Kalamazoo KS390HV-5 User manual

KS390HV-5 3” X 90” BELT GRINDER
AND DUST COLLECTOR
INSTRUCTION MANUAL
MADE IN USA

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.

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 (#13) OUT TO RETRACT HEAD, WHICH WILL RELEASE
BELT TENSION. PUSH (#13) 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 (#26) 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 (#27) 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 (#13),
CHANGE THE BE LT (MAKE SURE OF THE CORRECT ROTATION). RE-TENSION THE BELT WITH
(#13).

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 (#39) THEN ADJUST (#8) UP AND OR DOWN. ONCE ABRASIVE BELT IS
CENTERED LOCK (#39) 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.
BELT STORAGE
STORE COATED ABRASIVES IN A DRY AND COOL LOCATION.
OPERATING INSTRUCTIONS CONTINUED

G
A
A
4
1
35
X 6 PLACES
50
FRONT VIEW
32
3.00
D
FF
32
4
X 2 PLACES X 2 PLACES
HOLES FOR TABLE GUARD, PLATEN TOP GUARD COVER,
AND TOP BACK GUARDS ARE LOCATED AND DRILLED
AND TAPPED DURING FABRICATION.
1
2
2
2
34 15 9 28
44
6
45
51
15 9 8
X 4 PLACES
19
10
35
32
X 2 PLACES
32
32 32 32 32
50
31
30
32
52
55 9 39
X 4 PLACES
43
42
46
47
48
X 2 PLACES
53
53
RIGHT SIDE VIEW
32
?
54
1/4
1/4
4
1
43
42
34
10
50
2
2
54
31
35
3.00
CC
X 2 PLACES
1
ANGLE IRON #53 AND ASSOCIATED
BRACKETS ARE LOCATED AND WELDED
IN PLACE DURING FABRICATION.
51
2
22
35
LEFT SIDE VIEW
50
33
34
43
425352
53
54
1/4
1/4
DETAIL D
SCALE 1 : 2
TRACKING BLOCKS DETAIL
BOLT TOP IS GROUND
DOWN TO FIT.
38
38
36 8
39
38
37 40 38
41
10
EE
SECTION C-C
INTERNAL TOP VIEW
4
1029 29 1819
20
26
50
30
24
SECTION E-E
SCALE 1 : 2
ATTACHING MOTOR
TO FRAME
5 6
X 4 PLACES
4
0.25
0.25 0.25
9.5015.25
0.50
SECTION F-F
WELDING MAIN FRAME BRACES
TO TOP LID OF DUST COLLECTOR
2
2
2
MAIN FRAME IS WELDED IN PLACE AND MAIN
FRAME BRACKETS ARE WELDED TO DCV-6
DUST COLLECTOR DURING FABRICATION.
1/4 1/4 1/4
DETAIL G
FRONT VIEW OF MAIN
FRAME BRACES
3
222
2
B
B
SECTION A-A
SCALE 1 : 2
MAIN DETAILS SIDE VIEW
7
10
11
12
14
15
16
17
13
18
19
24
25
15 9 28
15 9 28
27
27
30
32
50
34
35
49
56 47
X 2 PLACES
54
HOLES FOR MAIN FRAME DOOR AND IDLER WHEEL
GUARD ARE LOCATED, DRILLED AND TAPPED
DURING FABRICATION.
1/4
1/4
1/4
1/4
1/4
1/4
1/4
SECTION B-B
SCALE 1 : 2
IDLER PULLEY DETAILS
10
18
35
19
20
23
21
22
50
PLEASE REFER TO DCV-6 DRAWING FOR ADDITIONAL
DETAILS REGARDING THE DCV-6 DUST COLLECTOR.
ANGLE IRON #53 AND ASSOCIATED
BRACKETS ARE LOCATED AND WELDED
IN PLACE DURING FABRICATION.
ITEM NO.
PART NUMBER
DESCRIPTION
QTY.
1
DCV-6
DCV-6 DUST COLLECTOR
1
2
041-083
BRACE FOR KS390HV AND KS490HV
3
3
291-016
MAIN FRAME FOR KS390 AND KS490
1
4
486-001
5 HP MOTOR FOR K12B, K14B,
KM14, KM14HS & S6MS-5HP
1
5
HHC5037020
3/8-16 X 1-1/4 HHCS GR5 Z
4
6
SLWZ037
3/8 SPLIT L/W Z
5
7
291-018
CAST IRON FRAME FOR S460 DRY
SANDERS
1
8
HHC5031020
5/16-18 X 1-1/4 HHCS GR 5 Z
5
9
SLWZ031 5/16 SPLIT L/W Z
12
10
960-012
YOKE AND TENSION SHAFT
ASSEMBLY FOR KS390 AND KS490
1
11
ROLA025024
1/4 X 1-1/2 ROLL PIN
1
12
697-024
S6 BELT TENSION SPRING
1
13
455-003
TENSION RELEASE LEVER FOR S6
SANDER HEADS
1
14
HHT5031032
5/16-18x2 HEX HEAD TAP BOLT GR5
ZINC
1
15
UFWZ031
5/16 USS F/W Z
9
16
BWWA031
5/16 BOWED SPRING WASHER 21/64
1
17
STNZ031
5/16-18 STOVER LOCK NUT ZINC-
WAX
1
18
936-009
WHEEL, CONTACT FOR KS390
SANDER WITH 1" BORE W/BEARINGS
1
19
701-032
SPINDLE, IDLER FOR KS390 AND
KS490 SANDERS
1
20
699-034
SPACER, IDLER WHEEL, FOR KS390
AND KS490
1
21
123-016
S6 IDLER PULLEY LOCK COLLAR
1
22
SSKA031006
5/16-18 X 3/8 SOC SET KNURL PT.
1
23
SSKA025004
1/4-20 X 1/4 SOC SET KNURL PT.
1
24
560-042
DRIVE PULLEY WITH P2X7/8 BUSHING
FOR KS390 AND KS490
1
25
049-074
P1 X 1-1/8 SPLIT TAPER BUSHING
1
26
563-009
PLATEN FOR KS390 AND KS490
SERIES
1
27
041-029
PLATEN SUPPORT BRACKET FOR
KS390 AND KS490 SANDERS
2
28
HHC5031016
5/16-18 X 1 HHCS GR5 Z
4
29
FSCA031016
5/16-18 X 1 FSHCS
2
30
291-016BACKPANEL KS390 AND KS490 MAIN FRAME
REAR GUARD PANEL
1
31
291-016TOPBACK
KS390 AND KS490 MAIN FRAME TOP
REAR GUARD
1
32
BSCA025008
1/4-20 X 1/2 BSHCS
11
33
291-016DOOR
KS390 AND KS490 MAIN FRAME
DOOR
1
34
829-025A
KS390 AND KS490 PLATEN TOP
GUARD COVER
1
35
829-025
TABLE, GUARD FOR KS390 AND
KS490 SANDERS
1
36
053-009
TRACKING BLOCK- 5/16 THREADED
HOLE
1
37 053-009B
TRACKING BLOCK- 1/2-13
THREADED HOLE
1
38
SHCA025012
1/4-20 X 3/4 SHCS 4
39
FHN5031
5/16-18 FHN GR5 ZINC
5
40
SPPA050020
1/2-13 X 1-1/4 SPRING PLUNGER W
BROWN DELRIN NOSE ALLOY
1
41
FJNZ050
1/2-13 F H JAM NUT Z
1
42
829-026
TABLE, WORK FOR KS390 AND KS490
SANDERS
1
43
455-014
ARM FOR KS390, KS490 WORK TABLE
1
44
HHC5037016
3/8-16 X 1 HHCS GR5 Z
1
45
UFWZ037
3/8 USS F/W Z
1
46
HHC5025012
1/4-20 X 3/4 HHCS GR5 Z
2
47
SLWZ025
1/4 SPLIT L/W Z
4
48
UFWZ025
1/4 USS F/W Z
2
49
PATCH
WELDED PATCH FOR KS390 AND
KS490 MAIN FRAME
1
50
342-147
IDLER WHEEL GUARD, FOR KS390HV
AND KS490HV GRINDER
1
51
291-045ANGLEIRON
BRACKET FOR KS39HV, KS490HV,
KS690HV MAIN FRAME
1
52
291-045BLOCK
LATCH MOUNTING BLOCK FOR
KS39HV, KS490HV, KS690HV
MAIN FRAME
1
53
170-001
BALL CATCH-DOOR LATCH FOR
MACHINE PANELS AND
ENCLOSURES
1
54
041-117
SWITCH BRACKET TO MOUNT
MAGNETIC SWITCH ON TO A
KS390, KS490, KS690 - 5HP
1
55
HHC5031012
5/16-18 X 3/4 HHCS GR5 Z
4
56
HHC5025008
1/4-20 X 1/2 HHCS GR5 Z
2
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 HORIZONTAL
VACUUM
DO NOT SCALE DRAWING
KS390HV
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.