User Manual - SuperMax Tools
Contents
1. YK Description SB24x2 BRACKET CHAIN GUARD CHAIN BRACKET IDLER TENSION WASHER 1 2 Not used on all models BUSHING SPROCKET DRIVE amp DRIVEN BOLT WASHER INTERNAL TOOTH 1 2 SPROCKET IDLER STUD WASHER flat 9 WASHER LOCK NUT BOLT 5 16 NUT RETAINING NUT 5 16 CHAIN ROLLER not shown CHAIN CONNECTING LINK not shown BRACKET GEAR MOTOR MOUNT GUARD MITER GEAR MITER GEAR HD COLLAR SHAFT BUSHING WASHER SET SCREW SOCKET HEAD STRAIN RELIEF GEAR MOTOR CONDUIT BOX SET SCREW Part Number Both Models 40 1047 40 1048 40 1046 20 1103 50 3107 13 1011 10 0407 11 0508 13 1010 10 9906 11 0209 11 0013 12 0009 10 9101 20 1159 12 0205 13 1013 13 1014 40 5000 40 5001 20 1100 20 1103 50 3107 50 3110 10 2404 72 6101 71 1173 70 0000 10 2804 SB36x2 Qty Unit 1 SUPERBRUSH ELECTRIC HEIGHT ADJUSTMENT Parts List 33 CHAIN ITEM 17 CHAIN MASTER LINK ITEM 18 NOT SHOWN 34 SUPERBRUSH OwNER s MANUAL Dimensions Dust Hood Dust Collection Brush Speed Brush Bearings brush Conveyor Conveyor Bed Conveyor Belt Stand Drive Motor Minimum Stock Length Height Adjustment Stock Thickness Cap2. BLUE RED BLUE CONTROLLER RHEOSTAT WIRE COLOR CODE GEAR MOTOR SUPERBRUSH ELECTRICAL DIAGRAM 25 SUPER BRUSH WIRING DIAGRAM 230 VOLT 3 PHASE 60 HZ A BLACK FUSE GRANGE ACROSS USE FUSE RANE TTD O 34 4 CONTRELLER RED ACROSS 2 3 2307 BLACK 4 2 1250 BLACK ACROSS TWD GREEN 7 WIRES DEDICATED SCRE 41 os A 2 _ MOTOR 5 iN WHITE POWER IN ORANGE SUPER BRUSH WIRING DIAGRAM 460 VOLT 3 PHASE 60 HZ 1 BLACK FUSE GRANGE ACROSS USE FUSE CRIME RANE Rer 4 CONTROLLER ee l 3 2 z BLACK ACROSS M REEN 800 CTO TTS gt E WHITE SECURE GREEN FA WIRES DEDICATED SCRE 2 WHITE A POWER 10 NEUTRAL MOTOR JP IN 27 _ 5 POWER IN ORANGE 26 OwNER s MA
3. 12 MONTHLY 12 Tres For MAXIMUM PERFORMANCE 12 TROUBLESHOOTING YOUR SUPERBRUSH TROUBLESHOOTING GUIDE 14 TROUBLESHOOTING GUIDE 15 TROUBLESHOOTING GUIDE MACHINE 16 SERVICING YOUR SUPERBRUSH ADJUSTING HEIGHT CONTROLS 2 22 2222 17 ADJUSTING TABLE SUPPORT CASTINGS 18 ADJUSTING BRUSH 18 LEVELING TABTE 18 MITER GEAR 18 BRUSH SPEED ADJUSTMENT ccccsssssscesccccceeessssseees 19 REPLACING BRUSH cccsessecsccececeeseessensneeeeeees 19 amp 20 REPLACING CONVEYOR BELTS 19 MANUAL CONTENTS 3 REPLACING V BELT 20 ROTATING REPLACING BEARINGS 21 REPLACING ELECTRICAL COMPONENTS 23 ELECTRICAL 8 0 2 00002012441 111 24 amp 25 SUPERBRUSH TECHNICAL SUPERBRUSH SPECIFICATIONS 2 00 2220 34 Parts List FOR STAND 27 Parts List FOR BRUSH 29 Parts List FOR CONVEYOR ASSEMBLY 31 SUPERBRUSH ACCESSORIES amp SUPPLIES 35 FOR YOUR SAFETY Read all instructions care fully and note the
4. Pulleys wobbling or out of round Set screws loose in pulley or bearing Bearing worn Inadequate support of stock Conveyor drive or driven rollers higher than conveyor bed Feed rate too slow 2 Excessive depth of cut 1 Conveyor belt is too loose 2 Excessive depth of cut Wood slipping on conveyor due to lack of contact Solution Readjust height control page 17 Replace V belt page 20 Tighten set screws or replace pulley page 22 Retighten set screws Replace bearing page 22 Use roller stands to support stock Readjust rollers page 19 Increase feed rate Reduce depth of cut decrease brush RPM Adjust belt tension Reduce depth of cut decrease brush RPM Use alternate feeding procedure page 12 SERVICING YOUR SUPERBRUSH 17 SERVICING YOUR SUPERBRUSH The basic adjustment procedures for your machine are covered under Setting Up Your page 6 Review that section first If following the general instructions does not solve a specific problem or result in smooth operation also check Troubleshooting Your SUPERBRUSH page 14 Below are suggested proce dures to follow when more thorough readjustment or replacement is necessary ADJUSTING HEIGHT CONTROLS Height adjustment problems may be the result of not loosening the 8 set screws in the table support castings before attempting operation This is covered on page 5 of this manu
5. ers are required depending on how the electrical configuration was ordered one or two service lines Three Phase 5 HP motors 208 Volt A single 40 Amp service breaker or two 20 Amp service breakers Fig 4 Conveyor motor fuse top height adjustment fuse bottom are required depending on how the electrical configu ration was ordered one or two service lines Three Phase 5 HP motors 440 460 Volt A single Fig 5 SuPERBRUSH Components Brush Speed RPM Handle Front Brush Speed RPM Handle Rear Adjusting Screw Support Brush Support Casting Height Adjusting Screw Table Support Casting Miter Gear Height Adjustment Handle Height Adjustment Switches 20 Amp service breaker or two 10 Amp service break ers are requited depending on how the electrical configuration was ordered one or two service lines Note 440 460 volt requires a neutral line See page 25 Other HP voltage and Hertz configurations are available See manual insert if custom unique electri cal configurations apply to your model Please call Su perMax Tools for more information 888 454 3401 CONNECTING Dust COLLECTORS Dust collection is necessary for all SupPERBRUSH models The SupERBRUSH 24 x 2 and the 36 x 2 are equipped with four 4 dust exhaust ports on the top of the dust cover To attach the to your collection sys tem install 4 hose from your collector See Tips For Maximum Per
6. Short or Long bristle Open or Dense wound a Eo 320 Grit Nylon Silicon Carbide Short or Long bristle Open or Dense wound Lo a Wire Carbon Steel Open or Close Wound Wire Stainless Steel Fineset Flatter Style Brush Head Assembly Flatter Style Brush Abrasives 36 400 grit various minerals widths lengths and densities Abrasives only Cloth polishing heads Scotch Brite Various grades and configurations These are just a few types of the dozens of brushes available Please contact SuperMax Tools for a complete listing of brushes and brush material available or to run test samples of your specific application SUPPLIES ITEM DESCRIPTION QTY 98 0050 CONVEYOR BELTS Polyurethane rib textured surface with monofilament backing For information on the SUPERBRUSH and supplies call SuperMax Tools 888 454 3401 or visit www supermaxtools com ONE YEAR WARRANTY Limited warranty SuperMax Tools will provide all replacement parts which are found to be defective in materials or workmanship Manufacturers warranties on conveyor belts and brush heads IMPORTANT SAFETY INFORMATION For SAFE SANDING OPERATION FOLLOW THESE GUIDELINES BECOME FAMILIAR WITH THE PROPER OPERATIONAL PROCEDURES FOR USING THIS MACHINE ALWAYS BE SAFETY CONSCIOUS WHEN OPERATING THE MACHINE ALWAYS WEAR E
7. bristle tips and slow to moderate RPM generally under 600 RPM Excessive contact will reduce brushing effectiveness and damage brush When using a nylon brush the tips of the bristles should be touching the stock being brushed Typical tip penetration is 1 16 Excessive bristle penetration will damage the brush and should only be set deep enough for good contact at the tip When using Flatter brush heads the tips should penetrate the lowest part of the stock being brushed approximately 1 8 1 4 Excessive penetration will prematurely wear abrasives BRUSH AND BRISTLE MAINTENANCE Wire brushes frequently every 8 hours of operation flipped end for end to reduce bending of bristles in one direction will extend brush life Caution if you choose not to flip the brush frequently it is better not OPERATING YOUR SUPERBRUSH 11 to flip the brush at all Ifa nylon nylon impregnated or Scotch Brite brush becomes unevenly worn the tips of the bristles or outer diameter be dressed This will even the bristle length outer diameter and expose fresh abrasive at the tips of the bristles Dressing Instructions Staple or glue a wide sheet of 60 grit sandpaper to a 1 2 thick flat wood surface Strips of narrow sand paper can also be used Raise 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 machi
8. each set screw with your fingers so it only lightly touches the column tube Hold each set screw in position with an Allen wrench and retighten the hex nut Failure to follow these procedures may result in misalignment of the brush and or the conveyor table Caution Do not loosen the set screws on the up per brush support castings Note Some models have a block under the main motors If so remove at this time TABLE SUPPORT J CASTING Hex amp SET SCREW Fig 3 Table support casting and set screws SupeRBRUSH OwNER s MANUAL SETTING YOUR SUPERBRUSH Your SUPERBRUSH 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 pre opera tional checks you should make after unpacking and final assembly Unnecessary problems can be avoided if these essential checks are performed before operat ing Likewise performing the recommended monthly maintenance procedures page 12 will help assure trouble free service MAKING ELECTRICAL CONNECTIONS Power for the brush heads for the standard double head brush sander is supplied by two 5 HP motors Optional 7 1 2 HP motors available Electrical service for the SUPERBRUSH 24x2 and 36 x 2 60 HZ Single Phase 5 HP motors 208 230 Volt A single 60 Amp service breaker or two 30 Amp service break
9. opposite side Adjusting the take up screw on both sides of the conveyor allows belt tracking adjustments to be made without affect ing belt tension Note Adjust the take up screw only 1 4 turn at a time Then allow time for the belt to react to the adjustments before proceeding further Try to avoid over adjustments REPLACING V BELT To change the V belt on the first dis connect power source to machine 1 Lower the main motor to its lowest position using the brush speed control RPM handle Raise the motor to its highest position This will loosen the V belt in the drive pulley so the V belt can be lifted off the driven brush pulley 2 Remove the miter gear from the right inboard side of the transfer rod Fig 14 Now 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 Make sure to catch the nylon washer which will drop off the transfer rod 3 Remove the inner half of the pulley guard by remov ing the six screws holding the inner half to the outer half Remove the inner half of the pulley guard 4 Remove V belt from drive pulley If there is not enough clearance to remove V belt loosen the four bolts securing the main motor to bracket Note location of motor before sliding motor out of the way for ease of reassembly Note the routing of the old V belt now remove the old V belt and replace it with the new V belt Fig 23
10. or driven roller and the straight edge 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 20 SupERBRUSH OwNER s MANUAL MOUNTING Botts Fig 19A Removing brush head some models the brackets that hold the drive or driven roller in place Tip this bracket until the distance between the drive roller and the straight edge are equal from side to side then tighten the bracket Conveyor Belt Tension To adjust the tension of the conveyor belt first adjust the take up screw Fig 21 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 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 bearings or conveyor belt Conveyor Belt Tracking Belt tracking adjust ments are made while the conveyor belt is running After the proper belt tension is obtained see above turn the conveyor unit on and set it at the fastest speed setting Watch for a tendency of the conveyor belt to drift to one side of the conveyor To adjust the belt tracking tighten the take up screw Fig 21 on the side the belt is drifting toward and loosen the take up screw on the
11. side of the conveyor To adjust the belt tracking tighten the take up screw see Fig 9 on the side the belt is drifting toward and loosen the take up screw on the opposite side Adjusting the take up screw on both sides of the conveyor allows belt tracking adjustments to be made without affecting belt tension Adjust the take up screw only 1 4 turn at a time Then allow time for the belt to react to the adjustments before proceeding further Try to avoid over adjustments NOTE Make sure wrench is removed when brushing Fig 8 Brush RPM gauge Fig 9 Adjusting conveyor belt tracking OPERATING YOUR SUPERBRUSH 9 OPERATING YOUR SUPERBRUSH Before using your SuPERBRUSH review the previous pages in this manual on initial set up and adjust ment 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 SurerBrusu offers considerable control and versatility through infinitely 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 aggres sive Too aggressive on the brush RPM may tend to raise the grain or excessively round edges It may be better to make two or more passes with a less aggres sive brush or setting The first brush is rotating against the direction of feed therefore the leading edge
12. stock that is twisted bowed or otherwise varies in thickness from end to end If possible support such stock as it is be ing 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 hazard ous situations Stock Feeding Angle Some pieces because of their dimensions will need to be fed into the machine at a 90 angle perpendicular to the brush However even a slight offset angle of the stock can provide for OPERATING YOUR SUPERBRUSH 13 more effective brushing on some stock such as pan eled doors or deburring metal Fig 12A amp 12B 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 slippage on the con veyor 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 brush Also brush the conveyor belt after cleaning operations If not cleaned the conveyor belt could allow stock to slip during brushing operations Fig 12 DRO Fig 12D Shims Rear brush contact adjustment 14 SUPERBRUSH OWNER S MANUAL TROUBLESHOOTING YOUR SUPERBRUSH Any operating problems with the SupERBRUSH will likely occur most often during the period that you are becoming familiar with its components and their adjustme
13. 18 4 98 0118 6 40 4122 98 0118 3 98 0118 2 98 0050 SB36x2 40 3655 30 3218 40 3658 Qty Unit 2 2 16 16 4 4 8 16 2 aN N N KR KR OH N RE SUPERBRUSH HEAD ASSEMBLY 29 30 SUPERBRUSH OwNER s MANUAL Ref Number mr WON 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 53 54 55 56 Description 1 4 20 1 2 ROUND HEAD MACH SCREW 1 4 20 HEX NUT SWITCH BRACKET ON OFE SWITCH Magnetic ON OFF SWITCH Manual not shown 3 Phase STRAIN RELIEF WASHER 1 4 INTERNAL TOOTH LOCK CONTROLLER 180 VDC VARIABLE SPEED CONVEYOR CORD SET SINGLE PHASE 32 CORD SET THREE PHASE 32 FUSE HOLDER one not shown MOTOR GEAR 180 VDC CORD SET MAIN W PLUG SINGLE PHASE CORD SET MAIN NO PLUG THREE PHASE V BELT SCREW SET 5 16 KEY 4 CORD SET SINGLE PHASE CORD SET THREE PHASE FUSE 34 AMP one not shown PULLEY DRIVE VARIABLE SPEED KEY 3 16 RETAINING NUT LOWER INNER BELT GUARD WASHER FLAT 3 8 5 16 18 FLANGED LOCK NUT MOTOR 5 HP TEFC SINGLE PHASE MOTOR 5 HP TEFC THREE PHASE BOLT CARRIAGE 5 16 CONTROL HOUSING RETAINING NUT 5 16 SET SCREW COUPLER 5 8 RA
14. ACKET LEFT SUSPENSION SPRING TENSION ROLLER BRACKET RIGHT SUSPENSION BUSHING 1 2 ID OILITE ROUND BRACKET SUSPENSION BASE NUT 1 4 20 RETAINING ROLLER TENSION 30 1218 NUT 5 16 18 FLANGE LOCK HINGE BRACKET DUST COVER MOUNTING 40 3659 SCREW 1 4 20X1 2 ROUND HEAD MACH WASHER 1 4 INTERNAL TOOTH LOCK SCREW 8X1 2 SELF TAPPING WASHER 1 4 SAE NUT 1 4 20 HEX NUT 5 16 18 WING WASHER 5 16 INTERNAL TOOTH LOCK BUMPER DUST COVER not shown GUARD BELT COVER GUARD BELT PLATE GUARD BELT LOWER GUARD BELT ANGLED NUT RETAINING NUT RETAINING SCREW 10 24X3 8 SLOTTED HEX HEAD BRUSH SPACER HEAD WASHER 5 8 KNOB LOCKING W SET SCREW SUPPORT ADJUSTING SCREW DEPTH GAUGE ROD DECAL SCALE BOLT HEX 3 8 X 4 1 2 HEX SCREW 5 16 SOCKET HEAD SET DRO DISPLAY BRACKET not shown DRO DISPLAY DIGITAL not shown DRO SCALE READ not shown DRO SCALE BRACKET not shown DRO HEAD READ not shown DRO FLEX LINK not shown SHIM Kit not shown Part Number Both Models 80 2841 10 9205 11 0206 40 0613 50 3086 10 8602 10 1203 50 0701 10 8903 12 0209 20 0764 10 3213 40 0323 20 3284 40 0326 50 3107 40 0322 20 1153 12 0207 40 0225 10 3205 11 0504 10 3904 11 0205 12 0001 12 9050 11 0505 80 1065 40 0009 40 0010 40 0011 40 0012 20 1155 20 1157 10 3803 See page 35 30 1310 80 2324 81 3132 30 1112 30 1260HR 94 1654 10 9209 12 0009 10 2903 40 4310 98 01
15. IL BED RH RAIL BED LH NUT FLANGE LOCK 3 8 BRACKET DRIVEN ROLLER SUPPORT BRACKET DRIVE ROLLER SUPPORT LH BRACKET DRIVE ROLLER SUPPORT RH BEARING DRIVE ROLLER ROLLER DRIVE ROLLER DRIVEN BEARING DRIVEN ROLLER BOLT CARRIAGE 3 8 BOLT 3 8 BOLT 3 8 BOLT TRACKING 3 8 WASHER INTERNAL TOOTH LOCK 1 2 SWITCH REVERSING SECOND BRUSH CONVEYOR BED WASHER 5 8 RETAINING CLIP BOLT HEX 3 8 WASHER 3 8 BELT CONVEYOR POLYURETHANE not shown CONTROLLER 180 VDC VARIABLE SPEED ADJ not shown Part Number SB24x2 30 3110 30 3109 40 4201 61 1011 Both Models 10 3205 12 0001 40 5005 72 1313 72 7810 72 6104 11 0504 72 1260 72 5315 72 5305 72 6202 71 1174 72 5430 72 5305 50 2029 10 2903 20 0762 72 5315 72 5305 72 6201 50 0704 20 0763 20 1157 40 1000 11 0104 12 0207 71 0502 71 1503 10 1203 40 5013 20 1159 10 8902 13 1017 40 0502 40 0503 12 0209 40 4152 40 4151 40 4150 13 1016 13 1015 10 1302 10 1303 10 9205 10 9215 11 0508 72 1310 50 3080 20 0753 10 9205 11 0104 72 1265 Qty 5836 2 Unit 30 3108 30 3111 40 4101 61 1008 00 Ee NH END SUPERBRUSH CONVEYOR amp MOTOR ASSEMBLY 21 32 SUPERBRUSH 5 MANUAL Ref Number CON DU KR WN
16. Keep This Manual Handy For Quick Reference SUPERBRUSH OWNERS MANUAL For SUPERBRUSH 24 x 2 and SuUPERBRUSH 2 IMPORTANT BEFORE OPERATING YOUR SurerBrusH READ THE INSTRUCTIONS IN THIS MANUAL FOR UNPACKING AND SETTING UP YOUR MACHINE sm SuperMax J ppls USA 2 OwNeER s MANUAL CONGRATULATIONS You have made a wise purchasing decision by adding this Made In USA machine to your tool line up main purpose in inventing and developing the machine you ve purchased was to bring a new dimen sion 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 maximum performance Your 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 select ing the right machine to helping you get top perfor mance when you put it to work in your shop Regard l
17. NUAL Ref Number SON NAW KR NH 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 32 33 34 34 35 36 38 39 40 41 42 44 45 46 47 48 50 51 52 SB24x2 HANDLE SWIVEL ASSY PIN ROLL 3 16X1 WASHER 5 8 I D OILITE RING 5 8 RETAINING SUPPORT ADJUSTING SCREW SCREW 1 4 20X1 2 SOCKET HEAD SET SCREW INBOARD HEIGHT ADJ FOLLOW CAP 1 PLASTIC GEAR MITER HEAVY DUTY BUSHING 1 2 I D OILITE ROUND RPM BRACKET RPM DECAL not shown COLLAR 1 2 I D SHAFT TUBE COLUMN SCREW RPM MOTOR MOUNT MOTOR NUT 5 16 18 HEX WASHER 5 16 SAE SCREW 5 16 18X3 4 BRASS TIPPED SET BOLT 3 8 16X1 1 2 HEX HEAD WASHER BOLT 3 8 16X1 HEX HEAD NUT 3 8 16 HEX CASTER SCREW OUTBOARD HEIGHT ADJ NUT 3 8 16 FLANGE LOCK BASE COLUMN BASE SUPPORT BRACKET 40 0230 NUT 5 8 11 HEX LOCK SCREW 1 2 13X1 2 SOCKET HEAD SET ROD TRANSFER 30 1213 SUPPORT BRUSH BOLT 3 8 16X1 1 4 HEX SUPPORT OUTBOARD TABLE DEPTH GAUGE ROD not shown DECAL SCALE not shown NUT 9 16 12 HEX LEG SE CAP PLASTIC COLUMN TUBE CLIP FRAME not shown MOTOR MOUNT SUPPORT INBOARD TABLE BRACKET TABLE MOUNT 40 0025 SCREW ADJUSTING MAIN HANDLE SWIVEL LARGE SUPPORT ADJUSTING SCREW W BEARING SPACER STAND LEG TIE RING RETAINING CLIP SET SCREW 5 16 WASHER 5 16 NUT 5 16 Part Number Both Model
18. YE PROTECTION WHILE OPERATING THE SANDER FEED STOCK AGAINST THE ROTATION OF THE BRUSH TYPICAL e NEVER PLACE HANDS UNDER THE BRUSH OR DUST COVER NEVER OPERATE 5 WITHOUT ITS DUST COVER OR PULLEYGUARD IN PLACE KEEP HANDS AND CLOTHING AWAY FROM OPERATING BRUSH BELT AND PULLEYS ALWAYS MAINTAIN CONTROL OF STOCK TO AVOID KICKBACK KNOW HOW TO PREVENT IT ALWAYS DISCONNECT ELECTRICAL POWER BEFORE PERFORMING SERVICING OR ADJUSTMENT OF THE MACHINE DO NOT 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 PART NO 92 2402 COPYRIGHT 2014 PRINTED IN USA
19. acity Shipping Weight approximate Tension Rollers SUPERBRUSH SPECIFICATIONS SuPERBRUSH 24 x 2 SUPERBRUSH 36 x 2 Warranty One year on parts and labor limited Manufacturer s warranties on conveyor belts and brush heads 24 2 Length 66 2 Length 66 Width 50 Width 62 Height 52 Height 52 24 x 2 Steel hood with four 4 vacuum ports hinged 36 x 2 Steel hood with four 4 vacuum ports hinged Mandatory Minimum 2400 CFM 600 CFM per port Infinitely variable 400 1200 RPM typical See Brushes and Supplies page 35 1 sealed permanently lubricated ball Variable Speed 0 30 ft min typical Steel reinforced with eight cross sections Polyurethane rough top Steel plated or powder coated 2 5 HP TEFC 1700 RPM 60 HZ Continuous Duty Three Phase 208 230 Volt Optional Three Phase 440 460 Volt or Single Phase 208 230 Volt Optional 7 1 2 HP 10 without fixtures can vary with application 3 32 per revolution Depth gauge included 9 typical Can vary with application and brush type 24 x 2 1100 155 36 x 2 1340 lbs 1 1 2 diameter rubber covered spring tensioned fully adjustable SUPERBRUSH SPECIFICATIONS 35 BRUSHES amp SUPPLY CHECKLIST SUPERBRUSH OPTIONS BRUSHES FOR THE SUPERBRUSH 24 X 2 AND SUPERBRUSH 36 2 DESCRIPTION QTY 80 Grit Nylon Silicon Carbide Short or Long bristle Open or Dense wound 240 Grit Nylon Silicon Carbide
20. al and also on the separate 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 mov ing 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 mecha nism See Fig 13 If it does not operate easily further adjustments may be necessary as outlined below Fol lowing these steps should result in smooth operation Readjustment Procedure 1 Loosen the set screws located at the front of the table support castings Fig 3 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 transfer rod Also apply grease or oil to the miter gears 3 If the height adjustment feels stiff check for misalignment of adjusting screw supports and the brush support castings which could cause binding on the adjusting screw Fig 5 These castings can be adjusted by loosening the set screws which se cure them to the column tubes Realign the adjust ing screw supports by loosening the two set screws that hold them to the column tubes and rotate to the proper position Also check to see that the column tube
21. and 24 NOTE If the V belt will not fit between the driven pulley and the brush support casting loosen or remove the bolts holding the bearings Lift brush enough to allow V belt to be removed After install ing new V belt retighten bolts Machine Reassembly 1 To reassemble the unit after replacing the V belt first reassemble the pulley guards 2 Place the transfer rod back through the machine and reinstall the nylon washer 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 3 Adjust the tension on the V belt by lowering the motor using the brush speed control handle 4 Make sure that the V belt is in alignment Also check that all belts are tight before using the SUPERBRUSH RotTATING REPLACING BRUSH BEARINGS Replacing the permanently lubricated bearings on the SUPERBRUSH is a relatively straight forward procedure Bearings should be replaced when they allow excessive play of the brush make excessive noise or otherwise indicate failure Bearing Replacement 1 Disconnect power source to the machine 2 Lower motor to its lowest position using the RPM adjustment handle Then raise motor to its high est position using the RPM adjustment handle This loosens the V belt tension so the V belt can be lifted off the driven pulley 3 Raise conveyor bed until the brush rests on bed If replacing both bearings begin with bearing o
22. and pulley and install on replacement brush Install replacement brush in machine and center brush before tightening bearing bolts Tighten bear ing set screws after bearing bolts are tightened Install SERVICING YOUR SUPERBRUSH 19 Fig 19 Removing brush head V belt on driven pulley and adjust pulley for proper V belt alignment before tightening pulley set screw REPLACING CONVEYOR BELTS To replace the conveyor belt the conveyor assem bly must be removed from the machine Lower the conveyor table Disconnect power source to machine Place conveyor motor assembly on top of dust cover Loosen the conveyor take up screws Fig 21 to relieve belt tension and slide the driven roller fully inward Remove the eight bolts that attach the con veyor assembly to the table mount brackets see Fig 20 Lift the conveyor and remove it from the ma chine by sliding the conveyor back Avoid tearing the belt on any edges underneath the conveyor bed during removal Reverse the procedure for re installation Note If the conveyor belt continually tracks to one side of the machine follow these steps 1 Check the conveyor drive and driven roller to make sure each is 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 outboard side extending it over the drive or driven roller Note the distance between the drive
23. ase brush speed RPM until the desired finish is achieved Fig 10A Forward Reverse switch Rear head Rear head Fig 10B Forward Reverse switch Fig 10C Variable speed control height adjustment 10 SuperBrusH 5 MANUAL To feed stock through the 0 rest and hold the stock to be sanded on the conveyor table allowing the conveyor belt to carry the stock into the brush Once the stock is halfway through reposition yourself to the outfeed side of the machine to receive and control the stock as it exits the unit TENSION ROLLER ADJUSTMENT Spring loaded infeed and outfeed Tension Rollers Fig 11 are provided to maintain downward pressure on stock being sanded and to prevent slippage of the stock on the feed 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 If the Depth Gauge is properly cali brated page 11 Tension Roller height is adjusted as follows Note Make sure brush head is appropriate for application and contact Flat Surfaced Stock Set the bottom of the tension rollers even with the bottom of the brush Loosen the four Tension Roller locking knobs Fig 11A amp 11B Raise the table to the 0 mark on the Depth Gauge At this position the brush and Tension Rollers are resting o
24. ate Purchased Dealer IMPORTANT KEEP MANUAL HANDY Please read this manual first It was designed to help you get the most from your SuPERBRUSH 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 THE SUPERBRUSH SYSTEM SUPERBRUSH 2 2 22 4 UNPACKING YOUR SUPERBRUSH 5 SETTING Up YOUR SUPERBRUSH MAKING ELECTRICAL CONNECTIONS ssessccsceseceeseeees 6 CONNECTING DUST COLLECTORS 0 7 CHECKING FOR MACHINE 04 7 CHECKING BRUSH 20 2 8 CHECKING TABLE HEIGHT 5 7 BRUSH SPEED 5 00 00 8 CHECKING CONVEYOR 8 OPERATING YOUR SUPERBRUSH BASIC OPERATING PROCEDURES 3 9 SUPERBRUSH OPERATING CONTROLS 9 ADJUSTING TENSION 5 2 SETTING DEPTH 11 BRUSH AND BRISTLE MAINTENANCE II SELECTING STOCK FEED RATES cssseescceeeceeeeeenees II USING THE DEPTH
25. ess 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 If you have any questions contact SuperMax Tools at 888 454 3401 or sales supermaxtools com or visit our website supermaxtools com 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 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 dust cover Keep hands and clothing away from operating brush Never operate the sander without its dust cover or pulley guarding in place 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 SUPERBRUSH sander is one of a family of ma chines from SuperMax Tools designed to help you achieve results comparable to industrial size sanders at a fraction of the cost The double SuPERBRUSH is available in 24 or 36 sizes For future reference find the model and serial numbers on the table mount bracket 42 page 27 and write them in below Model Serial Number D
26. formance page 12 of this manual The minimum recommended dust collector capacities for the 24x2 and the 36x2 are 2400 CFM 600 CFM per port For best results follow the recommendations of the manufacturer of your dust collection equip ment 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 SUPER Brus Before making fine tune adjustments to the machine place the unit where it will be used in the shop Adjust only if the machine is severely twisted one leg low Adjust by adding washers user sup plied between the caster and leg on the lowest corner Mark position of casters on the floor with tape so it can be returned to the same position HEIGHT ADJUSTMENT The table height is controlled by the UP DOWN switch located at the bottom right of the conveyor gear motor control panel Fig 4 A secondary switch offers control over a FAST or SLOW height adjustment speed Fig 4 The speed of SLOW conveyor UP DOWN is adjustable with SETTING Up Your SUPERBRUSH 7 Fig 6 Checking brush alignment and table height justment outboard side a small dial under the conveyor gear motor control panel and base bracket Fig 10C pg 9 Overload fuse protection is located between the two switches Fig 4 34 Amp max fuse size A manual
27. he variable speed controller or the conveyor motor use the following disassembly proce dure pages 23 25 To replace either the variable speed controller the ON OFF switch conveyor motor or the height adjust ment controller use the following disassembly procedure Fig 26 Disconnect the power supply to the machine Remove the height adjustment bottom tray from the control box by removing two bolts and disconnect three wires Loosen the set screws in the shaft coupler Re move the six bolts holding the conveyor motor assembly Fig 26 Remove the gear motor assembly and place it upside down on conveyor to access the leads to discon nect the leads from the components to be removed To replace the variable speed controller for the conveyor or height adjustment Fig 26 remove the variable speed control knob Remove the nut that holds the controller in place and pull the controller out of the housing Install the new controller referring to the correct electrical diagram and reverse the disassembly procedure To replace on off switch make sure power is discon nected to sander Remove the two screws holding the front cover of the switch in place Disconnect and mark wire leads connected to switch mechanism Remove switch from box and install new switch Connect wires to new switch following the wiring diagram and marked wires IMPORTANT Make sure bare wire does not touch any other wire or the switch box when connected Insta
28. ide ranging variety of tasks that will boost the return on your investment Learning to use its multiple adjustments and controls will allow you to fine tune the machine for maximum results regard less of the job to be done The best results come from experimenting with different machine adjustments to fit the job at hand Following is a listing of useful tips which can help you improve performance of your brush 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 than Ts When connecting to the dual ports of the SuPERBRUSH 36 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 Brushing Multiple Pieces At Once When brush ing multiple pieces simultaneously make sure to stag ger 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 To avoid personal injury take special care when brushing
29. ing bolts Fig 19 19A and 25 and lift brush out of machine Note Some models have two mounting bolts attaching the bearing housing down into the brush support bracket These two bolts can be used to remove the brush head instead of the bolts through the bearing flange 3 Loosen set screws in bearing collars and driven pulley and remove from brush shaft 4 Install new bearings and driven pulley Do not tighten set screws at this time 5 Install brush in machine and center before tighten ing bearing bolts Tighten bearing bolts and then set screws in bearings 6 Install V belt on driven pulley and adjust pulley for proper V belt alignment before tightening pul ley set screw 7 Check the alignment of the brush to the conveyor system For instructions on this procedure see page 8 of this manual 8 Lower the conveyor and spin the brush by hand to make sure the brush 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 brush within the collar then tighten the bolts in the bearing flange and then the set screws 9 Test run the before brushing stock to check that all is operating properly and is aligned be fore brushing good stock Also stop the SUPERBRUSH after a couple hours of use and check the bolts and set screws to make sure they are seated properly REPLACING ELECTRICAL COMPONENTS To replace either t
30. ll switch assembly and cover To replace the conveyor gear motor disconnect the two wire leads from the controller Also disconnect the SERVICING YOUR SUPERBRUSH 23 plastic grommet protecting the wires passing through the housing Remove the four cap head set screws that hold the motor to the housing bracket Remove the old motor and install new motor Install the wiring leads according to the electrical diagram pertaining to the cor rect model See following diagrams To replace conveyor fuse Fig 4 push and turn fuse cap 1 8 turn counter clockwise Pull cap with fuse from base Pull fuse from cap and replace with 3 4 amp fuse pages 24 and 25 Place fuse and cap into base Fig 26 Conveyor motor control box and brush on off switches 24 SUPERBRUSH MANUAL SUPER BRUSH WIRING DIAGRAM 230 VOLT 1 PHASE 60 HZ A FUSE HOLDER WHITE ACROSS FROM WHITE WHITE CONTROLLER 230V BLACK ACROSS 72 1260 FRIN SECURE TWO GREEN GROUND WIRES DEDICATED SCREW NEMA 14 30 PLUG HOLDER FUSE CONVEYOR UP DOWN SPEED HI LOW SWITCH SWITCH WIRING DIAGRAM MOTORIZED HEIGHT ADJUSTMENT CONTROL ASSEMBLY TO SAME COLOUR WIRES FROM GEAR MOTOR ASSY
31. mpany 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 dam age to the machine please read through the unpack ing instructions below before proceeding to set up the machine in your shop 1 Unbolt the machine legs from the shipping pal let Using a forklift lift machine from table mount brackets 42 page 27 While SuperBrush is sus pended with forklift install caster set Fig 2 2 Loosen the eight hex nuts and set screws on the table support castings Fig 3 and four on the motor support castings Fig 8 The set screws on the table support castings have been tightened at the factory to eliminate free play between the castings and the column tube during shipment There are two table support castings the one each for the right and left column tubes and two motor support casting all with set screws Fig 2 Caster and mounting hardware ABOUT THE SUPERBRUSH SYSTEM 5 Important These set screws are tightened for shipping and must be loosened and readjusted before operating either the height adjustment mechanism or the brush speed control handle To properly adjust for operation loosen each set screw by first loosening its hex nut with a wrench and then the set screw with an Allen wrench Then retight en
32. n 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 Improper conveyor belt tension Excessive depth of cut Excessive depth of cut Tension rollers too high Excessive feed rate Dirty or worn conveyor belt Belt out of adjustment Drive or driven conveyor belt rollers misaligned Conveyor table not flat and square Conveyor belt worn Drive roller worn or damaged Roller bushings elongated dueto excessive wear Solution Align shaft flats of gear motor and drive roller page 31 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 10 Reduce feed rate Clearn or replace conveyor belt Readjust belt page 10 Readjust page 19 Readjust by leveling machine page 7 Replace conveyor belt page 19 Replace drive roller page 19 Replace bushings page 19 16 SuperBrusH 5 MANUAL TROUBLESHOOTING GUIDE MACHINE Problem Brush height adjustment works improperly Knocking sound while running Sniping of wood gouging near end of board Burning of wood or melting of finish Gouging of wood Possible Cause 1 Improper adjustment of height control 1 V belt worn 2
33. n the left outboard side Replacing Left Outboard Bearing Make sure power is disconnected to the machine 1 Loosen set screws in bearing collar Remove the two Brush Mounting Bolts Fig 19A holding bearing assembly to frame of machine Slide bear ing assembly off shaft of brush head 2 Ifthe shaft of the brush 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 or bear ing flange bolts yet 3 Install and tighten the two Brush Mounting Bolts Fig 19A Tighten the two bearing flange bolts Tighten the two set screws in the bearing collar If the left outboard bearing is the only one that needs changing proceed to reassemble the unit You can check the brush at this point by lowering the conveyor bed and spinning the brush by hand This will help SERVICING YOUR SUPERBRUSH 21 Fig 20 Conveyor belt replacement determine if the inboard bearing needs to be changed to eliminate noise or excessive play in the brush Replacing Right Inboard Bearing Disconnect power source to brush 1 Lower motor to its lowest position using the adjustment handle Then raise motor to its highest position using the RPM adjustment handle This loosens the V belt tension so the V belt can be lifted off the driven pulley 2 Raise conveyor table so brush rests on conveyor 3 Remove four Brush Mounting Bolts f
34. n the table surface Lock all four Tension Roller knobs For example to brush a 3 4 thick flat board lower the table to 5 8 on the Depth Gauge This allows 1 8 for Tension Roller engagement and 1 8 brush penetration Contoured Surface Stock Example A 3 4 thick piece of molding with 3 8 of molding relief Loosen all eight tension roller locking bolts Fig 11A amp 11B Adjust the conveyor table 1 4 into the bristle tips measure with a ruler from 0 mark on depth gauge At this position the tension rollers are resting on the table surface and are positioned 1 4 above the bottom of the brush Lock all four Tension Roller locking bolts To brush the piece lower the table to the 3 8 position the Depth Gauge This allows for 1 8 of tension roller engagement and 3 8 of brush penetration SELECTING STOCK FEED RATES Fig 11B Tension Roller Adjustment Selecting the proper feed rate is essential to proper brushing Feed rate controls the duration of brushing on a particular spot A slower feed rate allows more brushing to occur In some instances a slow feed rate and slow brush speed may produce the same result as a fast feed rate and fast brush speed variable feed rate control of the conveyor belt adjusts the load on the machine it can be infinitely adjusted for maxi mum operating performance A faster feed rate allows faster brushing but fewer revolutions of the brush per inch
35. ne until the brush fibers are sharp and even When a nylon or wire brush is worn and needs changing the bristles will either have fractured and the brush head looks bald or the bristle length has worn and the bristles are too short for effective brushing When an abrasive or polishing brush is worn the brushing material will become smooth or the brush will be considerably smaller in diameter as compared to new Polishing brush heads may only need clean ing to rejuvenate the material 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 Many types of brush heads may be rewound with new bristles or re equipped with new brush material Please contact SuperMax Tools if you have questions about a new or re wrapped brush head Some types of brush heads some flatter brushes for example will allow changing of the brush material by the operator thus eliminating the need to send the brush head out for re wrapping Please call SuperMax Tools if you have any questions about re wrapping a brush Flatter bristles can be moved deeper into profiles to compensate for abrasive wear at the tips As long as the bristles can penetrate the stock being sanded the bristles can be set deeper into the material being brushed Note when brushing thin stock material the bristles may contact the conveyor belt thus causing faster conveyor belt wear 12 Supe
36. nts If you are experiencing a problem affecting the machine s brushing performance check the following listings for potential causes and solutions it may also pay to review the previous sections in this manual on setting up and operating your machine TROUBLESHOOTING GuIDE Problem Motors do not start Brush motor overloads Conveyor motor oscillates Brush motor or conveyor gear motor stalls Possible Cause Main power cord s un plugged from receptacle Brush motor cord unplugged from receptacle near power feed motor Circuit fuse blown or circuit breaker tripped Conveyor motor fuse blown Inadequate circuit Machine overloaded Motor not properly aligned Shaft collar or bushing worn Drive roller bent Excessive depth of cut Solution Plug in the primary power cord Plug in brush motor cord at recep tacle on machine if so equipped Replace fuse or retrip breaker after determining cause Replace 3 4 amp fuse page 24 amp 25 Check electrical requirements page 6 Use slower feed rate slower brush RPM reduce depth of cut Loosen housing bolts run motor retighten bolts Replace shaft collar or bushing page 31 Replace drive roller Page 31 Reduce depth of cut decrease brush speed reduce feed rate TROUBLESHOOTING YOUR SUPERBRUSH 15 TROUBLESHOOTING GUIDE CONVEYOR Problem Conveyor rollers ru
37. of sanding A slower feed rate provides more revolutions of the brush per inch of sanding Fig 4 The best feed rate will depend on a number of fac tors 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 SELECTING STOCK FEED RATES The standard conveyor feed rates for the 24x2 and 36x2 are infinitely adjustable from 0 30ft min This is read as a percentage on the dial The dial shows 0 100 For example a 50 setting would equal 15 min conveyor feed rate SETTING BrusH DEPTH CuT CONTACT SuperMax Tools tests sample applications for all cus tomers before selling a We recommend following the suggested RPM contact and conveyor settings outlined in the sample letter If you have questions about your application s or your needs change please contact SuperMax Tools for updated information or new sample testing as brush types materials etc may have changed The information and suggestions listed below are not specific to any application and may have changed since printing Please call SuperMax Tools if you have questions When using a wire brush for distressing wood a brush speed of 400 600 RPM with light contact of bristles and a moderate feed rate generally leaves the best finish and offers the longest brush life When brushing metal with a wire brush it is important to use light contact of the
38. override handle is located on the left out board side of the machine Fig 5 next to the infeed dust cover Turning the handle raises or lowers both sides of the conveyor simultaneously One revolution of the handle raises or lowers the conveyor 3 32 Before operating height adjustment be sure 8 set screws located in four table support castings Fig 3 are loose to allow table support to slide on both column Fig 7 Adjusting brush alignment 8 SUPERBRUSH OWNER S MANUAL tubes These set screws tightened for shipping BRUSH ALIGNMENT The brush must be parallel to the conveyor bed sur face Brush alignment can be visually checked by rais ing the tension rollers Fig 6 to their highest position See Tension Roller Adjustment page 10 and raising the table so that the brush just contacts the conveyor surface Brush contact should be equal across the width of the conveyor If the is prop erly leveled See checking machine for level page 7 brush misalignment can be corrected by loosening the two or four set screws in the outboard brush support casting Fig 7 and by raising or lowering casting to correct alignment NOTE Improper brush alignment will cause uneven results and lead to reduced brush life BrusH SPEED ADJUSTMENT RPM The is equipped with a variable speed drive which allows the brush to be operated anywhere between 400 and 1200 RPM Fig 8 The fa
39. ows Position the lower depth gauge casting along the scale to a desired finish thickness Then lock the lower depth gauge casting with the locking knob to prevent the conveyor table from being raised above that point DRO Dierra DEPTH GAUGE OPERATION Note The full manual for the DRO is included in the STOP bag along with the main brush manual Operation of the DRO is controlled by the buttons on the display panel The far left button is the on off The units button changes from inch to mm and from decimal to fraction settings The and button changes the readout of the measurement up or down Fig 12C MAINTENANCE For best results perform the following recommended maintenance procedures on a monthly basis e Lubricate bushings and check for wear light ma chine oil or graphite lube e Lubricate all moving parts such as threaded rods washers and column tubes Clean dust from the conveyor belt Blow dust from the motors e Check all bolts and set screws for tightness on parts such as brush support castings bearings conveyor coupler castings pulleys miter gears and brush heads Fig 12B Offset stock feeding angle metal e Clean brush if applicable e Use light weight machine oil penetrating lube or dry graphite powder for lubrication For PERFORMANCE The versatility designed into the SuPERBRUSH allows it to be used for a w
40. rBrusH 5 MANUAL SETTING REAR DEPTH OF height or contact of the rear brush is adjusted using shims page 13 Fig 12D between the bearing mount bracket and bearing bracket Generally most applications the tips of the bristles should be contact ing the top of stock To adjust loosen the two bolts holding the bearing bracket to the machine bracket page 20 Fig 19A and add or remove shims until the proper bristle contact is achieved DEPTH GAUGE OPERATION depth gauge see Fig 1 measures the distance be tween the conveyor table and the bottom of the sand ing brush The sanding brush must be parallel to the conveyor bed surface To calibrate the depth gauge loosen the locking knob of the lower depth gauge casting so it rests on top of the table support casting Raise the conveyor table until it touches the sanding brush Then loosen the locking knob of the upper depth gauge casting and position the 0 mark of the scale even with the top of the lower depth gauge cast ing Lock the upper depth gauge casting in position Once calibrated the locking knob of the lower depth gauge casting can be loosened allowing the lower depth gauge casting to ride on top of the table support casting The depth can then be read where the scale enters the lower depth gauge casting The depth Fig 12A Offset stock feeding angle wood gauge can also be used as a stop gauge as foll
41. rom both inboard and outboard bearings Fig 21 Tensioning and tracking conveyor belt 22 SUPERBRUSH 5 MANUAL Fig 23 Removing lower guard and transfer rod 4 Remove brush head from machine and place on flat surface making sure the brush cannot roll 5 Make note of pulley location on brush shaft Loosen set screw s in driven pulley and remove pulley 6 Loosen set screws in right bearing and remove bearing from shaft If the shaft of the brush is rough from the set screws use emery cloth or sandpaper to smooth down and roughness 7 Slide new bearing assembly onto shaft Do not tighten set screws or bolts 8 Reinstall pulley in same location and tighten set screw s 9 Place brush head back into machine Make sure brush head is centered 10 Tighten all four Brush Mounting Bolts Fig 19A Tighten bearing flange bolts 12 Tighten bearing collar set screws 13 Install V Belt on driven pulley 14 Confirm V Belt alignment and brush location before running Adjust if necessary 15 After running for a couple of hours check all bolts and set screws for tightness Fig 24 Removing main motor V belt REPLACING Brusa HEAD 1 Lower motor to its lowest position using the RPM adjustment handle Then raise motor to its high est position using the RPM adjustment handle This loosens the V belt tension so the V belt be lifted off the driven pulley 2 Remove the bear
42. s 31 0020 20 0772 50 3080 20 0752 30 1112 10 2804 30 1240 80 4013 20 1101 50 3107 40 0670 94 1674 20 1103 30 3044 30 1209 30 5103 12 0003 11 0206 10 9906 10 9207 11 9103 10 9205 12 0005 98 0131 30 1241 12 0209 30 1101 12 8015 10 8905 30 5206 10 9206 30 5204 30 1260HR 94 1654 12 0011 30 1103 80 4015 72 6208 40 0106 30 5205 30 1208HR 31 0030 30 1112 0 30 1045 20 0750 10 9906 11 0206 12 0205 SB36x2 40 4241 30 3117 40 0037 Qty Unit pe AR RD gt ARN N 9 ag laa 2 ON Or FP RYE NUR RNY RFP KN KH NNN ND SUPERBRUSH STAND ASSEMBLY 27 x _ 57 SA Sy 28 SUPERBRUSH OwNER s MANUAL Ref Number AMA BR 9 WD DOWD 9 59 9 2 BOHN 5 AMAR WHF FO ON DU 9 45 45 46 47 48 49 50 51 5 2 53 54 55 SB24x2 DUST COVER 40 3654 HANDLE DUST COVER BOLT HEX 3 8 16X1 WASHER 5 16 SAE BRACKET BEARING MOUNTING SEE FIG 25 BEARING SCREW 1 4 SOCKET HEAD SET BOLT 5 16 18X3 4 CARRIAGE PULLEY 77 10 TYPICAL SCREW 5 16 18X3 8 SOCKET HEAD SET NUT 3 8 16 FLANGE LOCK KEY STOCK 1 4X1 4X1 1 4 SCREW 1 4 20X1 3 4 ROUND HEAD MACHINE BR
43. s are cen Fig 13 Table support casting set screws Fig 14 Adjusting miter gears for proper mesh 18 SUPERBRUSH 5 MANUAL Fig 17 Adjusting table support castings tered inside the bore of the table support castings Fig 5 If not loosen the casting bolts and tighten the set screws at the front of table support casting to center the tube Retighten the bolts and loosen the set screws 4 If the height adjustment mechanism feels rough check the miter gear Fig 14 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 The mesh of the miter gears should be smooth and even If not adjust the gears for good mesh LEVELING TABLE To measure levelness of table measure the distance between the top of the base casting Fig 17 and the bottom of the table support castings This measure ment should be the same for both sides If it is not the same adjust as follows Remove the plastic cap from the miter gear Fig 14 on the outboard side of the machine Loosen the set screw of the miter gear and slide it back to dis engage it from the miter gear of the adjusting screw Turn the adjusting screw handle to raise or lower the outboard side of the table so that the measurement Fig 18 Comparing brush support casting heights taken above eq
44. s of contours will receive more sanding than trailing edges The rear brush should be rotating in the opposite direction for uniform brushing of all edges Stock may also be fed at an angle to allow more brush penetration on the sides OPERATING YOUR SUPERBRUSH The rear brush has a Forward Reverse switch located behind the ON OFF switches for the brush heads figs 10 amp 108 The correct rotation of the read brush will depend on the application and brush type Defuzzing profile sanding and deburring usually has the rear brush rotating opposite the first brush head Step sanding or graining with two different grit brushes usually has the rear brush rotating in the same direction as the first brush head Please note these are the typical scenarios your application s brush types etc may affect ideal rotation Contact SuperMax Tools if you have questions Basic OPERATING PROCEDURES After you have connected the machine to a dust collection system you are ready to begin to use the SupERBRusu The basic operating procedure for the SuPERBRUSH models is as follows Fig 5 1 Set depth of cut bristle contact page 11 2 Set tension rollers to type of stock being sanded See Tension Roller Adjustment page 10 3 Start sanding brush and select slow brush speed page 8 4 Start conveyor and select feed rate page 10 amp 11 5 Start dust collector system 6 Feed stock through unit 7 Gradually incre
45. safety cautions on the opposite page and on the back cover of this manual SuperBrusH 5 MANUAL ABOUT HE SUPERBRUSH SYSTEM This manual is designed to help familiarize you with your SurpERBRUSH sander and to help you take advantage of its exclusive features By under standing its major components and how they work together you will be able to get the most from your investment The SuPpERBRUSH system is basically made up of 1 a height adjustment control and handle which raises and lowers the conveyor table 2 two brush speed control handles which controls brush speed from 400 to 1200 RPM 3 Two motor starter switches which start and stop the drive mo tors and sanding brush and 4 a feed rate control knob which starts feed conveyor and selects feed rate from 0 30 feet per minute SANDING HEIGHT ADJUSTMENT _ Brust HANDLE DEPTH GAUGE TENSION ROLLER CONVEYOR LEFT OUTBOARD SIDE Ma n MOTOR DRO 76 BrusH SPEED CONTROL Hanne RPM Motor CONTROL SwITCH MITER lt _ GEARS FEED RaTE CONTROL GEAR GAUGE HEIGHT ADJUSTMENT RIGHT INBOARD SIDE SWITCHES Fig 1 nomenclature UNPACKING YOUR SUPERBRUSH Your SUPERBRUSH sander has been shipped assembled from the factory on a pallet and shrink wrapped If any damage has occurred as a result of shipment notify the transportation co
46. ster the brush speed the more aggressive the brush action The brush speed control handles Fig 5 1 amp 1A raises or lowers the motor support casting which activates the variable speed drive pulley Each brush head and motor is equipped with independent variable speed RPM first or in board brush is controlled by a handle on the right inboard side of the machine Fig 5 1 The second or outboard brush is controlled by a handle on the left outboard rear of the machine Fig 5 1A Each of these adjustment handles allows independent control of RPM for each brush head and is displayed on the RPM Gauge RPM The RPM gauge Fig 8 displays the brush speed and is read where the scale intersects the top of the screw support casting To calibrate the gauge lower the mo tor to the lowest position Loosen both hex nuts while holding set screws Position the RPM scale so that 400 RPM intersects the top of the screw support casting Fig 8 Tighten hex nuts to hold gauge in this position CHECKING THE CONVEYOR BELT 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 con veyor 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
47. t screw of table support castings to maintain adjusting screw posi tion during adjustment BrusH SPEED ADJUSTMENT If the brush speed adjustment does not operate easily perform the following check or adjustments 1 Loosen set screws located on front of motor sup port casting Fig 3 amp 13 2 Lubricate thoroughly Apply penetrating lubricant to motor support casting where it contacts the column tubes and to all contact points between adjusting screw and adjusting screw supports Fig 5 3 Improper alignment of adjusting screw supports may cause binding on the adjusting screw Loosen both set screws on each adjusting screw support to rotate or adjust screw supports Note that adjust ing screw supports control both lateral and vertical movement of the adjusting screw mechanism and must be adjusted accordingly CHANGING OR REPLACING BRUSH Changing the brush on the is relatively simple To begin first disconnect power source to the machine Lower the motor to its lowest position using the brush speed control handle Raise the motor to its highest position This loosens the V belt tension so the V belt can be lifted off the driven pulley pulled back and placed under the control handle to hold it out of the way Loosen and remove bearing bolts Fig 19 and 19A depending on model See also page 23 and Fig 25 Lift brush out of machine Loosen set screws of bearing collars and pulley Remove bearings
48. uals the inboard side of the table After adjusting is complete re engage miter gear making sure that miter gear set screw is aligned with flat on cross bar shaft MITER GEAR ALIGNMENT If height adjustment mechanism does not operate eas ily perform the following checks or adjustments 1 Loosen set screws located on table support castings Fig 13 2 Lubricate thoroughly Apply penetrating lubricant to table support castings where it contacts the column tubes and to all contact points of adjusting screws and cross bar Apply grease oil to miter gears 3 Check miter gear alignment Check and adjust gears so that gear mesh is not too tight nor too loose and that gear teeth align with opposing gear The miter gears can be adjusted on their shafts by loosening the set screws on the gears Note that set screws MUST align with flat of shaft 4 Check and adjust for misalignment of adjusting screw supports Fig 5 and brush support castings which could cause binding on the adjusting screw These castings can be slightly rotated by loosening the set screws which secure it to the inside of the column tubes NOTE adjusting screw sup port Fig 5 located immediately below the height adjusting handle and the outboard brush support casting must be set at the proper height along the column tubes to position the adjusting screws so that there is proper miter gear alignment Before adjusting these parts tighten one se
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