Kalamazoo KS390 User manual

KALAMAZOO
INDUSTRIES, INC.
KALAMAZOO, MI.
PH: [phone] www.kalamazooind.com
KI
KS390/ KS390V 3” X 90” BELT GRINDER
INSTRUCTION MANUAL
MADE IN USA

KALAMAZOO
INDUSTRIES, INC.
KALAMAZOO, MI.
PH: [phone] www.kalamazooind.com
KI
WARRANTY
All products are guaranteed for a period of one year from receipt of order to the original purchaser,
against defects in material workmanship under normal use. Electric motors are warranted by the motor
manufacturer for a period of one year and will be repaired by the nearest motor repair station. If non-
repairable, they will be replaced by Kalamazoo Industries. Please call for instructions [phone].
RETURN POLICY
Authorization must be obtained before returning merchandise. Please call our customer service
department for a return authorization number [phone]. Please include with your return a copy of
your invoice of packing slip. All material must be new and unused in the original packaging. Material
must be sent back prepaid (unless otherwise indicated) by Kalamazoo Industries. Credit upon inspection
at Kalamazoo Industries. All returns will be subject to a 10% restock charge. Used merchandise is non-
returnable. No returns will be accepted after one year of invoice date.
BELT GRINDER SAFETY
• READ THE OPERATING INSTRUCTIONS BEFORE RUNNING MACHINE.
• ALWAYS WEAR SAFETY GLASSES OR A FULL FACE SHIELD FOR PROTECTION.
• KEEP HANDS CLEAR OF THE SANDING AREA.
• NEAR WEAR GLOVES OR LOOSE FITTING CLOTHES WHEN OPERATING THIS
MACHINE.
• ALWAYS KEEP HAIR TIED BACK OR COVERED.
• LET MACHINE ROTATION COME TO A FULL STOP BEFORE CHANGING BELT.
• KEEP SAFETY GUARDS IN PLACE. DO NOT ALTER GUARD OR MACHINE IN ANYWAY.
ANY ALTERATIONS TO GUARDS OR MACHINE COULD CAUSE SERIOUS INJURY.
• ALL BELT SANDERS SHOULD BE OPERATED IN A WELL-VENTILATED AREA. THE
DUST CREATED WHEN SOME MATERIALS ARE SANDED CAN BE HARMFUL. DUST
MASKS ARE RECOMMEND AS A PRACTICAL MEAN OF MINIMIZING DUST
INHALATION. FUMES FROM OTHER OTHER SOURCES CAN ALSO CAUSES FIRES
WHEN INTACT WITH SANDING SPARK.
• SPARKS CREATED BY SANDING SHOULD BE DIRECTED DOWNWARD AND AWAY
FROM THE FACE AND BODY. DON NOT GRIND NEAR FLAMMABLE MATERIAL.
• ELECTRIC GRINDING MACHINES ARE NOT INTENDED FOR USE IN OR NEAR WATER.
THIS INCLUDES AN OPERATOR STANDING ON A WET FLOOR OR WORKING
AROUND CONTAINERS OF WATER OR OTHER CONDUCTIVE LIQUIDS.

KALAMAZOO
INDUSTRIES, INC.
KALAMAZOO, MI.
PH: [phone] www.kalamazooind.com
KI
READ AND UNDERSTAND ALL OPERATING INSTRUCTIONS AND SAFETY
PRECAUTIONS BEFORE OPERATING UNIT
OPERATING INSTRUCTIONS
INSPECT YOUR NEW UNIT CAREFULLY FOR SIGNS OF SHIPPING DAMAGE. IF DAMAGED,PLEASE
CONTACT CARRIER AND SUBMIT A CONCEALED DAMAGED REPORT. DO NOT RETURN GOODS TO
US WITHOUT OUR RGA NUMBER AND SHIPPING INSTRUCTIONS. SEE PAGE 2 FOR RETURN POLICY
AND WARRANTY.
BEFORE STARTING OR CONNECTING ELECTRICALS, VERIFY THE PHASE AND VOLTAGE OF THE
UNIT.
BE SURE MACHINE IS BALANCE CORRECTLY SO IT WILL NOT TIP OVER.
TO GUARD AGAINST CONCEALED DAMAGE, STAND CLEAR AND OBSERVE UNIT FOR THE FIRST
FEW MINUTES OF OPERATION. GUARDS MUST NEVER BE REMOVED. KEEP ALL SAFETY GUARDS,
WORK TABLES, ETC, IN PROPER ADJUSTMENT. WORK TABLE MUST BE KEPT WITHIN 1/8” FROM
THE SANDING BELT.
ABRASIVE BELT TENSION
ABRASIVE BELT IS CONTROLLED BY SPRING TENSIONS. THE TENSIONS RELEASE LEVER (#15)
CONTROLS THE BELT BELT TENSION. PULL (#15) OUT TO RETRACT HEAD, WHICH WILL RELEASE
BELT TENSION. PUSH (#15) IN TO EXTEND HEAD, WHICH WILL APPLY TENSION TO THE SANDING
BELT. ADJUST THE BELT TENSION TO THE MINIMUM SUFFICIENT TO ENSURE GOOD CONTACT
WITH THE DRIVE AND IDLER WHEELS. THEN THE BELT WILL TRACK PROPERLY UNDER BOTH
START UP AND GRINDING CONDITIONS..
PLATEN ALIGNMENT
USING A STRAIGHT EDGE, SET THE STRAIGHT EDGE ON THE PLATEN (#28) SO IT SPANS ACROSS
BOTH THE DRIVE AND CONTACT WHEEL PULLEY FACES. DRIVE PULLEY CLEARANCE SHOULD BE
1/8” LOWER THAN PLATEN FACE AT THE OUTER EDGES OF THE DRIVE PULLEY. CONTACT WHEEL
CLEARANCE SHOULD BE 1/32” LOWER THAN PLATEN FACE. USE BRACKETS (#29) TO LOWER OR
RAISE PLATEN HEIGHT.
DRIVE PULLEY
POOR BELT TRACKING CAN RESULT FROM NORMAL WEAR OVER TIME OF THE DRIVE PULLEY.
THE DRIVE PULLEY FACE IS CROWNED SLIGHTLY TO HOLD BELT TRACKING. WHEN THE CROWN
IS WORN DOWN AND THE DRIVE PULLEY BECOMES FLAT FACED, TRACKING PROBLEMS WILL
RESULT. A QUICK FIX WOULD BE TO WRAP A FEW LAYERS OF MASKING TAPE AROUND THE
CENTER HIGHER THAN THE OUTER EDGES IF THIS ALLEVIATES THE PROBLEM, THEN A NEW
PULLEY WILL WILL BE NEEDED WITH THE CORRECT CROWN ON IT.
CHANGING BELT
TURN MACHINE POWER OFF. RELEASE BELT TENSION WITH TENSION RELEASE HANDLE (#15),
CHANGE THE BE LT (MAKE SURE OF THE CORRECT ROTATION). RE-TENSION THE BELT WITH
(#15).

KALAMAZOO
INDUSTRIES, INC.
KALAMAZOO, MI.
PH: [phone] www.kalamazooind.com
KI
DUST COLLECTOR
IF YOUR GRINDER HAS A DUST COLLECTOR SYSTEM BE SURE TO THOROUGHLY CLEAN THE BASE
AND FILTER AFTER EVERY USE AND OR SWITCHING MATERIALS. DO NOT MIX MATERIALS.
MIXING MATERIALS COULD CAUSE A FIRE.
TRACKING THE BELT
TO TRACK BELT LOOSEN (#41) THEN ADJUST (#10) UP AND OR DOWN. ONCE ABRASIVE BELT IS
CENTERED LOCK (#41) TO KEEP BELT TRACKED. BE SURE THE ABRASIVE BELT FULLY COVERS
THE CONTACT WHEEL. DO NOT SLIP OFF THE ABRASIVE BELT AND RUB THE CONTACT
WHEEL WITH WORK PIECE. THIS WILL RADIUS THE CONTACT WHEEL FACE EDGES AND
RESULT IN POOR BELT TRACKING.
MACHINE HEAD ANGLE
KS390/KS390V CAN BE ADJUSTED FROM HORIZONTAL. LOOSEN CAP SCREW ON TILT BRACKET (#2)
ADJUST THE LEVELING STUD BY LOOSENING (#45) AND ADJUST THE LEVELING STUD UP AND OR
DOWN (#44) TO SUPPORT THE MACHINE HEAD. RE-TIGHTEN CAP SCREW ON TILT BRACKET (#2).
BELT STORAGE
STORE COATED ABRASIVES IN A DRY AND COOL LOCATION.
OPERATING INSTRUCTIONS CONTINUED

24.11
A
A
1
2
3
4
6
4
7
X 4 PLACES
X 4 PLACES
8
20
28
37
44
45
D
1
2
5
8
10 11 17
X 4 PLACES
12
21
20
34 34
34 37 34
33
36
30 11 17
X 2 PLACES
8
50
51 48
X 2 PLACES
HOLES FOR TABLE GUARD, PLATEN TOP GUARD COVER,
AND TOP BACK GUARDS ARE LOCATED AND DRILLED
AND TAPPED DURING FABRICATION.
44
45
52 47
4849
X 2 PLACES
32
3
4
53
46
1
33
36
37
20
46
5
8
2
43.64
48.74
EE
1
2
37
33
32
34
35
HOLES FOR MAIN FRAME DOOR ARE LOCATED AND
DRILLED AND TAPPED DURING FABRICATION.
44
45
48 51
50
X 2 PLACES
46
B
B
C
SECTION A-A
SCALE 1 : 2
INSIDE DETAILS/ SIDE VIEW
5
912
21
13
1415
16
17
18
19
20
26
27
2829 29
30
11
17
17 11 30
34
32
34
X 6 PLACES
37
33 36
BACK GUARD PLATE IS
WELDED TO MAIN FRAME
DURING FABRICATION.
1/4
SECTION B-B
SCALE 1 : 2
IDLER PULLEY DETAILS
5
21
20
22
23
24
37
SECTION C-C
SCALE 1 : 2
INSIDE DETAILS/ TOP VIEW
13
1215 14
19
16
20
22
23
25
DETAIL D
SCALE 1 : 1
TRACKING BLOCKS DETAIL
39
40
40
38
40
40
41
10
12
43
42
BOLT TOP IS GROUND
DOWN TO FIT.
SECTION E-E
2831 31
20
26
4 6
X 4 PLACES
8
32
34
36
5
ITEM NO.
PART NUMBER
DESCRIPTION
QTY.
1
716-015W
STAND ASSEMBLY FOR KS390
AND KS490
1
2
572-004
TILT BRACKET FOR KS390 AND
KS490 SANDERS
1
3
HHC5037016
3/8-16 X 1 HHCS GR5 Z
5
4
SLWZ037
3/8 SPLIT L/W Z
13
5
291-016
MAIN FRAME FOR KS390 AND
KS490
1
6
HHC5037020
3/8-16 X 1-1/4 HHCS GR5 Z
8
7
FHN5037
3/8-16 FHN GR5 Z
4
8
486-003
2HP, 1PH, 3450 RPM, 145TC W/O
FEET, 115/230 FOR KS390-490
1
9
291-018
CAST IRON FRAME FOR S460 DRY
SANDERS
1
10
HHC5031020
5/16-18 X 1-1/4 HHCS GR 5 Z
5
11
SLWZ031 5/16 SPLIT L/W Z
8
12
960-012
YOKE AND TENSION SHAFT
ASSEMBLY FOR KS390 AND KS490
1
13
ROLA025024
1/4 X 1-1/2 ROLL PIN
1
14
697-024
S6 BELT TENSION SPRING
1
15
455-003
TENSION RELEASE LEVER FOR S6
SANDER HEADS
1
16
HHT5031032
5/16-18x2 HEX HEAD TAP BOLT
GR5 ZINC
1
17
UFWZ031
5/16 USS F/W Z
9
18
BWWA031
5/16 BOWED SPRING WASHER
21/64
1
19
STNZ031
5/16-18 STOVER LOCK NUT ZINC-
WAX
1
20
936-009
WHEEL, CONTACT FOR KS390
SANDER WITH 1" BORE
W/BEARINGS
1
21
701-032
SPINDLE, IDLER FOR KS390 AND
KS490 SANDERS
1
22
699-034
SPACER, IDLER WHEEL, FOR
KS390 AND KS490
1
23
123-016
S6 IDLER PULLEY LOCK COLLAR
1
24
SSKA031006
5/16-18 X 3/8 SOC SET KNURL PT.
1
25
SSKA025004
1/4-20 X 1/4 SOC SET KNURL PT.
1
26
560-042
DRIVE PULLEY WITH P2X7/8
BUSHING FOR KS390 AND KS490
1
27
049-063
P2 X 7/8 SPLIT TAPER BUSHING
FOR KS390 AND KS490 DRIVE
WHEEL
1
28
563-009
PLATEN FOR KS390 AND KS490
SERIES
1
29
041-029
PLATEN SUPPORT BRACKET FOR
KS390 AND KS490 SANDERS
2
30
HHC5031016
5/16-18 X 1 HHCS GR5 Z
4
31
FSCA031016
5/16-18 X 1 FSHCS
2
32
291-016BACKPANEL KS390 AND KS490 MAIN FRAME
REAR GUARD PANEL
1
33
291-016TOPBACK
KS390 AND KS490 MAIN FRAME
TOP REAR GUARD
1
34
BSCA025008
1/4-20 X 1/2 BSHCS
11
35
291-016DOOR
KS390 AND KS490 MAIN FRAME
DOOR
1
36
829-025A
KS390 AND KS490 PLATEN TOP
GUARD COVER
1
37
829-025
TABLE, GUARD FOR KS390 AND
KS490 SANDERS
1
38
053-009
TRACKING BLOCK- 5/16
THREADED HOLE
1
39 053-009B
TRACKING BLOCK- 1/2-13
THREADED HOLE
1
40
SHCA025012
1/4-20 X 3/4 SHCS 4
41
FHN5031
5/16-18 FHN GR5 ZINC
1
42
SPPA050020
1/2-13 X 1-1/4 SPRING PLUNGER
W BROWN DELRIN NOSE ALLOY
1
43
FJNZ050
1/2-13 F H JAM NUT Z
1
44
709-012
STUD, LEVELING FOR KS390 AND
KS490 SANDERS
1
45
FHN5075
3/4-10 FHN GR5 Z
1
46
829-026
TABLE, WORK FOR KS390 AND
KS490 SANDERS
1
47
HHC5025012
1/4-20 X 3/4 HHCS GR5 Z
2
48
SLWZ025
1/4 SPLIT L/W Z
4
49
UFWZ025
1/4 USS F/W Z
2
50
168-004
VACUUM PORT FOR KS 390 AND
KS490 SANDERS
1
51
HHC5025008
1/4-20 X 1/2 HHCS GR5 Z
2
52
455-014
ARM FOR KS390, KS490 WORK
TABLE
1
53
UFWZ037
3/8 USS F/W Z
1
A A
B B
C C
D D
E E
F F
G G
H H
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
KS390 BELT
GRINDER
DO NOT SCALE DRAWING
KS390
SHEET 1 OF 1
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:5
WEIGHT:
REV
DWG. NO.
E
SIZE
TITLE:
NAME
DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
FINISH
MATERIAL
INTERPRET GEOMETRIC
TOLERANCING PER:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
ANGULAR: MACH
BEND
TWO PLACE DECIMAL
THREE PLACE DECIMAL
APPLICATION
USED ON
NEXT ASSY
PROPRIETARYAND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
<INSERT COMPANY NAME HERE> IS
PROHIBITED.

24.11
B
B
A
A
1
2
3
4
6
4
7
X 4 PLACES
X 4 PLACES
8
20
28
37
44
45
50
48
51
X 2 PLACES
E
1
2
5
8
10 11 17
X 4 PLACES
12
21
20
34 34
34 37 34
33
36
30 11 17
X 2 PLACES
8
50
51 48
50
51 48
X 2 PLACES
X 2 PLACES
51 48
X 4 PLACES
HOLES FOR TABLE GUARD, PLATEN TOP GUARD COVER,
AND TOP BACK GUARDS ARE LOCATED AND DRILLED
AND TAPPED DURING FABRICATION.
44
45
55 47
4849
X 2 PLACES
53
32
3
4
56
46
1
50
33
36
37
20
46
5
8
53
2
43.64
51.31
FF
1
2
37
33
32
34
35
51 48
X 4 PLACES
HOLES FOR MAIN FRAME DOOR ARE LOCATED AND
DRILLED AND TAPPED DURING FABRICATION.
44
45
48 51 50
X 2 PLACES
46
53
C
C
D
SECTION B-B
SCALE 1 : 2
INSIDE DETAILS/ SIDE VIEW
5
912
21
13
1415
16
17
18
19
20
26
27
2829 29
30
11
17
17 11 30
34
32
34
X 6 PLACES
37
33 36
BACK GUARD PLATE IS
WELDED TO MAIN FRAME
DURING FABRICATION.
1/4
SECTION C-C
SCALE 1 : 2
IDLER PULLEY DETAILS
5
21
20
22
23
24
37
SECTION D-D
SCALE 1 : 2
INSIDE DETAILS/ TOP VIEW
13
1215 14
19
16
20
22
23
25
DETAIL E
SCALE 1 : 1
TRACKING BLOCKS DETAIL
39
40
40
38
40
40 41
1012
43
42
BOLT TOP IS GROUND
DOWN TO FIT.
SECTION F-F
2831 31
20
26
4 6
X 4 PLACES
8
32
34
36
5
SECTION A-A
INSIDE DUST COLLECTOR
52
53
#54 LOCATION
CAGE IS PRESSED ONTO
FLANGE OF VACUUM
MOTOR AFTER MOTOR
IS ATTACHED TO THE
DOOR PANEL.
ITEM NO.
PART NUMBER
DESCRIPTION
QTY.
1
716-016W
STAND, VACUUM ASSEMBLY FOR
KS390 AND KS490
1
2
572-004
TILT BRACKET FOR KS390 AND
KS490 SANDERS
1
3
HHC5037016
3/8-16 X 1 HHCS GR5 Z
5
4
SLWZ037
3/8 SPLIT L/W Z
13
5
291-016
MAIN FRAME FOR KS390 AND
KS490
1
6
HHC5037020
3/8-16 X 1-1/4 HHCS GR5 Z
8
7
FHN5037
3/8-16 FHN GR5 Z
4
8
486-003
2HP MOTOR FOR KS390-490
1
9
291-018
CAST IRON FRAME FOR S460 DRY
SANDERS
1
10
HHC5031020
5/16-18 X 1-1/4 HHCS GR 5 Z
5
11
SLWZ031 5/16 SPLIT L/W Z
8
12
960-012
YOKE AND TENSION SHAFT
ASSEMBLY FOR KS390 AND KS490
1
13
ROLA025024
1/4 X 1-1/2 ROLL PIN
1
14
697-024
S6 BELT TENSION SPRING
1
15
455-003
TENSION RELEASE LEVER FOR S6
SANDER HEADS
1
16
HHT5031032
5/16-18x2 HEX HEAD TAP BOLT
GR5 ZINC
1
17
UFWZ031
5/16 USS F/W Z
9
18
BWWA031
5/16 BOWED SPRING WASHER
21/64
1
19
STNZ031
5/16-18 STOVER LOCK NUT ZINC-
WAX
1
20
936-009
WHEEL, CONTACT FOR KS390
SANDER WITH 1" BORE
W/BEARINGS
1
21
701-032
SPINDLE, IDLER FOR KS390 AND
KS490 SANDERS
1
22
699-034
SPACER, IDLER WHEEL, FOR
KS390 AND KS490
1
23
123-016
S6 IDLER PULLEY LOCK COLLAR
1
24
SSKA031006
5/16-18 X 3/8 SOC SET KNURL PT.
1
25
SSKA025004
1/4-20 X 1/4 SOC SET KNURL PT.
1
26
560-042
DRIVE PULLEY WITH P2X7/8
BUSHING FOR KS390 AND KS490
1
27
049-063
BUSHING FOR KS390 & KS490
DRIVE WHEEL
1
28
563-009
PLATEN FOR KS390 AND KS490
SERIES
1
29
041-029
PLATEN SUPPORT BRACKET FOR
KS390 AND KS490 SANDERS
2
30
HHC5031016
5/16-18 X 1 HHCS GR5 Z
4
31
FSCA031016
5/16-18 X 1 FSHCS
2
32
291-016BACKPANEL KS390 AND KS490 MAIN FRAME
REAR GUARD PANEL
1
33
291-016TOPBACK
KS390 AND KS490 MAIN FRAME
TOP REAR GUARD
1
34
BSCA025008
1/4-20 X 1/2 BSHCS
11
35
291-016DOOR
KS390 AND KS490 MAIN FRAME
DOOR
1
36
829-025A
KS390 AND KS490 PLATEN TOP
GUARD COVER
1
37
829-025
TABLE, GUARD FOR KS390 AND
KS490 SANDERS
1
38
053-009
TRACKING BLOCK- 5/16
THREADED HOLE
1
39 053-009B
TRACKING BLOCK- 1/2-13
THREADED HOLE
1
40
SHCA025012
1/4-20 X 3/4 SHCS 4
41
FHN5031
5/16-18 FHN GR5 ZINC
1
42
SPPA050020
1/2-13 X 1-1/4 SPRING PLUNGER
W BROWN DELRIN NOSE ALLOY
1
43
FJNZ050
1/2-13 F H JAM NUT Z
1
44
709-012
STUD, LEVELING FOR KS390 AND
KS490 SANDERS
1
45
FHN5075
3/4-10 FHN GR5 Z
1
46
829-026
TABLE, WORK FOR KS390 AND
KS490 SANDERS
1
47
HHC5025012
1/4-20 X 3/4 HHCS GR5 Z
2
48
SLWZ025
1/4 SPLIT L/W Z
10
49
UFWZ025
1/4 USS F/W Z
2
50
168-004
VACUUM PORT FOR KS 390 AND
KS490 SANDERS
2
51
HHC5025008
1/4-20 X 1/2 HHCS GR5 Z
8
52
486-008
VACUUM MOTOR FOR KS390V
AND S612V (OLD STYLE)
1
53
342-037
GUARD, VACUMM MOTOR FOR
KS390 SANDERS
1
54
5X878
CLOTH BAG FOR DCV-4 DUST
COLLECTOR
1
55
455-014
ARM FOR KS390, KS490 WORK
TABLE
1
56
UFWZ037
3/8 USS F/W Z
1
A A
B B
C C
D D
E E
F F
G G
H H
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
KS390 BELT GRINDER W
VACUUM IN BASE
DO NOT SCALE DRAWING
KS390V
SHEET 1 OF 1
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:5
WEIGHT:
REV
DWG. NO.
E
SIZE
TITLE:
NAME
DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
FINISH
MATERIAL
INTERPRET GEOMETRIC
TOLERANCING PER:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
ANGULAR: MACH
BEND
TWO PLACE DECIMAL
THREE PLACE DECIMAL
APPLICATION
USED ON
NEXT ASSY
PROPRIETARYAND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
<INSERT COMPANY NAME HERE> IS
PROHIBITED.