Extrema Machinery XS-1A25 User manual

XS-1A25
EXTREMA MACHINERY COMPANY, INC.
PO BOX 1450, ALBANY, LOUISIANA 70711
[phone] FAX [phone]

TABLE OF CONTENTS
General Safety Rules 2
Shipping & Receiving Instructions 3
Unpacking & Checking Contents 4
Cleaning the Machine 4
Lifting the Machine 4
Installation Instructions 5
Connection to Air Supply Line 5
Electrical Safety Rules 6
Electrical Connection 7
Starting & Stopping the Machine 8
Abrasive Belt Oscillation & Tracking Safety 8
Tracking Adjustment 9
Abrasive Belt Tracking Device Illustration 9
AirDiagram 12
Adjustment of the Platen 13
Changing of an Abrasive Belt 14
General Maintenance of the Conveyor Belt 15
Maintenance of the Air Unit 16
Greasing & Lubrication 16
Disturbances 17
Deficiencies During the Sanding Operation 18
Deficiencies in the Sanding Pattern 19
PartsList 22

GENERAL SAFETY RULES
There is a certain amount of hazard involved with the use of woodworking machinery. Using
the machine with the respect and caution demanded as far as safety precautions are
concerned will considerably lessen the possibility of personal injury. However, if normal safety
precautions are overlooked or ignored, severe personal injury to the operator can occur.
1. Read the operation manual before operating this machine.
2. If you are not thoroughly familiar with the machine operation, obtain advice from a
supervisor or other qualified person.
3. The machine should be disconnected from the power source before performing
maintenance or adjustments to the internal mechanisms, or when making repairs.
4. After maintenance job is finished, check to see if there are any tools or objects left on the
machine. Close all safety guards.
5. Before leaving the machine, make sure the work area is clean.
6. Check timber for loose knots, nails, or other items, which may cause a hazard or affect the
machine’s performance.
7. Learn the machine’s applications and limitations, as well as the specific potential hazards
peculiar to it. Keep the machine in top condition for best and safest performance.
8. Keep all guards in place and in working order.
9. Do not force the machine. It will do the job better and be safer working at the rate for which
it was designed.
10.All children and visitors should be kept a safe distance from the working area.
11.The operator should keep proper footing and balance at all times.
12.Do not operate the machine while under the influence of drugs, alcohol, or any other
medication.
13.Avoid awkward operations and hand positions where a sudden slip could cause your hand
to move into the machine.
14.Never leave the machine until it comes to a complete stop, and never leave the machine
running unattended.
15.The employer is responsible for selecting competent and qualified employees.
16.The employer must make sure that employees study and utilize this safety information.
17.Supervisors must alert personnel of any unsafe practices they observe.
18.All employees should be aware of first aid facilities and be encouraged to use them,
regardless of the severity of the injury.
19.Fire prevention must be practiced and must be available to prevent loss of life, personal
injury, and property damage.
20.Safety shoes should be worn to provide protection against rolling objects, falling objects,
and sharp edges in the workplace.
21.Eye protection should be worn and such devices should be carefully selected, fitted and
used. Compulsory wearing of glasses with impact resistant lenses and side shields is a
good safety policy. All eye protection should conform to ANSI 87 standards.
22.Wear hearing protection when operating the machine.
23.Do not wear rings, necklaces or jewelry around moving machinery.
24.Do not wear loose fitting clothes. Clothing should be comfortable, but long sleeves,
neckties, etc. should not be worn.
25.Do not wear gloves or other hand covering articles around moving machinery.
26.Dover long hair with a hair net or cap.

27.Protective guards and shields must be in place at all times unless they must be removed
for specific service or maintenance. They should be immediately replaced when service or
maintenance is completed.
28.Make sure that operator clearly knows how to stop the machine before starting work.
29.Never clean or remove chips while the machine is running.
30.Maintain the machine in good operating condition. Report unusual conditions or machine
malfunctions immediately.
31.Do not alter or remove guards or warning labels.
32.Keep the immediate area clean. Do not allow the floor to become slippery, or covered with
dust or obstacles. Dust that accumulates in the work area is a hazard that can cause you
to fall or slip against the machine or its controls.
33.Employees should be required to report to their supervisors any hazardous condition of the
machine or in the immediate area.
34.Be careful with your hands on the following sports when operating the sander.
SHIPPING & RECEIVING INSTRUCTIONS
This machine has been carefully inspected and tested before packing. It was delivered in
good condition and was shipped in one wooden pallet.
When receiving this machine, inspect the wooden pallet and check to see if there is any
damage. Then check the machine model and all items as according to the packing list.
If there is any damage on the machine or any missing parts, report it to your local distributor or
the machine manufacturer immediately.

UNPACKING & CHECKING CONTENTS
The machine has been well packed at the manufacturer’s factory and shipped in good
condition. The machine is shipped in one wooden pallet.
Upon receiving the machine, carefully unpack it and check all items as according to the
packing list.
If you find any part is missed or damaged, contact your local distributor or the manufacturer of
the machine immediately. Do not attempt to operate the machine until the missing parts are
obtained and are installed correctly.
CLEANING THE MACHINE
The machine is coated with rust preventative oil before shipment. When the machine has
been moved to the proper work site, wipe the oil from the machine using a soft cloth soaked in
kerosene. Do not use gasoline, lacquer thinner, or any other volatile solvent, as these may
damage the paint surface of the machine.
LIFTING THE MACHINE
The machine should be lifted or moved by a forklift. Make sure the loading capacity of the
forklift is sufficient to raise the machine. Pay special attention to the machine balance while
lifting the machine to prevent the machine from falling. The forks of the forklift must protrude
over the machine bottom for uniform distribution of the entire machine weight.

INSTALLATION INSTRUCTIONS
1. Upon arrival, the machine is to be checked as to damage that may have occurred during
transport. In case of damage, the shipping company is to be informed as soon as possible
and a corresponding complaint is to be made.
2. The machine is to be placed on a concrete foundation floor having a thickness of at least 9
inches and of such dimensions that the machine can be easily placed in position.
3. After removing the wooden case, move the machine to its foundation by means of lifting
slings or a forklift truck.
4. The machine may be placed directly on the floor, and if preferred, may be bolted to the
floor.
5. In order to avoid corrosion the blank parts of the machine have been treated with grease.
This grease should be removed by using solvents.
CONNECTION TO AIR SUPPLY LINE
1. The machine is to be connected to an air supply unit that supplies a minimum pressure of
90PSI. We recommend the use of a refrigerated air dryer to remove all moisture from the
airlines. Failure to use a refrigerated air dryer will void warranty on all pneumatic parts due
to moisture related problems.
• It should be checked whether this unit supplies dry and clean air. If this is not the case
a special water separator and air filter must be installed in front of the machine, for even
the slightest moist particle affects the interior of the machine and disturbs the optimal
operation.
• If the pressure is lower than 90PSI an extra buffer tank must be installed between the
compressor and the machine.
• Attention should be paid to the fact that the pressure may never drop below 70PSI,
otherwise the belt control will be adversely affected.
2. The connection of the air supply hose into the machine must be done by means of a hose
on the air filter situated at the right bottom side in front of the machine.
3. The reducing valve of the main connection has been adjusted by the manufacturer at
90PSI. check this valve and readjust, if necessary, by turning the adjusting screw.
4. The machine should also be connected to an extraction unit of a satisfactory capacity.
• The speed of the air in the suction pipe has to be minimum 90 ft./sec. the suggested
suction pipe diameter is 6” for capacity 1300CFM.
5. Air-jet belt cleaner:
If the machine has been equipped with one or more air-jet belt cleaners, these must be
connected separately to the air filter, which has been installed next to the air filter of the
machine.

ELECTRICAL SAFETY RULES
1. Do not alter or bypass any protective interlock.
2. Before starting the machine, read and observe all warning labels and markings such as
nameplates and identification plates.
3. Only personnel who are properly trained and have adequate knowledge and skill should
undertake all electrical/electronic troubleshooting and repair.
4. Use extra precautions in damp areas to prevent yourself from accidental grounding.
5. Make sure you body and your tools are clear of electrical grounding.
6. The control panel doors should be opened only when it is necessary to check the electrical
equipment or electrical wiring.
7. Before applying power to any equipment, establish without a doubt that all persons are
clear.
8. Be alert and be sure you can work with no outside distractions.
9. Avoid wearing metal frame glasses or wearing a metallic necklace or chain, and never work
on electrical equipment while wearing rings, watches, or bracelets.
10.When replacing conductors, make sure they conform to the manufacturer’s specifications,
including proper color-coding.
11.Do not alter the electrical circuits. If machine damage is caused by an unauthorized
alteration, the user is responsible, not the manufacturer.
12.Always assume the electrical power is ON and treat circuit as live. This caution develops a
habit that may prevent an accident.
13.Give capacitors time to discharge. Otherwise, it should be done manually with care.
14.Use proper test equipment to make certain you have an open circuit. Test equipment must
be checked and calibrated at regular intervals.
15.Open the control panel doors only when it is necessary to check the electrical equipment or
disconnecting handle mechanism is in its proper position.
16.All covers on junction boxes must be closed before leaving any job.

ELECTRICAL CONNECTION
An authorized electrician should do the electrical connection.
1. Check whether the main voltage is in accordance with the connecting voltage mentioned on
the switch panel or wiring diagram.
• The main cable should be screwed to the machine. The cable should be securely
fastened to the wall and connected with a main switch.
2. Now the connections in the terminal box must be taken care of. Notice the correct
connecting points (R-S-T and Ground). The ground wire color should be green or yellow-
green. To check proper rotation of the machine, press table up button. If the table goes
down, switch the R and T wires.
3. Now the conveyor motor is to be started and check the right rotation of conveyor belt. Also,
start the main motor and check the right rotation of the contact drum.
• Tension should be placed on sanding belt before starting the main motor.
4. Close the cover of the terminal box carefully, so that no dust can accumulate in it.
• Dust is the biggest enemy of electricity and could be the cause of many
disturbances.
5. Also check the V-belt tension. The belt may be pushed together a maximum of ¾” per belt.
After two weeks of operations the V-belt tension must be checked again since these will be
stretched initially.

STARTING & STOPPING THE MACHINE
Before starting the machine all weekly or daily greasing points must be done.
A. Starting the Machine:
1. Open the aircock. Make sure the air pressure is at 90PSI.
NOTE: The machine cannot be started if the aircock is closed.
2. Start the dust extraction unit.
3. Apply tension to the abrasive belt by turning switch.
4. Now start the motor of contact roller by using the push button. Then start the
motor of the sanding pad.
NOTE: If the tension roller has not set tension to the abrasive belt, the machine
cannot be started.
5. Afterwards you can start the conveyor belt motor. It has a variable speed
regulated by a hand wheel.
NOTE: Do not adjust the hand wheel when conveyor belt is stopped.
B. Stopping the Machine:
1. Switch the conveyor belt motor off.
2. Switch the contact roller and sanding pad motors off.
3. Wait until both aggregates have come to a complete stop.
4. If the machine has the air jet belt cleaner, switch it off now.
5. Shut off the aircock.
C. Emergency Stop:
Only use the emergency stop in the following situations:
1. The abrasive belt runs off or tears.
2. When something apparently goes wrong caused by an inexpert maneuver.
For these purposes, press the big mushroom red button, which results in
automatically braking of the aggregates and interrupting the current to the motors.
ABRASIVE BELT OSCILLATION & TRACKING SAFETY
1. Abrasive belt tracking is necessary to prevent the belt from running sideways.
2. Belt oscillation is through an electric eye system.
3. The abrasive belt tracking is achieved by changing the position of the tension (or idler)
roller.
4. The tracking cylinder achieves movement of the tension roller.
5. In case of oscillation failure the abrasive belt will run sideways. An automatic brake system
prevents the belt from being damaged.
6. Belt Oscillation Setting:
The stroke of the belt oscillation and the speed of oscillation can be set with speed
controller. This speed controller regulates the pressure in the tracking cylinder.

TRACKING ADJUSTMENT
Check tracking by moving a piece of paper in and out of the electric eye. At this time, the
tension roller should move from side to side. If the tension roller does not move, the electric
eye and solenoid valve must be checked.
If belt runs to one side and the tracking cylinder is extended out full travel, loosen jam nut on
cylinder and move the cylinder push cap out, or move the spring tension in.
If belt runs to side and the cylinder shaft is in, add spring tension by loosening jam nut, then
turn the spring tension screw in.
ABRASIVE BELT TRACKING DEVICE ILLUSTRATION
1. Abrasive Belt Tracking Cylinder
2. Locking Nut
3. Tracking Angle Adjusting Nut
4. Rod End Bearing
5. Air Speed Control Valve (Backward)
6. Air Speed control Valve (Forward)
Tracking Instructions:
1. Start on the main motor after the abrasive belt and the tension cylinders were checked
correctly.
2. If the abrasive belt goes to outside direction, then loosen the locking nut and turn the
adjusting nut clockwise.
3. If the abrasive belt goes in the inside direction, then turn the adjusting nut counter-
clockwise.

AIR DIAGRAM
1. Air Supply Valve
2. Turning Switch (for abrasive belt tensioning)
3. Tension Cylinder
4. T-way
5. Solenoid Valve (for brake oscillation)
6. Brake Cylinder
7. Solenoid Valve (for abrasive belt oscillation)
8. Speed Control Valve
9. Tracking Cylinder
10.Electric Eye

ADJUSTING THE PLATEN
The combination head sander contains a flat platen behind the contact drum.
The combination head sander can be operated in 3 modes:
1. Platen up (Fig. 1): The sander functions as a drum only machine.
2. Platen in level position with the contact drum (Fig. 2): Contact drum and platen are both
working.
3. Platen down (Fig. 3): the platen below contact drum is frequently used for final finish with
finer grits of sandpaper.
How to Adjust the Platen Up and Down (Fig. 4):
1. Loosen the fixed screw (1) by handle.
2. Remove the adjusting lever by handle (2) to move the sanding pad upward or downward.
3. Tighten the handle (1) after the sanding pad is in correct position.
NOTE:
1. The platen should not be moved downward too much, since otherwise the sanding belt
could be clogged too quickly or cause burns on belt and work piece.
2. After sometime the height of platen should be re-adjusted when the sanding belt has worn
off a little.
3. Don’t forget to fix handle (1) after adjustment.

CHANGING ABRASIVE BELT
1. Open the main aircock.
2. Move turning switch downward, by which the tension roller is lowered.
3. The quick release handle is to be turned to the front and pull it upwards. Now supporting
lock is to be removed.
4. Remove the old belt and insert a new one beginning at the tension roller and afterwards the
contact roller or sanding pad.
5. Replace the supporting block and fix it again by means of the quick release handle.
6. Move turning switch upward to place tension on the belt.
7. Now the motor is to be started and immediately shut off to check that the sanding belt runs
correctly and the oscillation works properly.

GENERAL MAINTENANCE OF THE CONVEYOR BELT
1. Tension of the Conveyor Belt:
A. The feeding conveyor has auto tracking by limit switch and air cylinder.
B. The conveyor belt can be adjusted, if it is too loose, with the socket wrench
provided.
C. We do not recommend tightening the conveyor belt, as this affects the life of the belt.
2. Re-conditioning of the Conveyor Belt:
This should be done if the surface of the belt is too smooth, so that the work piece is
slipping or if the surface of the belt shows irregularities.
A. Apply a sanding belt with 60 grit or coarser.
B. Put the table on the lowest position.
C. Put the front pressure roller on position 0.
D. Switch off the table floating (if on machine).
E. Switch on the main motor together with the feed motor.
F. The table is to be raised slowly.
G. The conveyor belt should be sanded off as little as possible. See to it that the whole
surface is touched.
H. Lower the table about 3mm, then switch off the main motor and feed motor.
NOTE: Sanding of the conveyor belt can be properly done if the contact drum is parallel
to the table and the pressure roller.
THIS SHOULD BE CHECKED FIRST
MAINTENANCE OF THE AIR UNIT
1. Daily Maintenance: Remove condensation water from air filter.
2. Monthly Maintenance:
A. Clean the inside of the plastic housing with a dry rag. Do not clean with detergent or
other liquid.
B. Remove brass filter unit and clean with acetone or petrol and air pistol.
3. Clean the electric eye with dry rag.

GREASING & LUBRICATION
1. Check all oil and grease nipples weekly.
2. Check oil tank level monthly.
3. Check the gearbox yearly.
4. Lubricate the shaft and the bushing of the tension unit regularly.
5. First month only:
• Drain out oil and change with new oil after the first month of operation. In running
period, change oil at 2500 hours or 6-month intervals, whichever comes first.
DISTURBANCES
Disturbances Possible Cause Solution
Fuses are blown Insert a new fuse
Not enough tension on
sanding belt Use turning switch to apply tension to belt
Emergency stop button still
pressed in Press button again
Pressure is too low Check the air supply unit
Thermal relay switched off Press the button of the
thermal relay
The machine does not run
Sanding belt touching the belt
protection switch Push the belt backwards
Irregular air supply Check air supply unit and
remedy any disturbances
Water in the air unit Draw off the water
Overload of the sanding
aggregate Remove less material during sanding
Machine repeatedly stops
Rattling of the sanding belt
against the forks of the auto
belt protection
Check sanding belt and
replace if necessary. Adjust
belt protection somewhat
wider
Speed control valve is not
correctly adjusted To be re-adjustedSanding belt runs off to one side Oscillation of the belt is not
correct To be re-adjusted
Slipping of the conveyor belt Contact roller is too high Lower the contact roller

DEFICIENCIES DURING THE SANDING OPERATION
1. The stock to be sanded is thinner at the beginning.
CAUSE:
• The rear pressure bar is too low in relation to the contact roller.
2. The stock to be sanded is thinner at the end.
CAUSE:
• The front pressure bar is too low in relation to the contact roller.
3. The sanding paper clogs too quickly.
CAUSE:
• The grit of the sanding paper is too fine.
• Too much material is sanded off.
• The wood is too oily and clogs the abrasive grains too quickly.
• The exhaust is insufficient.
• There is too much dirt of glue on the wood.
• The wood is too moist.
4. When sanding veneers it sands through too quickly.
CAUSE:
• The front pressure bar is not fixed.
• The front pressure bar is too high.
5. Too much rounding occurs along the edges when solid wood is sanded.
CAUSE:
• Too much material is removed so that the contact roller is pressed too much.
6. There are differences in thickness between the left and the right side of the work piece.
CAUSE:
• The table is not in correct position in relation to the contact roller.
• The front pressure bar is not in a correct position in relation to the contact roller.
7. There are differences in thickness between the front and backsides of the work piece.
CAUSE:
• Through feed speed is too high.
• Too much stock is being removed.
• The sanding paper is too fine in relation to the stock removal.
8. The work piece slips on the conveyor belt.
CAUSE:
• Too little pressure between the pressure bar, work piece and/or table, work piece.
• When sanding veneers, too little table pressure.
• Conveyor belt is too smooth.
• Too much dust on the conveyor belt.
• The rear pressure bar is too low, so that this stops the work piece.

DEFICIENCIES IN THE SANDING PATTERN
1. Notches or grooves in the work piece straight strip
CAUSE:
• Dirty pressure bar
2. Snake marks on a part of the work piece
CAUSE:
• Local damage of the sanding belt
3. Straight parallel running stripes over the entire width of the work piece
CAUSE:
• Joint of the sanding belt is too thick or open
4. Gleaming spots on the wood
CAUSE:
• The sanding belt is too old
• The rear pressure bar is too low
• The contactor roller is too high

MAIN FRAME GROUP