Bluerock Tools 40A Quick start guide

OPERATIONAL MANUAL
MODEL: 40A GRINDER/SANDER/POLISHER
by BLUEROCK ® Tools
Volume
1.1

MWS-40A GRINDER/SANDER/POLISHER
UNPACKING THE ITEM
Caution: This machine is packed together with items that may be sharp, oily and overly heavy objects. Remove the machine from
the packaging in a safe manner. Check to ensure all accessories are included with the item while unpacking. If any parts are found
to be missing, contact the retailer as soon as possible. Do not throw away the packaging until the item is out of the guarantee
period. Dispose of the packaging in an environmentally responsible manner. Recycle if possible. Keep all plastic bags away from
children due to risk of suffocation.
WEEE - Waste Electrical & Electronic Equipment. Note this machine should be disposed of as electrical & electronic waste.
©THE NEWMAN TRADING COMPANY LLC DBA BLUEROCK® TOOLS 2016
1100 SW 16th St • Suite D
Renton, WA 98057
Phone [phone] • Fax [phone]
www.bluerocktools.com

40A GRINDER/SANDER/POLISHER
Table&of&Contents&
SAFETY' 1!
PRE-OPERATIONAL SAFETY CHECKS! 1!
OPERATIONAL SAFETY CHECKS! 1!
HEALTH WARNINGS! 2!
SPECIFICATIONS' 3!
INCLUDED'ACCESSORIES' 3!
ADDITIONAL'AVAILABLE'ACCESSORIES' 3!
ADDITIONAL ACCESSORIES FOR THIS MACHINE CAN BE FOUND IN BLUEROCK ®TOOLS ONLINE SHOP AT
WWW.BLUEROCKTOOLS.COM OR FROM YOUR LOCAL RETAILER.! 3!
OPERATIONS' 4!
PURPOSE! 4!
OPERATIONAL PRINCIPLES! 4!
MACHINE COMPONENTS! 4!
TRANSPORTING THE MACHINE! 5!
RUNNING THE MACHINE! 5!
INSTALLING SANDING BELTS! 6!
TROUBLESHOOTING' 7!
GENERAL'MAINTENANCE' 8!
OCCASIONAL'MAINTENANCE' 8!
PARTS'LIST' 9!
BREAKDOWN'VIEW'10!

40A GRINDER/SANDER/POLISHER
1
Safety
DO NOT USE THIS MACHINE UNLESS YOU HAVE READ THE OPERATING INSTRUCTIONS!
Safety glasses must be worn at all times in
work areas. Use a full face mask whenever
possible.
Long and loose hair must be
contained.
Appropriate footwear must be worn.
Close fitting/protective clothing
must be worn.
Safety gloves should be worn at all times and
jewelry must not be worn.
Hearing protection should be worn
when using this machine.
Read operational manual prior to use.
Dust mask must be worn while
using this machine.
PRE-OPERATIONAL SAFETY CHECKS
ØExamine the power cord and plug for damage.
ØExamine the body of the machine and inspect for damage or defects.
ØExamine the sanding belt to insure it is operable.
ØEnsure that the sanding belt is correctly attached to the machine.
ØMake certain the on/off switch is in the off position.
OPERATIONAL SAFETY CHECKS
ØONLY to be operated by qualified personal who have read instructions.
oNOTE: Failure to read and follow instructions could result in electrical shock, fire, property damage and/or
serious injury!
ØDO ensure all non-essential people are clear of the immediate work area.
ØDO keep body parts, clothing & power cords clear of turning pieces.Stay alert and use common since when using
this tool.
ØDO allow machine to reach operating speed before contacting with surface.
ØDO use both hands when using this machine.
Chapter
1

40A GRINDER/SANDER/POLISHER
2
ØDO unplug machine while changing or adjusting belts so as not to accidentally turn machine on.
ØDO guard against electric shock by preventing body contact with grounded surfaces such as pipes, radiators, ranges,
refrigerators, etc.
ØDO be mindful that power tools can expose an operator to vibrations transmitted trough contact with the machine.
Prolonged exposure can lead to medical issues which should be discussed with a medical professional.
ØDO use a dust extraction system for working materials that create dust. The operator should also wear a protective
respiratory device.
ØDO NOT make adjustments to machine while the machine is running.
ØDO NOT use this machine with water or any type of liquids.
ØDO NOT leave the machine running when not in use.
ØDO NOT hold the work piece by hand or using body. Always mechanically clamp or secure work piece.
ØDO NOT allow liquids or dust to enter the machine’s ventilation system.
ØDO NOT operate machine outside of machine specifications.
ØDO NOT touch moving parts while the machine is running as death or dismemberment could occur.
ØDO NOT remove machine plastic panel while machine is connected to a power source. Only to be removed for
service by qualified personal and put back on the machine after service is complete.
ØDO NOT allow children or untrained personal to operate machine.
ØDO NOT use this machine in the rain or a wet environment. If using outdoors, make sure the surface is clean and dry.
ØDO NOT operate in the presence of explosive materials as power tools create sparks which may ignite dust or fumes.
ØDO NOT use on a work area that may contain a live electrical wire/circuit.
ØDO NOT operate this machine on the same work surface where welding is being performed. This could result in
severe damage to the machine or personal injury to the user.
ØDO NOT operate this machine on a lower voltage as this could limit the motor life and work efficiency.
oNOTE: Use of long small gauge power extension cords can result in decreased voltage. As local voltages
can vary, it may be a good idea to test the voltage at the end of the extension cord to ensure proper voltage
requirements are met. You might also consult an electrician to make sure the length of cord matches up
with the proper wire gauge for this size motor. Make sure to use outdoor cords when operating outdoors.
Use a GFCI circuit if using in wet locations.
HEALTH WARNINGS
ØCertain dust created by sanding contains chemicals known to cause a variety of health issues including cancer, birth
defects or other reproductive harm. The examples of some of these chemicals are below (this is not an exhaustive
list):
oLead from lead based paint.
oCrystalline silica from bricks, cement and assorted masonry products.
oGlues in certain woods.
oMetal fragments.
§TO REDUCE RISK OF EXPOSURE TO THESE CHEMICALS, WORK IN A WELL VENTILATED
AREA WITH VACUUM SYSTEMS, RESPIRATORS AND WITH ALL SUITABLE SAFETY
EQUIPMENT. DO FOLLOW ALL LOCAL AND NATIONAL SAFETY STANDARDS WHEN
WORKING WITH SPECIFIC MATERIALS.

40A GRINDER/SANDER/POLISHER
3
Specifications
ELECTRICAL DATA
Voltage
110V, 60Hz
Current
8.18 Amps
Motor Size
900W
Power Connection
US Standard 2 Prong Plug
MECHANICAL DATA
Belt Length
760mm (30”)
Belt Width
40mm (1.57”)
Machine Speed
900-2800 RPM Variable Speed Gearbox
Max Pipe Diameter
7” Max
Minimum Pipe Diameter
None
Wrap
270 Degree Max Wrap
SHIPPING DATA
Shipping Weight
10 Lbs
Shipping Carton
20” x 8” x 6”
Included Accessories
DESCRIPTION
QTY
Instruction Manual
1
Secondary Handle
1
760mm x 40mm Sanding Belt
1
Spare Brush
2
Additional Available Accessories
Additional accessories for this machine can be found in BLUEROCK ® Tools online shop at
www.bluerocktools.com or from your local retailer.
Chapter
2
40A Sanding Available Belts
Coarse Grit Non-woven Nylon Polishing Belts
#60 Grit Sandpaper Zirconia Alumina Sanding Belt
#80 Grit Sandpaper Zirconia Alumina Sanding Belt
#180 Grit Sandpaper Aluminum Oxide Sanding Belt
#400 Grit Sandpaper Aluminum Oxide Sanding Belt
#800 Grit Sandpaper Aluminum Oxide Sanding Belt

40A GRINDER/SANDER/POLISHER
4
Operations
Note
THOROUGHLY READ THROUGH THE ENTIRE MANUAL BEFORE OPERATING THIS MACHINE!
PURPOSE
ØThe purpose of the 40A is to sand, grind, burnish and polish a variety of surfaces from wood to steel.
ØThis machine uses a spring loaded sanding head, which allows for use on round surfaces. This increases
the sanding surface area making for a faster more uniform surface treatment.
OPERATIONAL PRINCIPLES
ØThe main round machine shaft rotates in a forward direction (when holding the machine by the main
handle). The motor connects to the main rubber drive, which makes contact with the non-abrasive side of
the sanding belt.The two smaller secondary drive wheels also make contact with the non-abrasive side of
the belt.
MACHINE COMPONENTS
ØThe main components of the 40A are the belt holder assembly, gearbox, motor, housing and main handle.
The belt holder is driven by the gearbox and the motor.
oThese components must be not be removed except by a qualified technician. Power must be
disconnected prior to any service.
ØThe machine has a variable speed switch located on the main handle by the power cord base. This switch
has numbers signifying low (1) to high (6) speeds.
Chapter
3

40A GRINDER/SANDER/POLISHER
5
1)
Main Rubber Drive
7)
Secondary Handle
2)
Secondary Drive Wheels
8)
Lock for Main Rubber Drive
3)
Abrasive Side of Belt
9)
Main Handle
4)
Non-Abrasive Side of Belt
10)
On/Off Switch
5)
Spring Arm
11)
Variable Speed Switch
6)
Plastic Guard
TRANSPORTING THE MACHINE
ØWhen transporting the machine, always carry with both handles.
ØIf transporting inside a vehicle, it is recommended to transport it on its side so as to avoid the item falling
over.
ØDO NOT carry the machine by the cord.
ØDO NOT allow the cord or plug to drag along the floor when transporting.
RUNNING THE MACHINE
ØDo all pre-operational and operational safety checks from Chapter 1.
ØConsider your security and stability as well as the orientation of the machine in the work area.
oConsider the work surface material, condition, strength, density and rigidity. These factors
directly affect the tools operation and user safety.
ØEnsure the secondary handle is securely attached.
oIt can be connected from the right or left side.
ØEnsure the work surface is free of debris, oil, etc.
ØSelect appropriate grit sanding paper. Install paper.
oNote: See section below for more information on paper installation.
ØSelect rotational speed 1-6 using speed chart below (meters per second):
o1
o2.7 m/s
o4
o6.3 m/s
o2
o3.8 m/s
o5
o7.6 m/s
o3
o5.1 m/s
o6
o8.5 m/s
ØPlug the machine into power source.
ØTurn the machine on.
oStart the machine by sliding switch 1 in picture below forward.For continuous operation, tilt
switch downwards until it engages. Stop the machine by sliding the switch backwards and
release.
o
ØVery slowly engage the sanding paper with the material surface by lightly engaging towards the material.
Ensure the sanding belt is parallel to the work surface. Operating at right angles will ensure the belt does
not fall off the rollers.
oNOTE: Do not force the sanding. Let the machine do most of the work. Excessive physical effort
should be avoided as it can cause damage to the machine or the user.

40A GRINDER/SANDER/POLISHER
6
oCAUTION: This machine is equipped with motor overload protection. If the unit shuts down due
to overload, turn switch off. Wait 5 seconds and turn the machine back on and run under no-load
for 20 seconds to allow for motor cooling. Not doing this could result in motor failure.
oIf the motor stops due to paper failure, stop the machine immediately to prevent injury.
Disconnect the machine from the power supply and change paper.
ØFinish sanding the surface.
ØTurn the motor off.
oCAUTION: Only lay the machine down on surface once the belts have come to a complete stop.
INSTALLING SANDING BELTS
ØCheck that the replacement belt is not damaged.
oSanding belts that are damaged should not be used.
ØMake certain the machine is unplugged from power.
ØDepress the spring arm (number 5 in the picture above) inwards and remove the old sanding belt.
ØPlace the new sanding belt on the rollers so it’s direction of circulation (arrows on the non-abrasive side of
the belt matches the arrow on the machine’s gearbox.
ØRelease the spring arm and ensure the belt is completely on the rollers.

40A GRINDER/SANDER/POLISHER
7
Troubleshooting
Note
SERVICING SHOULD ONLY BE DONE BY A QUALIFIED TECHNICIAN.
DON’T FORGET TO UNPLUG POWER TO UNIT PRIOR TO SERVICE!
PROBLEM
SOLUTION
Motor does not turn on.
1) Check external power source (extension cord, breaker, etc).
2) Loose internal wire. Check and secure if necessary.
3) Motor brushes defective. Replace if necessary.
4) Check to ensure the motor on/off switch is operable. Replace if necessary.
5) Variable speed switch is defective. Replace switch.
Excessive sparking when
motor is running.
1) This may indicate the presence of debris in the motor or worn out carbon brushes.
Check the brushes for unusual wear and replace if necessary. Clean out the
internal motor armature if necessary.
2) Armature has a rough edge. Inspect and replace if necessary.
Machine is not sanding.
1) Belt is dull. Replace belt.
2) Work area material is not appropriate for belt type.
Chapter
4

40A GRINDER/SANDER/POLISHER
8
General Maintenance
ØInspect electrical cords and electrical connections.
ØKeep machine clean and free of debris.
ØCheck for misalignment, binding and breakage of all moving parts. If damaged, repair tool before use.
Occasional Maintenance
ØHave the power tool serviced by a qualified service technician using identical replacement parts.
oChange motor brushes:
1) Disconnect machine from power.
2) Take of motor handle housing.
3) Unscrew left and right side brush holder caps.
4) Take out old brushes.
5) Replace with exact same size new brushes.
6) Screw in brush holder caps tightly.
7) Replace motor handle housing.
Chapter
5

40A GRINDER/SANDER/POLISHER
9
Parts List
Drawing
No.
Name
qty
Drawing
No.
Name
qty
1
Output Shaft
1
31
Self-tapping screw
2
2
Woodruff key
1
32
Stator
1
3
Front Cap Screw
4
33
Housing
1
4
Dust Cap
1
34
Flat washer
1
5
Front Cover
1
35
Tapping screw
1
6
Bearing
1
36
Switch Push Button
1
7
Gland
1
37
Switch push Lever
1
8
Gland Screw
3
38
Tension disc screw
2
Flat washer
1
39
Cable disc
1
9
Gear (big)
1
40
Switch
1
10
Set Screw
4
41
Tapping screw
3
11
Set Screw
42
Back frame
1
12
Clamp spring for self-locking
1
44
Sheath
1
13
Clamp spring for Output shaft
1
45
Cable
1
14
Quill roller
1
47
Speed-control switch
1
15
Self-locking spring
1
48
Carbon Brush
1
16
Self-locking
1
49
Carbon brush holder
1
17
Head Cap
1
50
Earth wire
18
Bearing Set Screw
1
51
Aluminum Upper Spider
1
19
Clamp spring
1
52
Handle
1
20
Gear (small)
1
53
Belts cover
1
21
Bearing
1
54
Belt main wheel
1
22
Gear Case Spindle
1
55
Aluminum Lower Spider
1
23
Spur Gear (small)
1
56
Spider set screw
4
24
Bearing Retainer
1
56
Spring
25
Bearing
1
57
Screw
1
26
Rotor
1
58
Spindle
3
27
Rotor axis
1
59
Bearing
2
28
Bearing
1
60
Plastic wheel
4
29
Bearing housing
1
61
Clamp spring
2
30
Windshield
1
62
Belt
1
Chapter
6

40A GRINDER/SANDER/POLISHER
10
Breakdown View