SuperMax 25 User manual

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.

2 SUPERMAX OWNER’S MANUAL
CONGRATULATIONS
You have made a wise purchasing decision by
adding this designed in the 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, cleaning
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.
• 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.
• 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 drum 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 can’t solve, please call your SuperMax Tools
dealer.

CONTENTS
MANUAL CONTENTS 3
ABOUT THE SUPERMAX SYSTEM
SUPERMAX Nomenclature ....................... 4
Unpacking Your SUPERMAX Sander ....... 5
SETTING UP YOUR SUPERMAX
Making Electrical Connections .............. 6
Connecting Dust Collectors .................... 7
Checking For Machine Level ................. 7
Checking Drum Alignment .................... 7
Checking The Conveyor Belt ................. 8
Checking Table Height Controls ............. 9
Monthly Maintenance ............................. 9
Wrapping Abrasive Strips ..................... 10
OPERATING YOUR SUPERMAX
Basic Operating Procedures ................. 12
SUPERMAX Operating Controls ............. 12
Setting The Depth of Cut ...................... 13
Setting Single or Primary Drum ............ 13
Setting Secondary Drum
(Dual Drum Machines) ...................... 13
Disengaging The Drums
(Dual Drum Machines) ...................... 14
Selecting Intellisand™ Feed Rates ....... 14
Using The Depth Gauge ....................... 15
Selecting Drum Abrasives .................... 16
Tips For Maximum Performance .......... 17
T ROUBLESHOOTING Y OUR
SUPERMAX
Troubleshooting Guide: Motors ............ 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 Rollers ..................... 28
Replacing Sanding Drums ..................... 29
Replacing Conveyor Belts ..................... 31
Replacing V-Belt ..................................... 32
Rotating/Replacing Drum Bearings ...... 33
Replacing Electrical Components ......... 36
Electrical Diagram ................................ 36
SUPERMAX TECHNICAL DATA
S UPER M AX Specifications ........................ 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
S UPER M AX Accessories & Supplies ......... 47
FOR YOUR SAFETY: Read all instructions carefully,
and note the safety cautions on the opposite page and
on the back cover of this manual.

4 SUPERMAX OWNER’S MANUAL
ABOUT THE SUPERMAX SYSTEM
This manual is designed to help you become familiar
with your SUPERMAX drum sander, and to help
you take advantage of its exclusive features. By
understanding its major components, and how
they work together, you will be able to get the most
from your investment.The SUPERMAX system is
basically made up of the following five major
components: 1) precision machined revolving
drums wrapped with abrasive strips held by a 2)
patented take-up mechanism to process stock fed
by the 3) no-give conveyor table which is adjusted
by 4) an infinitely variable power feed motor and a
5) convenient height adjustment mechanism. The
illustration below shows the major components.
Fig. 1. SUPERMAX nomenclature.
DUST COVER
SANDING DRUM(S)
D
RUM A
DJ.
KNOB
HEIGHT
HANDLE
(H
EIGHT
CONTROL BOX
MOTOR
LEFT (OUTBOARD) SIDE
MAIN MOTOR
RIGHT (INBOARD) SIDE

ABOUT THE SUPERMAX SYSTEM 5
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 enclosed Warranty Statement.
Important: To avoid problems and potential
damage to the machine, please read through the
unpacking instructions below before proceeding to
set up the machine in your shop.
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.
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 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.
Fig. 2. Leveling feet and mounting hardware. Fig. 3. Table support casting and set screws.
L
EVELING
F
EET
STAND LEG
CASTING
HEX NUT & 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.
M AKING E LECTRICAL C ONNECTIONS
A cord and plug are not included. Consult with
an electrician and confirm all applicable
electrical codes before wiring. 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 plug and cord
is not supplied. Single phase SUPERMAX
sanders require a minimum dedicated circuit of
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
lengths 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
do not include a cord or plug. Three phase
SUPERMAX sanders require a minimum dedicated 20-
amp circuit. Extension cords are not recommended,
Fig. 4. Thermal-overload switch, on some models.
4
2 1
3
4
5
6
6
10
9
7
8
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.

SETTING UP YOUR SUPERMAX 7
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.
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.
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).
DRUM

INBOARD
KNOB
SHAFT
INDICATOR
NEEDLE
SCALE
HEX NUT
8 SUPERMAX OWNER’S MANUAL
Fig. 8. Adjusting primary drum alignment. Fig. 9. Rear drum adjustment indicator.
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 indicators 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
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 instruction 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

TAKE-UP
SCREW NUT
HEIGHT
ADJ.
DRUM
TABLE
HEX NUT &
SET SCREW
GEAR
SETTING UP YOUR SUPERMAX 9
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 pro-
ceeding further. Try to avoid over-adjustments.
Make sure wrench is below surface when sanding.
C HECKING T ABLE H EIGHT C ONTROLS
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
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 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.
• 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 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.)
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” 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
toallowitto bepulledinto thedrumasneeded
(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-i). 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: A sandpaper cleaning stick may be used to
remove deposits and help extend sandpaper life. To
use, operate the sanding drum with the dust cover
open. (Caution: For your own safety, always wear
eye 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-
Fig. 12-a. Marking and cutting taper on strip.
SANDPAPER STRIP
Also see Fig. 12-b and Fig. 12-c.
3"
C

SETTING UP YOUR SUPERMAX 11
Fig. 12-b. Trim about 3" from end of cut taper. Fig. 12-c. Trimmed tapered end ready to install.
Fig. 12-d. Insert tapered end into outboard slot. Fig. 12-e. Wrap strip around drum without overlap.
Fig. 12-f. Mark strip where it crosses drum edge. Fig. 12-g. Insert tapered end into inboard slot.
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.
Fig. 13. SUPERMAX operating controls.
SECONDARY
D
RUM
KNOB
FEED RATE
C
ONTROL
K
NOB
HEIGHT
HANDLE
DRUM

FRONT DRUM
OPERATING YOUR SUPERMAX 13
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.
A 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 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
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.
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
Fig. 14. Relative positions of dual drums.

14 SUPERMAX OWNER’S MANUAL
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 performance. Here
is a 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
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 has
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.
DUAL DRUM
GRIT COMBINATIONS & SETTINGS
ABRASIVE 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.

OPERATING YOUR SUPERMAX 15
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
for thickness dimensioning of boards. To calibrate
the depth gauge, raise the conveyor table until the
drum(s), wrapped with abrasive, touches the con-
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. This will
give a desired exiting thickness to the material and
help prevent under dimensioning.
Fig. 15. Intellisand Controller and depth gauge. Fig. 16. Depth gauge components, on some models.
DRUM
DEPTH
INDICATOR
LIGHT
DEPTH
S
CALE
INDICATOR
N
EEDLE
D
EPTH
STOP
ADJ.
TABLE
SUPPORT
CASTING

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 grit 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 best
combinations of grits for future work.

OPERATING YOUR SUPERMAX 17
TIPS 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 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
Specifications, page 37). Going to longer pieces is
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 & 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 gouge 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 offset 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
available 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
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 (Regalite™) 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 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.
Fig. 17. Offset stock feeding angle. Fig. 18. Cleaning abrasive strips.

TROUBLESHOOTING YOUR SUPERMAX 19
TROUBLESHOOTING YOUR SUPERMAX
Any operating problems with the SUPERMAX sanding performance, check the following listings
drum sander will likely occur most often during for potential causes and solutions; it may also pay
the period that you are becoming familiar with its to review the previous sections in this manual on
components and their adjustments. If you are setting up and operating your machine.
experiencing a problem affecting the machine’s
TROUBLESHOOTING GUIDE: MOTORS
Problem Possible Cause Solution
Motors do not start.
1. Main power cord
Plug in primary power
unplugged from receptacle.
cord.
2. Circuit fuse blown or circuit
Replace fuse or retrip
breaker tripped.
breaker (after
determining cause).
3. Drum motor thermal
Reset after allowing to cool;
overload protector tripped
check circuit and/or reduce load
(single phase only).
or slow feed rate.
Magnetic starter thermal
overload protector tripped
(SUPERMAX SE single and
three phase models).
Drum motor
overloads.
1. Inadequate circuit.
2. Machine overloaded.
Check electrical requirements.
Use slower feed rate and/or
reduce depth of cut.
Conveyor
motor oscillates.
1. Motor not properly
aligned.
2. Shaft collar worn.
3. Drive roller bent.
Loosen housing bolts,
run motor, retighten bolts.
Replace shaft collar (page 5).
Replace drive roller (page 31).
Drum motor
or conveyor gear
motor stalls.
1. Excessive depth of cut.
Reduce depth of cut;
reduce feed rate.

20 SUPERMAX OWNER’S MANUAL
Problem
TROUBLESHOOTING GUIDE: MACHINE
Possible Cause Solution
Abrasive strip comes
off drum.
1. Slack in abrasive strip
on drum.
2. Abrasive improperly
installed.
Remove slack in strip
(page 10).
Read section on abrasive
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
prematurely.
1. Excessive depth of cut.
2. Excessive feed rate.
3. Inadequate dust collection.
4. Inadequate abrasive.
5. Stock fed at 90° angle.
to drum.
Reduce depth of cut.
Use slower feed rate.
Increase air flow at dust ports.
Use open-coat abrasive.
Angle stock to avoid resin
line build-up.
Conveyor rollers run
intermittently.
1. Shaft coupling loose.
Align shaft flats of gear motor
and drive roller, and tighten
shaft coupling set screws.
Conveyor belt slips
on drive roller.
1. Improper conveyor belt
tension.
2. Excessive depth of cut.
Adjust belt tension (page 8).
Reduce depth of cut;
reduce feed rate.
Board slips on
conveyor belt.
1. Excessive depth of cut.
2. Tension rollers too high.
3. Excessive feed rate.
4. Dirty or worn conveyor
belt.
Reduce depth of cut.
Lower tension rollers (page 28).
Reduce feed rate.
Clean or replace conveyor
belt (page 31).