KAKA Industrial BTM250 User manual

Belt /Disk Sander
Model: BTM250
Operation manual
Table of Contents

2
Cover Page ...........................................................................................…………………1
Table of Contents .................................................................................………………...2
General Specifications ..................................................................................3
Warnings .......................................................................................…..........3
Operating Instructions ...................................................................…..........4
Maintenance ............................................................................................…6
Setup and Installation ............................................................ ...........…......8
Wiring Diagrams .............................................................. .........................10
Troubleshooting ..................................................................................…...13
Replacement Parts ...........................................………...................….…...14

3
General Specifications
General Machinery Cautions
- Misuse of this machine can cause serious injury.
- For safety, the machine must be set up, used and
serviced properly.
- Read, understand and follow the instructions in the
operator’s and parts manual which was shipped with your
machine.
When setting up the machine:
- Always avoid using the machine in damp or poorly
lighted work areas.
- Always be sure the machine is securely anchored to the
floor.
- Always keep the machine guards in place.
Always put the start switch in the “OFF” position before
plugging in the machine.
When using the machine:
- Never operate the machine with safety guards missing.
- Always wear safety glasses with side shields (See ANSI
Z87.1)
- Never wear loose clothing or jewelry.
- Never overreach — you may slip and fall into the
machine.
- Never leave the machine running while unattended.
- Always shut the machine off when not in use.
When servicing the machine:
- Always unplug the machine from the electrical power
while servicing.
- Always follow the instructions in the operators and parts
manual when changing accessory tools or parts.
You — the stationary power tool user — hold the key to
safety.
Read and follow these simple rules for best results and full
benefits from your machine. Used properly, the machinery
is among the best in design and safety. However, any
machine used improperly can be rendered inefficient and
unsafe. It is absolutely mandatory that those who use our
products be properly trained in how to use them correctly.
They should read and understand the Operators and
Parts Manual as well as all labels affixed to the machine.
Failure in following all of these warnings can cause
serious injuries.
General Machinery Warnings
1. Always wear protective eye wear when operating
machinery. Eye wear shall be impact resistant, protective
safety glasses with side shields which comply with ANSI
Z87.1 specifications. Use of eye wear which does not
comply with ANSI Z87.1 specifications could result in
severe injury from the breakage of the eye protection.
2. Wear proper apparel. No loose clothing or jewelry
which can get caught in moving parts. Rubber soled,
nonslip, footwear is recommended for best footing.
3. Do not overreach. Failure to maintain a proper working
position can cause you to fall into the machine or cause
your clothing to get caught — pulling you into the
machine.
4. Keep the guards in place and in proper working order.
Do not operate the machine with the guards removed.
5. Avoid dangerous working environments. Do not use
stationary machine tools in wet or damp locations. Keep
work areas clean and well lit.
6. Special electrical precautions should be taken when
working on flammable materials.
7. Avoid accidental starts by being sure that the start
switch is in the “OFF” position before plugging in the
machine.
8. Never leave the machine running while unattended.
The machine shall be shut off whenever it is not being
Table size
Disc:12x16 3/8 in. (254x416mm)
Belt: 7 3/8x14 3/4 in. (187x355mm)
Table tilt
(both) 45° down, 20° up
Miter gauge groove
(both) 3/8x3/4 in. (9.5x19mm)
Disc diameter
12 in. (305mm)
Disc Speed
1960 RPM
Platen size
6 1/4x14 3/4 in. (159x375mm)
Belt size
6x48 in. (152x1214mm)
Belt speed
2850 SFM
Dimensions w/platen
19x16x57 1/2 in.
vertical (depth,W, H)
(475x400x1437mm)
Dimensions w/platen
25 1/2x16x43 in.
horizontal (depth, W, H)
(637x400x1075mm)
Weight
90Kg

4
used.
9. Disconnect the electrical power before servicing,
whenever changing accessories or when general
maintenance is done on the machine.
10. Maintain all machine tools with care. Follow all
maintenance instructions for lubricating and the changing
of accessories. No attempt shall be made to modify or
have makeshift repairs done to the machine. This not only
voids the warranty but also renders the machine unsafe.
11. The machinery must be anchored to the floor.
12. Secure your work. Use clamps or a vise to hold your
work, when practical. It is safer than using your hands and
it frees both hands to operate the machine.
13. Never brush chips away while the machine is in
operation.
14. Keep work area clean. Cluttered areas invite
accidents.
15. Remove adjusting keys and wrenches before turning
the machine on.
16. Use the right tool. Don’t force a tool or attachment to
do a job it was not designed for.
17. Use only recommended accessories and follow
manufacturers instructions pertaining to them.
18. Keep hands in sight and clear of all moving parts and
cutting surfaces.
19. All visitors should be kept at a safe distance from the
work area. Make your workshop completely safe by using
padlocks, master switches, or by removing starter keys.
20. Know the tool you are using — its application,
limitations, and potential hazards.
General Electrical Cautions
This machine should be grounded in accordance with the
National Electrical Code and local codes and ordinances.
The work should be done by a qualified electrician. The
machine should be grounded to protect the user from
electrical shock.
Wire Sizes
Caution: For circuits that are a great distance from the
electrical service box, the wire size must be increased in
order to deliver ample voltage to the motor. To minimize
power losses and to prevent motor overheating and
burnout, the use of wire sizes for branch circuits or
electrical extension cords according to the following table
is recommended:
Safety Requirements for Abrasive
Sanding Machines
Abrasive sanding can be hazardous to operators and
bystanders. Sanding sparks, chips and dust particles
thrown off by the sanding disc can cause serious injury if
contacted or inhaled. To avoid such injuries you must
comply with the following safety requirements:
1. Always wear protective eyewear when operating
machinery. Eye wear shall be impact resistant, safety
glasses with side shields which comply with ANSI Z87.1.
Use of eye wear which does not comply with ANSI Z87.1
specifications could result in severe injury from the
breakage of the eye protection.
2. Wear leather safety gloves, arm guards, leather aprons
and safety shoes.
3. A dust collection system is recommended, The operator
should also wear a dust mask at all times.
4. Additional precautions may be necessary for sanding
materials which are flammable or have other hazardous
properties. You should always consult the manufacturer of
such materials for instructions on sanding and handling.
5. Do not force or jam the workpiece into the sanding disc.
6. Before sanding, always allow the motor to come up to
operating speed, then check the sanding disc for wobble,
runout, or any unbalanced condition. If the disc is not
operating accurately and smoothly, immediately stop the
motor and make repairs before attempting any sanding
operations.
7. Abrasive discs must be stored in a controlled
environment area. Relative humidity should be 35% to
50% and the temperature should be between 60oand 80o
Fahrenheit. Failure to do so could cause premature disc
failure.
8. Examine the face of the sanding disc carefully.
Excessive sanding that wears down to the backing
material can tear the disc. Never use a disc which shows
backing, nicks or cuts on the surface or edge or damage
due to creasing or poor handling.
9. When installing a new disc, be certain the disc is
accurately centered on the drive wheel. Failure to do so
could cause a serious unbalanced condition.
10. Always present the workpiece to the wheel while
resting the workpiece firmly on the table. Failure to do so
could result in damage to the workpiece or throwing of the
workpiece off the wheel.
11. Safety shoes which comply with ANSI Z41.1 should be
worn.
12. Personal hearing protection such as ear plugs or ear
muffs should be used to protect against the effect of noise
exposure.
Operating
Instructions
These sanders can be used to remove stock from a
wide variety of machinable materials. Different materials
require different grit types and grades to achieve the
desired stock removal rate and surface finish. Please
consult with your abrasive materials supplier for specific
recommendations on the correct grit material and grade
required for your specific needs.
When removing stock from soft materials (wood,
plastic, etc.) these machines are typically called
"sanders." When removing stock from hard materials (cast
iron, steel, etc.) they are referred to as "grinders". The
word "sander" is used, more-or-less consistently,
throughout this manual. It refers to the machines and not
the type of abrasive finishing being performed.
Before operating your sander, please read the basic
instructions on safe machine usage on the preceding two
pages.
Belt Sander
The sanding belt must be in good condition, at proper
tension, and tracking correctly, before doing any sanding,
grinding or other abrasive machining operations. Refer to
the section on Track Mechanism Maintenance if you have
any problems with belt tension or tracking.
Adjusting the Belt Sander Table

5
You can tilt the table in a range between 20oupward
and 45odownward. A single locking handle on the side of
the table is used to lock and unlock the table to permit
adjustment.
There are two positive lock stop positions: at 90o(that is, at
a right angle to the platen) and at 45odownward
(essentially 90o+ 45oor 135ototal to the platen.)
To Tilt the Belt Sander Table:
1. Unlock the locking handle on the side of the table.
2. Using the pointer and scale, set the angle to any
required angle between 20oupward and 45odownward.
3. Lock the lock handle.
To Tilt the Table to Exactly 45o:
1. Flip out the stop bracket (see Figure 20).
2. Unlock the locking handle.
3. Move the table until it contacts the stop bracket.
4. Lock the table lock handle.
Figure 1: Locking handle for belt table
Using the Indexing Lock Handle
The lock handle is spring loaded and can be repositioned
on its shaft to permit easy locking and unlocking.
To Reposition the Handle:
1. Pull outward against its spring.
2. Rotate the handle to the position you require.
3. Release the handle and its spring will return it to the
correct operating position.
Adjusting the Belt Sander Arm
The arm which holds the sanding belt can be
positioned at a full vertical position, a full horizontal
position, or at any angle in between which is convenient to
the type of sanding you are doing.
A positive stop mechanism is used to permit quick
adjustment to the vertical or horizontal positions.
To Adjust to Vertical:
1. Unlock both of the lock bolts. These are located under
the arbor cover.
2. Move the arm to vertical until it contacts its stop.
3. Tighten both of the lock bolts, and replace arbor cover.
To Adjust to Horizontal:
1. Unlock both of the lock bolts.
2. Move the arm to horizontal until it contacts its stop.
(See Figure 3.)
3. Tighten both of the lock bolts and replace arbor cover.
To Adjust the Arm to Any Angle
Between Vertical and Horizontal:
1. Unlock both of the lock bolts.
2. Use a machinist's protractor and level to set the arm to
the required angle.
3. Tighten both of the lock bolts and replace arbor cover.
Figure 2: Lock bolts for belt arm
Figure 3: Arm at horizontal -- note that the table is
removed. The table may be removed or left in position,
and may also be set to any angle to allow horizontal
sanding of various angles.
Figure 4: Disc sander table adjustment
Adjusting the Disc Sander Table
1. Unlock the two locking knobs underneath the table at
each end. (See Figure 4.)
2. Using the pointer and scale, set the angle to any
required angle between 20oupward and 45odownward.
3. Lock the two locking knobs underneath the table.
CAUTION: NEVER ADJUST THE TABLE
ANGLE WHILE THE SANDER IS RUNNING.
ALWAYS TURN THE MOTOR OFF BEFORE
ADJUSTING THE TABLE ANGLE.
CAUTION: NEVER ADJUST THE TABLE
ANGLE WHILE THE SANDER IS RUNNING.
ALWAYS TURN THE MOTOR OFF BEFORE
ADJUSTING THE TABLE ANGLE.
CAUTION: NEVER ADJUST THE TABLE
ANGLE WHILE THE SANDER IS RUNNING.
ALWAYS TURN THE MOTOR OFF BEFORE
ADJUSTING THE TABLE ANGLE.

6
Use of the Miter Gauge
The miter gauge can be used on either the disc or
belt surfaces to sand accurate angles on workpieces.
When using the gauge, alone, you sand a single angle.
However, by tilting the table and using the miter gauge in
combination with the table tilt, it is possible to sand
compound angles, as well.
When grinding a compound angle you should always
check the accuracy of your setup by sanding a piece of
scrap material before doing any finish sanding on the
actual workpiece.
1. Set the angle you wish to sand using the scale on the
miter gauge.
2. Tighten the miter gauge securely so the miter reference
surface will not move while you are sanding.
3. Place the workpiece against the miter reference surface
and slide it along the reference surface and into the
sanding disc or belt. The basic method is shown in Figure
5, below.
Figure 5: Use of the miter system
Maintenance
Belt Replacement
1. Disconnect the power to the machine to prevent
accidental start-ups. If the machine is plugged into an
outlet, unplug it. If the machine is hardwired to a branch
circuit with a junction box, remove the fuse or trip the
circuit breaker to the branch.
2. Remove the lock knob and top cover (See Figure 6).
3. Remove the side guard and table.
4. Release the belt tension by turning the tension handle
in a counterclockwise direction (See Figure 7). If the
handle is difficult to turn, perform Track Mechanism
Maintenance according to the instructions following this
section.
5. Remove the belt.
6. Check the drums and platen for scoring or signs of wear
which might require service or replacement.
7. Check the height of the platen with a straight edge. If it
is not 1/32 in. above the drums, adjust it according to the
instructions in Platen Replacement or Adjustment in the
Machine Setup section of this manual.
8. Check the drums for looseness which might cause
tracking problems. Correct any loose condition by
tightening or replacing any parts as required.
9. Slip the new belt onto the drums and platen.
10. Adjust the tension handle clockwise until the belt is flat
against the platen and there is no curling or buckling of the
belt in the middle.
11. Turn the drums by hand to see if the belt tracks
moreor- less true. JUST BECAUSE THE OLD BELT
TRACKED CORRECTLY DOES NOT MEAN THE NEW
BELT WILL. Always check the tracking when replacing a
belt.
12. To adjust the tracking:
12.1. Plug the machine back into the outlet or
reestablish power in the branch.
12.2. Loosen the tracking lock knob.
12.3. Jog the motor on and off as necessary to observe
the tracking, and turn the tracking knob as
necessary to make the belt track in the center of the
platen and drums. Turn the tracking knob clockwise to
move the belt toward the right and counterclockwise to
move the belt toward the left.
12.4. When the belt seems to be tracking correctly, turn
the motor on and leave it running while fine tuning the
tracking.
12.5. Lock the tracking lock knob.
12.6. When the lock knob is secure, turn the power
off and disconnect the machine from the outlet or
branch as in Step 1, above.
13. Replace the table, side guard, top cover and lock knob
by reversing steps 3 and 2, above.
14. If you have not already done so, reconnect the power
to the machine and return it to service.
To p c o v e r
To p c o v e r lo c k sc re w
Tra c k a d ju stin g k n o b
Tra c k in g lo c k k n o b
B e lt
Figure 6: Top cover components

7
Figure 7: Belt adjustment components (Note top cover
removed for removal and replacement of belt.)
Track Mechanism Maintenance
While the use of a dust collection system can extend
service intervals, an accumulation of dust will almost
certainly require periodic cleaning of the tracking
mechanism. The more continuous the use of the machine,
the more frequently this maintenance should be
performed.
As mentioned in the preceding section, the need for
required maintenance is often indicated by difficulty in
adjusting the tension/tracking mechanism.
Maintenance:
1. With the belt removed according to the instructions in
Belt Replacement, pull out the upper tracking system and
clean away all built up material in the upper part of the
bracket casting.
2. Take the two keys off of the idler pin bracket, wipe off,
and re-grease.
3. Reverse the above steps to make the machine ready
for reinstallation of the belt according to the Belt
Replacement instructions.
Installing Abrasive Discs
1. Disconnect the power to the machine to prevent
accidental start-ups.
2. Peel off the old abrasive disc.
3. Clean the drive disc surface using naptha or a similar
nonflammable solvent that will dry film-free.
4. Pull the protective backing half off the new abrasive
disc.
5. Position the new disc carefully so it is centered
accurately on the drive disc. (See Figure 8.)
6. When accurately centered, remove the rest of the
protective backing and press the abrasive disc firmly
against the drive disc so complete adhesive contact is
made.
7. Reconnect the power to the machine.
Figure 8: Installing new abrasive disc
Replacing the V-Belt.
1. Disconnect the power to the machine to prevent
accidental start-ups.
2. Remove the belt guard (Figure 9) and disc table
3. Remove the table tilt lock knob (Figure 10).
Figure 9: Removing belt guard
Figure 10: Disc table lock knob
3. Loosen the four motor bolts so the motor can slide on
its plate.
4. Remove the belt from the motor pulley.
5. Remove three of the base mounting bolts, then loosen
the fourth bolt slightly. This allows you to rotate the
machine on the machine base (See Figure 11).
Figure 11: Rotating the machine casting to remove the
disc guard bolts

8
6. Remove the two bolts, underneath the machine casting,
that secure the disc guard to the casting (See Figure 11).
7. Through the hole in the disc guard casting, locate and
remove the TWO set screws that secure the drive disc to
the arbor. One set screw clamps on the arbor key and the
other clamps on the arbor shaft, itself. Be sure you loosen
both of them.
Figure 12: Locating the set screws that secure the disc to
the arbor
8. Slide the disc and its guard off of the machine, together
(See Figure 13).
Figure 13: Removing the guard and drive disc, together.
9. The V-belt can now be removed from the drive arbor.
10. Install the new belt on the top pulley.
11. Slide the disc and guard back into position.
12. Reinstall the disc guard bolts underneath the table.
13. Position the drive disc so that it is no more than 1/16
inch away from the table, then tighten BOTH of the set
screws by inserting the hex wrench through the hole in the
disc guard casting.
14. Rotate the machine back onto its base and secure it
with all four mounting bolts.
15. Install the belt over the bottom pulley.
16. Tension the belt so that when pressed, in the middle of
its travel, it has no more than one belt's width of
movement -- then tighten the four motor bolts.
17. Observe the alignment of the motor pulley and arbor
pulley. If necessary, correct their alignment by shifting the
motor slightly on its mount (which involves loosening and
retightening the mounting bolts and checking tension) or
by shifting the pulley slightly on the motor shaft (which
involves loosening the motor pulley set screw and sliding
the pulley into alignment) or by moving the arbor pulley
slightly on its shaft (See Figure 14).
18. When the pulleys are accurately aligned, reinstall the
belt guard.
19. Reestablish electrical power to the machine.
Machine Setup
Basic Setup
1. Position the machine where it will be located on the
shop floor. When positioning the machine, consider the
type of work which will be done on it so you allow sufficient
room not only for the workpieces, but also for service to
the machine.
2. Open the door in the base of the machine and, using
the holes in the base as a template, mark the floor for the
position of the hold-down bolts.
3. Move the machine to expose the hold-down bolt marks
and install anchors for the hold-down bolts.
4. Put the machine back over the hold-down anchors and
bolt the machine securely to the shop floor. THIS MUST
BE DONE FOR SAFE OPERATION OF THE MACHINE.
5. Establish an electrical service connection to the
machine. This will vary according to the model purchased.
ALL ELECTRICAL CONNECTIONS SHOULD BE MADE
BY A QUALIFIED ELECTRICIAN WHO IS FAMILIAR
WITH YOUR STATE AND LOCAL CODES. Many models
of these machines make use of high voltages which pose
a significant risk of serious injury or DEATH if proper
knowledge and precautions are not used. Electrical
instructions are included in the Electrical section of these
Machine Setup instructions.
6. Machines with belts are shipped with the belts in slack
condition. During the electrical hookup phase of machine
setup, the belt will have to be tightened and checked for
tracking. See the Belt Replacement section for
instructions on this procedure.
Figure 14: Loosening pulley set screws to allow the
adjustment of pulley on arbor shaft.

9
Disc Table Angle Adjustment
1. Disconnect the power to the machine to prevent
accidental start-ups.
2. Loosen the table locking knobs on either end of the
table.
3. Using a machinist's square against the table and disc,
set the table at exactly 90oto the disc (See Figure 15).
4. Tighten the table locking knobs.
5. Check the pointer. If it is not exactly on the zero mark,
loosen the pointer attaching screw, adjust the pointer, and
retighten the screw.
6. Reconnect the power to the machine.
Figure 15: Using a square to check the disc table scale.
Disc Table Miter Parallelism
Adjustment
1. Disconnect the power to the machine to prevent
accidental start-ups.
2. Set the table angle to zero.
3. Place a scale or adjustable machinist's square against
either the left or right edge of the disc face and measure
the distance to the miter slot edge (See Figure 16).
4. Move the measuring device to the opposite edge of the
disc and measure the distance to the miter slot.
5. Adjust the table by loosening the four attachment
screws under the table, then move the table until the
distance between the miter slot and the disc is equal on
both sides (See Figure 17).
6. Tighten the four attachment screws.
7. Reconnect the electrical power to the machine.
Figure 16: Using an adjustable square to set the table
parallelism.
Figure 17: Table attachment screws -- loosen to adjust
miter groove parallelism.
Disc Table Gap Adjustment
1. Using a scale, check the gap between the edge of the
table and the face of the disc. It should be very close to
3/32 inch. If it is much more or less than that distance,
adjust it as follows:
2. Disconnect the electrical power to the machine.
3. Using the access hole on the top of the disc guard,
locate and loosen the two set screws that secure the disc
to the shaft.
4. Slide the disc in or out along its shaft until the
table-todisc gap is 3/32 inch (See Figure 18).
5. Tighten both set screws.
6. Reconnect the electrical power to the machine.
Figure 18: Table-todisc gap measurement.
Belt Table Miter Slot Parallelism
Adjustment
1. Disconnect the power to the machine to prevent
accidental start-ups.
2. Set the table angle to zero.
3. Place a scale or adjustable machinist's square against
either the left or right edge of the belt or platen and
measure
the distance to the miter slot edge (See Figure 19).
4. Move the measuring device to the opposite edge of the
belt or platen and measure the distance to the miter slot.
5. Adjust the table by loosening the three attachment
screws under the table, then move the table until the
distance between the miter slot and belt or platen is equal
on both sides.
6. Tighten the three attachment screws.
7. Reconnect the electrical power to the machine.
Belt Table Angle Adjustment
1. Loosen the table locking handle and tilt the table
upward to about 15o.
2. Flip out the stop bracket (See Figure 21).
3. Lower the table until its adjusting screw touches

10
the stop bracket.
4. Place a machinist's square against the table and
belt or platen.
5. If adjustment is required, turn the adjusting screw
(Figure 20) until the table is exactly square to the platen.
6. Check the pointer. If it is not on 0o, loosen the
pointer screw and adjust the pointer until it is on 0o.
7. Tighten the pointer screw.
8. Loosen the table lock handle and tilt the table until its
stop contacts the 45ostop position.
9. Using a machinist's protractor set on 135o(90o+
45o) adjust the screw until the table and platen are in
correct adjustment. DO NOT reset the pointer after this
operation.
Figure 19: Using an adjustable square to check and
set miter slot parallelism on the belt table.
Figure 20: Location of adjustment (socket head) screws
and pointer attachment screw for table angle adjustment.
Figure 21: Locations of stop lugs and stop bracket for zero
and 45otable positions.
Adjusting or Replacing the Platen
1. Disconnect the electrical power to the machine to
prevent accidental start-ups.
2. Remove the top cover, side guard and belt as outlined
in Belt Replacement.
3. Remove the table by unscrewing the locking handling
and lifting the complete table assembly, from the machine.
4. If you are replacing the platen, remove the three screws
that hold it to its mount -- then install the new platen and
replace the mounting screws finger tight.
5. If you are only adjusting the platen, loosen the three
mounting screws to allow adjustment.
6. Using a straight edge as shown in Figure 22, adjust the
platen height until it is 1/32 inch higher than the crown of
both the drive and idler drums.
7. Tighten the platen adjustment screws.
8. Reinstall the table and belt.
9. Check and adjust, if necessary, the tracking of the belt
according to instructions in Belt replacement.
10. Reinstall the guards and covers.
11. Check and adjust the table angles and miter slot
squareness, according to table adjustment instructions in
this manual.
12. Reconnect the electrical power to the machine.
Figure 22: Method for adjusting height of platen above
drive and idler drums.
Electrical
Caution: The sanders are available in a wide variety of
electrical configurations to meet the needs of the
purchaser with respect to power available and compliance
with electrical codes. Each machine is tested at the
factory for operation before shipment and the power cord
is tagged with the power requirements for the machine, as
shipped. HOWEVER, before attempting any electrical
hookup, you should be certain:
1. The electrical characteristics of the service branch
match the requirements of the motor.
2. The service branch is equipped with wires of the
required gauge or size.
3. The branch circuit intended for the machine is protected
with a time delay fuse or circuit breaker with a rated
amperage just slightly greater than the full load current of
the motor.
CAUTION: All electrical service work on your
Wilton sander should be performed by a qualified,
licensed electrician who is familiar with all safe standard
electrical installation practices and all applicable electrical

11
codes. This includes local electrical codes which may
affect the connection and operation of the Wilton sander in
your specific manufacturing
operation.
Single Phase Electrical Hookup
When connecting your machine to single phase
power, you may be connecting to either 115 or 230 volts,
depending upon the motor type provided. Local codes
may, or may not, permit the use of a plug type of
connection for your machine. Where a plug connection is
permitted, the following installation practices must be
followed:
1. The plug used must be a grounding type of plug. That is,
on a 115 volt single phase connection, the plug must be a
three-prong plug with two flat, parallel blades for the
power wires and a single rounded or U-shaped prong for
the ground connection. On 230 volt single phase
connections, the lug must be a three prong plug with two
flat blades in tandem to carry the current, and a third
round or U-shaped prong for the ground connection.
2. The service branch to which the plug is connected must
be a branch with a separate ground wire so the grounding
prong of the plug can be connected to ground effectively.
Note: Local electrical codes in many jurisdictions
DO NOT ALLOW THE USE OF PLUG TYPE
CONNECTIONS FOR SINGLE PHASE POWER WHEN
THE MACHINE IS USED IN A COMMERCIAL OR
INDUSTRIAL ESTABLISHMENT.
In these cases you must connect your machine to
the service branch using a hardwired junction box
connection.
Motor Rotation
The motor should be turning counterclockwise, the
belt sander should be moving downward, and the disc
sander should be turning clockwise. These motors are
wired at the factory for correct rotation.
Voltage Conversion
Single phase machines are pre-wired for 115V or
230V per customer request. If it becomes necessary to
change the voltage, remove the back cover from the base
and place the machine on its side. Remove the terminal
cover from the motor. Rewire the motor according to the
motor connection diagram, Different electrical plugs are
required depending on which voltage you select. This
completes the voltage conversion process.
Circuit Protection
Where the service branch is protected with overload
protecter that has too high a value to offer protection to
the motor supplied, overload protecter box should be
used at the point where the machine connection is made
and the time delay overload protecter should be a
value just slightly higher than the maximum load current
draw.
Three Phase Electrical Hookup
1. Be certain the power to the branch you are connecting
is off and locked out, so power cannot be reestablished
accidentally.
2. Connect the ground wires. These wires will be either
green, or green with a white stripe.

12
3. Connect the remaining three cable wires to the three
power wires in the service branch.
4. Reestablish the power to the branch.
Motor Rotation
The motor should be turning counterclockwise,
the belt sander should be moving downward and the disc
sander should be turning clockwise. If this is the case, the
machine can be considered wired correctly. If the motor is
not turning in the correct direction, take the following
corrective action:
1. Disconnect power in the branch again and be certain it
cannot be accidentally turned on while you correct the
wiring.
2. Reverse ANY TWO of the power wires to the machine.
3. Reestablish the power to the machine.
4. Turn the machine on. The motor should now be turning
in the correct direction.
Voltage Conversion
Three phase machines are pre-wired for 230V or
460V per customer request. If it becomes necessary to
change the voltage, remove the back cover from the base
and place the machine on its side. Remove the terminal
cover from the motor. Rewire the motor according to the
motor connection diagram. This completes the voltage
conversion process
Circuit Protection
Where the service branch is protected with a fuse or
circuit breaker that has too high a value to offer protection
to the motor supplied, a fuse or circuit breaker box should
be used at the point where the machine connection is
made and the time delay fuse or circuit breaker should be
a value
just slightly higher than the maximum load current draw.

13
Troubleshooting
Fault
Probable cause
Suggested remedy
Motor will not run
1. Motor is defective
2. Voltage is too low
3. Switch is defective
4. Branch circuit fuse is blown or the circuit
breaker is tripped
5. Branch is shut down for service
6. Open circuit in the wiring
1. Replace the motor.
2. Check the power supply for the proper
voltage.
3. Replace the switch.
4. Determine the reason for the blown
fuse or tripped circuit breaker -- then
replace the fuse or reset the breaker.
5. 5. Check all personnel and machines
on the branch to be certain someone
has not shut down the branch for
service. DO NOT replace the fuse or
reset the breaker unless you are
certain no personnel are working on
the machines, wires or con trols in the
circuit.
6. 6. Inspect all the wire connections for
loose or open connections.
Motor stalls easily
1. Low voltage.
2. Fuse is blown (three phase motors
only.)
3. Improper wiring.
1. Check for proper voltage at the motor
-- correct as necessary.
2. Replace the blown fuse.
3. Check for proper connections.
Abrasive belt or disc slows
down although motor keeps
running at working speed
1. Belt is slipping
1. Replace the belt.
Poor tracking
1. Tracking is out of adjustment.
2. Too much belt tension.
3. Not enough belt tension.
4. Belt is jointed improperly.
5. Lack of crown on the drive roller.
6. Worn bearings.
1. Adjust the belt tracking.
2. Loosen the tension until the belt is just
taut.
3. Tighten the tension until the belt is
more taut.
4. Check the belt for an irregular seam
or shape.
5. Remove the belt and put a straight
edge along the drive roller. There
should be a slight crown (high spot
toward the middle of the roller.) If the
crown has worn away, replace the
roller.
6. Check all the bearings for excessive
heat or loose shafts. Replace if
necessary.
Unsteady belt
1. Slack in the abrasive belt.
1. Adjust the belt tension.
Short belt life
1. Excessive pressure applied while
grinding.
2. Working on only one side of the belt
or only in one area of the disc.
3. Incorrect abrasive material or grit size.
1. Allow the belt to do the cutting.
Excessive pressure only dulls the grit
and removes it from the cloth.
2. Use all the surface areas of the
abrasive cloth.
3. Check with your abrasives supplier for
rec ommendations on the type and coarse
ness of the abrasive required for the
workpieces you are sanding or grinding.
CAUTION: For all of the electrical faults and corrections in the above table we recommends the use of a qualified and
licensed electrician for all circuit tracing, diagnosis and repair.

14

Parts List of BTM250
No.
Description
Quantity
No.
Description
Quantity
1
Knob M6X15
2
32
guard cover
1
2
coolant cover
1
33
flat washer
4
3
stand
1
34
phillips head screw M5x6
4
4
fat lock nut M6X8
1
35
block plate
1
5
hex boltM8X20
4
36
flat washer
4
6
flat washer 8
8
37
phillips head screw M5x6
4
7
hex bolt M8
4
38
grinding wheel disc
1
8
nut M8
4
39
belt wheel 1
1
9
motor
1
40
flat lock screw M6x8
1
10
hex nut M8
4
41
Belt Wheel shaft
1
11
flat washer 8
8
42
hex bolt M10x25
2
12
stand for motor
1
43
flat washer 10
2
13
hex bolt M8X50
4
44
key 5x5x75
1
14
flat washer 10
3
45
spring ring17 for shaft
2
15
hex bolt M10X25
3
46
bearing
2
16
belt cover
1
47
supporting stand
1
17
connecting shaft
1
48
spring ring for shaft 17
1
18
fixed seat
1
49
belt wheel 2
1
19
flat washer 6
2
50
hex bolt M10x40
2
20
hex bolt M6X20
2
51
flat wahsr 10
2
21
hex bolt M8X20
1
52
swivel stand
1
22
belt wheel 3
1
53
spring ring for shaft 17
4
23
table stand
1
54
bearing
2
24
hex bolt M10X25
1
55
lower wheel shaft
1
25
spring column pin 6x40
1
56
key 5x5x32
1
26
scale
1
57
lower idler wheel
1
27
hex bolt
4
58
flat lock screw M8x10
2
28
flat washer
8
59
phillips head screw M5x16
2
29
stand 2
1
60
Dust box
1
30
adjusting stand
1
61
table stand
1
31
table
1
62
hex bolt
3

16
No.
Description
Quantity
No.
Description
Quantity
63
flat washer
3
93
washer
4
64
spring column pin 4x40
1
94
upper cover
1
65
big washer
1
95
small pressing plate
1
66
knob M6X35
1
96
pressing plate
1
67
table
1
97
phillips head screw M5x10
2
68
scale plate
1
98
flat washer 5
2
69
flat washer
1
99
phillips head scwew M5x6
8
70
knob
1
100
flat wahsr 5
8
71
phillips head screw M5x6
1
101
guard cover
1
72
pointer
1
102
phillips head screw M5x6
2
73
sliding pole
1
103
flat washer 5
2
74
supporting body
1
75
adjusting handle sleeve
1
76
adjusting handle
1
77
flat washer
2
78
hex nut M8
2
79
adjusting shaft
1
80
hex bolt
1
81
knob
1
82
flat washer
2
83
small pressing spring
1
84
hex nut M6
1
85
nut M6
1
86
washer
1
87
adjusting stand
1
88
upper idler wheel shaft
1
89
bearing
2
90
Upper idler
1
91
spring ring for shaft 12
2
92
phillips head screw M5x16
4

17