drum is rough from the set screws use emery cloth or sandpaper to smooth down any raised edges Slide the new bearing on the shaft but do not tighten the set screws yet 3 Install the outer half of the original bearing flange and tighten the bolts on the rear drum After tightening the rear bolt in the flange loosen it approximately 1 4 turn which allows the rear drum to pivot Then tighten the set screw in the bearing collar Fig 43 4 Now move to the front drum and repeat Steps 1 through 3 but do not loosen the rear bolt as instructed in Step 3 Important Be sure to note the sequence of parts used for the rear drum indi cator assembly Also when reinstalling do not Fig 42 Removing front bearing inboard side over tighten the nut that holds the indicator in place see exploded view page 43 Bearing Replacement Right Side If the left outboard bearings are the only ones that need changing proceed to reassemble the unit You can check the drums at this point by lowering the con veyor bed and spinning the drums by hand This will help determine if the inboard bearing s
41. er turn Depth Gauge included 25 and 25x2 6 37 and 37x2 12 Model 25 350 Ibs Model 25x2 375 lbs Model 37 400 lbs Model 37x2 455 lbs Mandatory for all models LINE Ol a a ii CONTROLLER P N 72 2270 DH Fa GEN aoe GRANGE POWER TO SWITCH MOTOR SWITCH P N 72 131 Y 10 MOTOR WIRING DIAGRAM SUPERMAX INTELLISAND 5 HP FRREE PHASE 60Hz 230 VOLT PEWER CI893 PRI DGESSP Three phase wiring diagram 38 SUPERMAX OWNER S MANUAL SUPERMAX STAND ASSEMBLY PARTS LIST Ref Description Part Number Qty Number SM25x2 Both SM37x2 Unit Models l HEIGHT ADJUSTMENT HANDLE ASSEMBLY 31 0020 l 2 3 16 x1 ROLL PIN 20 0772 l 3 5 8 I D OILITE WASHER 50 3080 2 4 3 PLASTIC COLUMN TUBE CAP 80 4015 2 5 ADJ SCREW SUPPORT CASTING 30 1112 3 6 1 4 20x1 2 SOCKET HEAD SET SCREW 10 2804 6 7 5 16 18x3 8 SOCKET HEAD SET SCREW 10 2903 4 8 PLASTIC CAP 80 4013 3 2 SELF TAPPING SCREW 10 3905 2 10 DEPTH GAUGE POINTER 40 1102 l 11 DEPTH GAUGE SCALE 40 1101 94 1654 l 11 DEPTH GAUGE NOT SHOWN 30 1260HR l 12 DRUM SUPPORT CASTING SINGLE 30 5106 2 DUAL 30 5206 2 15 DEPTH LOCK CASTING 30 1112 2 14 INBOARD TABLE SUPPORT CASTING SINGLE 30 5104 l DUAL 30 5204 1 15 5 16 18 HEX NUT 12 0003 4 16 5 16 SAE WASHER 11 0206 4 17 5 16 18x3 4 BRASS
42. etting Single or Primary Drum 13 Setting Secondary Drum Dual Drum Machinses 13 Disengaging The Drums Dual Drum Machinses 14 Selecting Intellisand Feed Rates 14 Using The Depth Gauge 15 Selecting Drum Abrasives 16 Tips For Maximum Performance 17 TROUBLESHOOTING YOUR SUPERMAX Troubleshooting Guide Mototrs 19 Troubleshooting Guide Machine 20 Troubleshooting Guide Operations 22 SERVICING YOUR SUPERMAX Adjusting Height Controls 24 Adjusting Table Support Castings 25 Adjusting Sanding Drums 26 Adjusting Tension Rollen u u u saa 28 Replacing Sanding Drums 29 Replacing Conveyor Belts 31 Replacing V Belt uuu ukasaypussasaawasinayakaquqa 32 Rotatine Replacing Drum Bearings 33 Replacing Electrical Components 36 Electrical Diaprani u L a kashaq 36 SUPERMAX TECHNICAL DATA SUPERIVIAX Speci CaU ONS asseruit 37 Parts List For SUPERMAX Stand 38 Parts List For Single Drum Assembly 40 Parts List For Dual Drum Assembly 42 Parts List For Conveyor Assembly 44 SUPERMAX Accessories amp Supplies 47 FOR YOUR SAFETY Read all instructions carefully and note the safety cautions on the opposite page and on the bac
43. for thickness dimensioning of boards To calibrate the depth gauge raise the conveyor table until the drum s wrapped with abrasive touches the con INTELLISAND CONTROLLER Ki Fig 15 Intellisand Controller and depth gauge OPERATING YOUR SUPERMAX 15 veyor table Loosen the two slotted screws holding the indicator needle to the table mount bracket Fig 16 Raise or lower the indicator needle to read at zero and tighten the two slotted screws USING THE PROSCALE DEPTH GAUGE The ProScale depth gauge Page 35 Fig 45A has its own manual The ProScale can be calibrated by raising the conveyor until the drum s are touching the conveyor and zero the readout Another calibra tion method is to sand a piece of wood measuring the thickness of the wood and change the reading on the ProScale See included ProScale manual for details on calibrating and operation USING THE DEPTH STOP A depth stop Fig 16 is located on the column tube just above the tale support casting on the right inboard side The depth stop casting has a lock ing knob located on one side of the casting To operate the depth stop Determine desired thick ness of sanded part by either referencing the depth gauge or sanding a part and measuring the thickness of the sanded part At this sanding thickness posi tion the depth stop along the column tube with the gauge resting on the table support casting and tight en the locking knob on the depth stop Thi
44. g up glued panels or finish sanding either thick stock or the thinnest veneers 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 you 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 owner s manual before operat ing this machine Always heed and follow all nor mal safety precautions including the following Always wear eye protection while operating the sander e Always feed stock against the drum rota tion Never place hands or fingers under the drum or dust cover Keep hands and clothing away from operat ing drums Never operate the sander without its dust cover or drum and belt guarding in place e Always maintain control of boards to avoid kickback know how to prevent it Always disconnect electrical power before doing any servicing or adjusting of the machine MODEL IDENTIFICATION Your SUPERMAX drum sander is one of a family of machines from SuperMax Tools designed to help you achieve results comparable to industrial size sanders at a fraction of the cost The SUPERMAX is available in 25 or 37 sizes in single d
45. gths up to 10 and of at least 8 gauge wire for longer lengths Three Phase The drums of SUPERMAX three phase sanders are powered by a 5 hp 208 230 volt three phase motor Three phase machines include a five wire cord but no plug Three phase SUPERMAX sanders require a minimum dedicated 20 amp circuit Fxtension cords are not recommended Fig 4 Thermal overload switch on some models Fig 5 SUPERMAX Components 1 Height Adjustment Handle 2 Adjusting Screw Support 3 Drum Support Casting 4 Height Adjusting Screw 5 Table Support Casting 6 Adjusting Screw Support 7 Miter Gear 8 Motor Support Casting 9 Transfer Rod 10 Shaft Collars but if used should be 12 gauge wire for lengths up to 10 and 10 gauge wire for longer lengths Note The Intellisand Control Fig 6 pro tects both motors from most overload situations The conveyor motor for feeding stock is infinitely variable from 0 15 ft min If the load on the drum motor reaches its optimum the SandSmart Control will automatically slow the feed rate of the conveyor When the load is decreased on the main motor the feed rate will automatically increase but never exceed the manual setting on the dial CONNECTING DUST COLLECTORS Dust collection is necessary for all SUPERMAX models The SUPERMAX 25 models are equipped with one 4 diameter dust exhaust port at the top of the drum cover The SUPERMAX 37 models have two 4 dust exhaust ports
46. itch and depth gauge with the two inboard bolts Reassembly Procedure 1 Lower the conveyor and spin the drums by hand to make sure the drum shaft is not binding in the bearing If the bearings bind loosen the set screws and the bearing flange for one bearing at a time Spin the drum within the collar then tighten the set screws and then the bearing flange Fig 40 2 Next check the alignment of the drums to the SERVICING YOUR SUPERMAX 35 Fig 44 Installing rear bearing inboard side conveyor system For instructions on this proce dure see pages 7 and 8 of this manual Make sure the drums are parallel to each other 3 Reinstall the V belt on the motor pulley and adjust its tension Then reinstall the pulley guard 4 Test run the sander before sanding stock to re check that all is operating properly and is aligned before sanding good stock Also stop the sander after a couple hours of use and check the bolts and set screws to make sure they are seated properly Fig 45A Conveyor control box on off switch and ProScale SUPERMAX SE 36 SUPERMAX OWNER S MANUAL Fig 45 Conveyor control box and on off switch SUPERMaAx HD REPLACING ELECTRICAL COMPONENTS To replace either the variable speed Intellisand control the on off switch or the conveyor motor use the following disassembly procedure Fig 45 and 45A First disconnect the power supply to the SINGLE PHASE SE SWITCH Pa y
47. k cover of this manual 4 SUPERMAX OWNER S MANUAL ABOUT THE SUPERMAX SYSTEM This manual is designed to help you become familiar components 1 precision machined revolving with your SUPERMAX drum sander and to help drums wrapped with abrasive strips held by a 2 you take advantage of its exclusive features By patented take up mechanism to process stock fed understanding its major components and how by the 3 no give conveyor table which is adjusted they work together you will be able to get the most by 4 an infinitely variable power feed motor and a from your investment The SUPERMAX system is 5 convenient height adjustment mechanism The basically made up of the following five major illustration below shows the major components DUST COVER SECONDARY DRUM ADJ KNOB HEIGHT anta ND 537 DLE SANDING DRUM S TENSION ROLLER MITER GEARS HEIGHT JUSTMENT CONTROL Box CONVEYOR GEAR MOTOR LEFT OUTBOARD SIDE RIGHT INBOARD SIDE Fig 1 SUPERMAX nomenclature UNPACKING YOUR SUPERMAX Your SUPERMAX sander has been shipped com pletely assembled from the factory in a cardboard shroud on a pallet and shrink wrapped in plastic If any damage has occurred as a result of shipment notify the transportation company as soon as pos sible and ask them to make an immediate inspec tion Ask for a damage or loss report Also notify your dealer of any loss or damage during ship ment See enclo
48. l Lovato _ e e Single phase wiring diagram SINGLE PHASE HD machine Next remove the bottom plate from the control box Loosen the set screw in the shaft cou pler and then remove the four 5 16 bolts that hold the conveyor motor assembly in place Fig 45 Next remove the assembly from the machine then turn it upside down to disconnect the leads from the components to be removed To replace the Intellisand control remove the knob by loosening screw and remove nut that was under knob Turn housing over and remove the nuts holding control board in place Lift control board from housing Install the new controller referring to the correct electrical diagram and reverse the disassembly procedure To replace the on off switch remove the two screws holding cover in place Pull switch from box Disconnect wire leads from switch and remove cover plate from switch Referring to the correct electrical diagram reverse the disassembly procedure To replace the gear motor disconnect the three wire leads from the controller Disconnect the plastic grommet protecting the wires passing through the sheetmetal Then remove the four set screws that hold the motor to the sheetmetal bracket Remove the old motor and install the new motor Referring to the correct electrical diagram reverse the disassembly procedure WIRING DIAGRAM SUPERMAX INTELLISAND HP SINGLE PHASE BOHz 230 VILI WHITE CONTRILLER PAN 72 90 Dimensi
49. l 21 ON OFF SWITCH DRUM THREE PHASE 72 1311 l 28 1 4 20 HEX NUT 12 0001 3 29 LARGE STRAIN RELIEF 72 1404 5 30 CORD SET SINGLE PHASE 72 5315 I 30 CORD SEL THREE PHASE 72 5305 l 31 6 32x1 1 4 PHILLIPS PAN HEAD SCREW 10 3902 2 32 KNOB 72 1270 1 l 33 SMALL STRAIN RELIEF 72 6102 l 35 180 VOLT GEAR MOTOR 71 1171 i 36 MAIN CORD SET SINGLE PHASE 72 5430 l 36 MAIN CORD SET THREE PHASE 72 5305 l 3 5 16 18x1 2 HEX HEAD BOLT 10 9101 4 38 CONTROL HOUSING 40 5013 l oy INTELLISAND CONTROLLER SINGLE PHASE 72 2280 l 39 INTELLISAND CONTROLLER THREE PHASE 72 2270 i 40 6 32 NUT 12 9001 2 4 6 WASHER 11 0202 2 42 5 16 18 RETAINING NUT 20 1159 4 43 1 4 20x1 4 SOCKET HEAD SET SCREW 10 8802 2 44 COUPLING CONVEYOR 30 3102 l 45 5 16 18x3 4 CARRIAGE BOLT 10 1203 4 46 5 H P TEFC ELECTRIC MOTOR SINGLE PHASE 70 0507 l 46 5 H P TEFC ELECTRIC MOTOR THREE PHASE 70 1503 l 47 3 8 WROUGHT WASHER 11 0104 2 48 5 16 18 FLANGED LOCK NUT 12 0207 4 49 LOWER INNER BELT GUARD 40 1000 l 50 10 24 RETAINING NUT 20 1157 2 51 4 1 2 DRIVE PULLEY 50 0450 i 32 1 4 x1 KEY STOCK 20 0762 l 53 5 16 18x3 8 SOCKET HEAD SET SCREW 10 8903 i 54 CORD SECTION SINGLE PHASE 72 5315 i 54 CORD SECTION THREE PHASE 72 5305 l a RETAINING CLIP 72 6210 l 56 V BELT SINGLE DRUM 25 50 2021 l DUAL DRUM 25 50 2023 1 56 V BELT DUAL DRUM 37 50 2030 l 57 5 16 LD THIN WASHER 72 1270 3 l 58 5 16 32 JAM NUT 72 1270 4 l Dy CONVEYOR BELT NOT SHOWN
50. l level the front and then the rear drum see pages 7 and 8 before proceeding further 6 Readjust the tension of the V belt by sliding the motor down and then tightening the pinch bolt in the motor support casting Make sure all pulleys are aligned and all bolts tight before using the sander 7 Reinstall the outer belt guard using the two 5 16 x 1 2 hex head bolts Reinstall the lower belt guard using the two 10 32 screws and the middle inner guard using two 10 32 screws REPLACING CONVEYOR BELTS To replace the conveyor belt the conveyor assem bly must be removed from the machine Lower the conveyor table to its lowest position with the height adjustment handle Remove the bottom cover from control box rotate shaft to access set screws in shaft coupler Important Disconnect power to sander Loosen one set screw Remove the four 5 16 bolts holding the conveyor motor control box base bracket Fig 45 Remove con veyor motor control box and place on dust cover Loosen the conveyor take up screws Fig 35 and Fig 36 to relieve belt tension and slide the driven roller fully inward Remove the four bolts that attach the conveyor assembly to the table mount brackets see Fig 36 Lift the conveyor and remove it from the machine by sliding the convey or out toward the front of the machine Avoid tearing the belt on any edges underneath the con veyor bed during removal Reverse the procedure for re installation Note If the
51. machine Again adjust the contact between the drum and guide so the drum can barely be turned by hand Measure at both sides of the drum to check that the secondary drum is parallel to the table To adjust the secondary drum alignment use the right and left drum adjustment knobs Fig 27 to raise or lower each side of the drum At this point both the primary and secondary drums will be aligned parallel to the table and both drums will be at the same height above the table Set the secondary drum adjustment indicators by loosening the hex nut Fig 27 moving the scale so that the zero mark is directly under the needle and retightening the hex nut Zero the indicator for SERVICING YOUR SUPERMAX 27 other side of drum in the same manner Caution Do not overtighten the hex nut of the indicator Fig 27 This can flare the brass bush ing and render the indicator inoperable Also the secondary drum adjustment knobs should turn with a slight resistance to avoid any movement during operation To adjust knob resistance turn the knob clockwise to reveal the set screw on the INDICATOR NEEDLE INDICATOR SCALE INDICATOR HEX NUT Fig 27 Secondary drum adjustment indicator 28 SUPERMAX OWNER S MANUAL shaft collar below the bracket then loosen the screw Making sure the adjustment knob is tightly seated on top of the bracket raise the shaft collar up against the bracket from below and tighten the set screw Not
52. mance Here Isa quick way Raise the rear drum so it is higher than the front drum with the indicators showing a 3 setting Place the stock to be sanded under the front drum Then raise the conveyor table so the front drum contacts the wood but still can be rotat ed by hand Sand the piece with the front drum and stop the machine Then insert the stock in from the back so it is under the rear drum only Turn down the rear drum using the plastic adjustment knobs on each side Lower the rear drum until it contacts the stock but still can be rotated by hand Use this setting and note the readings on the depth indica tors for future reference DISENGAGING THE DRUMS On dual drum models either the primary front or secondary rear drum may be disengaged so that the other drum can be used alone To use the pri mary drum as a single drum sander disengage the secondary drum by raising it to the 2 setting on the indicators on both sides To use the secondary drum alone lower it to the 4 setting on both sides In this mode the table height adjustment handle is used to determine the depth of cut which will be limited to about 1 32 of an inch before the primary drum starts contacting the work piece SELECTING INTELLISAND FEED RATES Selecting the proper feed rate is essential to proper finish sanding The variable feed rate control of the conveyor belt adjusts the load on the machine it can be infinitely adjusted for maximum operating
53. ons Dust Hood Drums Bearings Abrasive Strips Conveyor Bed Conveyor Motor Conveyor Belt Stand Construction Drive Motor Minimum Stock Length Height Adjustment Stock Thickness Capacity Shipping Weight Dust Collection SUPERMAX TECHNICAL DATA 37 SUPERMAX SPECIFICATTONS SUPERMAX 25 amp 37 single drum SUPERMAX 25x2 amp 37x2 dual drum Model 25 amp 25x2 Height 43 3 4 Width 46 Depth 31 Model 37x2 Height 49 Width 58 Depth 31 Model 25 amp 25x2 4 vacuum port hinged back Model 37 amp 37x2 Two 4 vacuum ports hinged back Model 25 5 x 25 Model 25x2 Two 5 x 25 Model 37 5 x 37 Model 37 x2 Two 5 x 37 All drums extruded aluminum precision machined and balanced 1 600 RPM All Models 1 sealed permanently lubricated flanged ball bearings Tapered aluminum oxide or ceramic cloth backed abrasive strips recommended Fasteners accept any grit No felt velcro or adhesive necessary One strip included All Models Steel conveyor bed reinforced with four steel cross sections All Models 100 in Ibs torque direct drive DC motor Infinitely variable from 0 to 15 feet per minute with Intellisand All Models 100 grit abrasive conveyor belt included All Models Cast aluminum zinc plated steel Column tubes are centerless ground All Models 5 HP TEFC 1 740 RPM 208 230 volts 60 HZ Models 25 amp 37 2 1 2 Models 25x2 amp 37x2 3 1 2 All Models 3 32 p
54. oosen it approximately 1 4 turn which allows the rear drum to pivot After the machine has run for a half hour stop to check that the set screws and bearing bolts are tight The general procedure outlined below suggests replacing bearings on the left outboard side one at a time starting with the rear drum of dual drum sanders then moving to the front drum Then if needed proceed to the right inboard side also working on the rear drum of dual drum sanders first then the front drum Disassembly Procedure 1 To begin the procedure in all cases disconnect power to sander 2 Remove the outer belt guard cover by removing the two 5 16 x 1 2 hex head bolts holding it in place then the four 10 32 screws in the lower half Slide the middle section back and the outer guard to the side SERVICING YOUR SUPERMAX 33 3 Loosen the pinch bolt of the motor support casting and raise the motor to loosen the V belt 4 Next level the drums to each other see pages 7 and 8 in this manual Then raise the conveyor bed until the drum s rest on the conveyor bed With this done follow the steps below cowry ees ot neon eo a bec aes nas o T Fig 40 Locating bearing set screws 34 SUPERMAX OWNER S MANUAL Fig 41 Removing rear drum bearing Bearing Replacement Left Side If replacing all bearings work first on the bearings on the left or outboard side of the sander first one at a time starting with the r
55. performance A faster feed rate allows faster sanding but fewer revolutions of the drums per inch of sanding A slower feed rate provides more revolu tions of the drum per inch of sanding to allow a greater depth of cut and smoother sanding The Intellisand control See Fig 15 continuously monitors the load on the drum motor and automat ically regulates the speed of the conveyor motor to maintain the highest feed rate without overload If the load on the drum motor increases the Intellisand control will decrease the conveyor feed rate and will stop the conveyor under extreme con ditions If the load on the drum decreases the SandSmart control will increase the feed rate but WILL NOT increase it faster than the manual set ting on the switch dial For abrasive planing and thicknessing the feed rate can be set at any speed after adjusting for the proper depth of cut If the load on the drum motor approaches its optimum due to inconsistent stock the feed rate will automatically slow down As the load on the drum motor decreases the feed rate will automatically increase to its original setting When finish sanding with grits finer than 80 the best finish will be achieved if the conveyor does not change speeds during operation While the Intellisand control will slow the feed rate when the main motor reaches its optimum it is advisable to operate below the regulation point When the red indicator light comes on the Intellisand control h
56. position 5 The take up fastener is designed to automati cally 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 12 h 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 posi tion so it no longer is able to maintain tension on the strip Fig 12 1 If this occurs it will be neces sary to reset the take up lever by raising it pushing the strip end into the slot and then releasing the clip lever Note sandpaper cleaning stick may be used to remove deposits and help extend sandpaper life To use operate the sanding drum with the dust cover open Caution For your own safety always wear eye protection while performing sandpaper clean ing 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 opera mi lt LT v Vy e hy CE j ET Ne SETTING UP YOUR SU
57. rit grade when progressing through a sanding sequence For fine work such as furniture try not to skip any grit grades during the sanding process In gen eral premium quality abrasives such as Genuine Performax abrasives will produce a better finish with a less noticeable scratch pattern Caution Grits that are too fine can sometimes burnish the wood and leave a glossy surface which will not accept stains evenly This will vary by type of wood Oak for example is susceptible to burnish ing because of its open pores Selecting Grit Combinations The chart shown on page 14 is a general guide to consult when selecting grits to use on dual drum machines and setting the rear drum This chart is also provided under the dust cover on the SUPERMAX for quick reference The first column suggests grits for the primary front drum of dual drum models while the second column suggests a corresponding grit to use on the second rear drum The third col umn suggests depth settings to try on the rear drum depending on the grit used The setting val ues are based on a 0 reading when the drum contacts the work piece but still can be rotated by hand Note that the grits and settings are starting sug gestions only Other combinations and settings are possible depending on your particular circum stances It is a good idea to keep records of the combinations you use and their results Keeping these records handy will help you select the be
58. rum or dual drum models For future reference attach the Model Serial Bar Code label below or find the model and serial numbers on the front table mount 20 page 39 and write them in below Model Serial Number Date Purchased Dealer IMPORTANT KEEP THIS MANUAL HANDY Please read this manual first It was designed to help you get the most from your SUPERMAX drum sander Before unpacking or using 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 a problem you cant solve please call your SuperMax Tools dealer MANUAL CONTENTS 3 CONTENTS BOUT THE SUPERMAX SYSTEM SUPERMAX Nomcenclatutre 4 Unpacking Your SUPERMAX Sander 5 SETTING UP YOUR SUPERMAX Making Electrical Connections 6 Connecting Dust Collectors 7 Checking For Machine Level 7 Checking Drim Alignment aaa a aaaasa Y Checking The Conveyor B lt lt 8 Checking Table Height Controls 9 Monthly Maintenance s a 9 Wrapping Abrasive Strips 10 OPERATING YOUR SUPERMAX Basic Operating Procedures 12 SUPERMAX Operating Controls 12 Setting The Depth Ne 13 S
59. s in this manual on setting up and operating your machine TROUBLESHOOTING GUIDE MOTORS Solution Plug in primary power cord Replace fuse or retrip breaker after determining cause Reset after allowing to cool check circuit and or reduce load or slow feed rate Check electrical requirements Use slower feed rate and or reduce depth of cut Loosen housing bolts run motor retighten bolts Replace shaft collar page 5 Replace drive roller page 31 Reduce depth of cut reduce feed rate 20 SUPERMAX OWNER S MANUAL TROUBLESHOOTING GUIDE MACHINE Problem Possible Cause Solution Abrasive strip comes 1 Slack in abrasive strip Remove slack in strip off drum on drum page 10 2 Abrasive improperly Read section on abrasive installed installation page 10 Abrasive strip loose 1 Strip caught on inside edge Readjust strip end of slot or on inboard side of in slot and or trim abrasive drum edge 2 Strip not cut properly Recut and install abrasive strip page 10 Abrasive loads up 1 Excessive depth of cut Reduce depth of cut prematurely 2 Excessive feed rate Use slower feed rate 3 Inadequate dust collection Increase air flow at dust ports 4 Inadequate abrasive Use open coat abrasive 5 Stock fed at 90 angle Angle stock to avoid resin to drum line build up Conveyor rollers run 1 Shaft coupling loose Align shaft flats of gear motor intermittently and drive roller and tighten
60. s will give a desired exiting thickness to the material and help prevent under dimensioning ms GAUGE SCALE INDICATOR NEEDLE Seas jr a i L a T ast _ k i r as i I PF a EET ms EEE i i DEPTH STOP TABLE SUPPORT CASTING Fig 16 Depth gauge components on some models 16 SUPERMAX OWNER S MANUAL SELECTING DRUM ABRASIVES It is important to select the proper grit of abrasives for the type of sanding being performed to achieve maximum sanding results As with any sanding operation first begin sanding with a coarser grit depending on the roughness of the stock or the amount of stock to be removed Then progressive ly work toward finer grits The chart below shows the general uses for the various grits Performax Products offers abrasives in the ten different grits shown Selecting Abrasive Grits The amount of stock to be removed is a major consideration when choos ing the grit grade to start with Grits 24 36 50 and 60 are primarily designed for stock removal Grits 24 and 36 will remove the most material in one pass whether you are doing abrasive planing cleaning up glued panels or flattening stock Grits from 100 through 220 are primarily finishing grits designed to remove the scratch pattern from the previous grit used For best results never skip more than one g
61. sed 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 1 Unbolt the machine legs from the shipping pallet Install the rubber based leveling feet or cast ers on legs Fig 2 The feet and mounting hard ware are in the STOP bag packed with your machine 2 Loosen the hex nut and set screws on the table support castings Fig 3 The set screws on the table support castings have been tightened at the factory to eliminate free play between the table support casting and the column tube during ship ment There are two table support castings on the SUPERMAX one each for the right and left column tubes Important These set screws are tightened for shipping and must be loosened and readjusted before operating either the height adjustment mechanism or the conveyor drive To properly adjust for operation loosen each set screw by first loosening its hex nut with an open end wrench and then the set screw with an Allen wrench Then retighten each set screw with your fingers so it only lightly touches the column tube Fig 2 Leveling feet and mounting hardware ABOUT THE SUPERMAX SYSTEM 5 Hold each set screw in position with an Allen wrench and retighten the hex nut Failure to fol low these procedures may result in misalignment of the drum s and or the conveyor table Caution On the SUPERMAX
62. shaft coupling set screws Conveyor belt slips 1 Improper conveyor belt Adjust belt tension page 8 on drive roller tension 2 Excessive depth of cut Reduce depth of cut reduce feed rate Board slips on 1 Excessive depth of cut Reduce depth of cut conveyor belt 2 Tension rollers too high Lower tension rollers page 28 3 Excessive feed rate Reduce feed rate 4 Dirty or worn conveyor Clean or replace conveyor belt belt page 31 TROUBLESHOOTING YOUR SUPERMAX 21 TROUBLESHOOTING GUIDE MACHINE Continued Possible Cause Problem Conveyor belt tracks to one side or oscillates from side to side Table height adjustment works improperly Drum drive belt slips Knocking sound while running Re Belt out of adjustment Drive or driven conveyor belt rollers misaligned Conveyor table not flat and square Conveyor belt worn or defective Roller bushings elongated due to excessive wear Improper adjustment of height control Improper V belt tension Bearing out of alignment V belt worn Loose weight in drum Pulleys wobbling or out of round Set screws loose in pulley or bearing 6 Abrasive fastener on drum loose without abrasive strip in place Bearing worn idler pulley bearings Solution Readjust belt page 8 Readjust page 8 Readjust by leveling with leg glides page 7 Replace conveyor belt
63. sides of the drum to check that the primary drum is parallel to the table To adjust the primary drum alignment loosen both set screws at the front of the right inboard drum support casting Fig 24 and raise or lower the casting on the column tube to correct drum alignment Retighten the set screws and recheck the alignment Note Do not loosen the set screws of the left outboard drum casting as this will cause miter gear misalignment Achieving a very precise primary drum align ment can be accomplished by disengaging the right inboard miter gear Fig 25 from the height adjustment cross bar and using the height adjustment handle to finely raise or lower the inboard side of the table to achieve parallel align DRUM lt lt SUPPORT CASTING SUPPORT CASTING NR HEX NUT amp SET SCREW Fig 25 Adjusting primary drum ment of the drum see Adjusting Table Level page 7 Note that if only fine adjustment of the primary drum alignment is required these adjust ment procedures can be used to correct alignment without relieving V belt tension or adjusting ten sion rollers as described above The above procedure is all that is required to align the drum on a single drum SUPERMAX sander If yours is a dual drum machine follow the procedure below Secondary Drum Alignment With the primary drum properly aligned use the same thickness gauge and insert it between the secondary drum and the table from the back side of the
64. st combinations of grits for future work ABRASIVE SELECTION GUIDE GRIT COMMON APPLICATION 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 Tirs For MAXIMUM PERFORMANCE The versatility designed into the SUPERMAX drum sander allows it to be used for a wide ranging vari ety of tasks that will boost the return on your investment For example its capabilities range from taking the place of a planer to thickness rough stock all the way to speeding up fine sand ing work often done with slower dust generating hand sanders Learning to use its multiple adjustments and controls will allow you to fine tune the machine for maximum results regardless of the job to be done The best results come from experimenting with different abrasive combinations and machine adjustments to fit the job at hand Following is a listing of useful tips which can help you
65. tall the new drums If the bearings need replacing replace them at this time see page 33 i 1 1 PUR i Sy a t iS y i f Paes hey w i a KE tae ak l 0 K 4 Tan 5 _ A a i a J Fig 30 Removing bolts from drum support casting 30 SUPERMAX OWNER S MANUAL Reassembly Procedure 1 To assemble the unit after replacing drums install the sanding drum support brackets Slide the drums through the bearings but do not tighten the set screws in the bearings yet Install the V belt pulleys but dont tighten the set screws yet 2 Remove the 2x6 from the conveyor bed at this time Align the cross brace and the dust cover at this time Install the four bolts on the right inboard side Install the on off switch with the infeed bolts and two bolts on the left outboard side of the sander and tighten securely 3 Tighten the two set screws in each of the four bearing collars Spin the drums by hand to check if they spin freely Fig 31 Drum support casting bolts outboard side Fig 32 Supporting re with 2x6 on edge Fig 33 Loosening drum bearing set screws Fig 34 Removing sanding drum support bracket 4 Align the V belt pulleys with the pulley on the motor and then tighten the set screws in the V belt pulleys Spin the drums by hand to make sure the pulleys are in proper alignment 5 Check the alignment of the front drum to the conveyor table If they are not paralle
66. uge or dip as the drum goes from sanding the rails at full width to sanding just a few inches of width on the stiles To prevent this problem for example make sure that when using abrasives finer than 80 grit the drum is in contact with the wood but can still be spun by hand If there is room angling the stock on the conveyor belt can also help Slowing the conveyor feed when coming to a rail in the stock can help prevent a dip or gouge This allows the abrasive to work the wider width with less effort and to achieve better consistency of the finished surface Stock Feeding Angle Some pieces because of their dimensions will need to be fed into the machine at a 90 angle perpendicular to the 18 SUPERMAX OWNER S MANUAL drums However even a slight oftset angle of the stock will provide for more effective stock removal The optimum feeding angle for stock removal is about 60 see Fig 17 Angling the workpiece for stock removal provides other advantages such as less loading of certain areas of the drums due to glue lines or mineral streaks in the stock more even wear of abrasive strips potentially faster feed rates and lighter loads on the motor Note that to get the best final finish however the stock should be fed through the machine so it will be sanded in line with the grain of the wood on the final one or two passes Cleaning Abrasive Strips Regularly clean the abrasive strips on the drums with commercially avail
67. upport castings may need to be recentered on the column tubes To do this loosen the 3 8 x 1 hex head bolts in each table support casting adjust and tighten the set screws to hold the casting in position Then tighten the hex head bolts and loosen the set screws ADJUSTING SANDING DRUMS After any adjustments of the castings on the columns check to make sure the sanding drums are in alignment To begin realignment of the sanding drum s first remove the abrasive strip from the drum Release the V belt tension from the motor by loosening the pinch bolt of the motor support casting see 8 Fig 5 page 6 Loosen two screws in lower belt guard Slide the motor mount up the column tube and retighten the pinch bolt After the feed table has been lev eled loosen all four tension roller suspension bolts Fig 24 Comparing dam support casting heights see 1 Fig 28 page 28 Raise the tension roller suspension assembly 2 Fig 28 to its highest position so that the tension rollers are positioned higher than the bottom of sanding drum s Then retighten the four tension roller suspension bolts to hold the tension rollers in that position during drum alignment Primary Drum Alignment Using a flat piece of wood or a steel rule as a thickness gauge insert it between table and primary front drum and adjust the table height to gauge the thickness Raise the table just so the drum can be barely turned by hand Measure at both
68. ures for your machine are covered under Setting Up Your SUPERMAX Sander page 6 Review that section first If follow ing the general instructions does not solve a specif ic problem or result in smooth operation also check Troubleshooting Your SUPERMAX page 19 Below are suggested procedures to follow when more thorough readjustment or replacement is necessary ADJUSTING HEIGHT CONTROLS Height adjustment problems may be the result of not loosening the set screws in the table support castings before attempting operation This is cov ered on page 5 of this manual and also on the sep arate unpacking sheet which was shipped with your machine If the set screws were not loosened as instructed do so now before proceeding further Also make sure all moving parts of the height adjusting mechanism are well lubricated including the miter gears column tubes and threaded height adjusting screws When troubleshooting the height adjustment mechanism first check the conveyor table for level see page 7 Then test the height adjustment mechanism See Fig 19 If it does not operate HEIGHT ADJ HANDLE DRUM SUPPORT CASTING x ar al VE SUPPORT i F CASTING ee HEx NUT amp SET SCREW ADJ SCREW SUPPORT AKAN MITER G Fig 19 Table support casting set screws easily further adjustments may be necessary as outlined below Following these steps should result in smooth operation Readjustment Procedure

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