Wilton 4002 User Manual

Operating Instructions — Parts Manual

1-Inch Belt / 8-Inch Disc Sander

Model 4002

Part No. 9078321

Revision A1

Table of Contents

Cover.................................................................................................................................... 1

General specifications ..........................................................................................................3

Machine general safety warning ........................................................................................... 4

Safe operation precautions................................................................................................... 5

Setting up the sander............................................................................................................ 6

Operating instructions ........................................................................................................... 9

Adjustments ........................................................................................................................ 10

Typical operations............................................................................................................... 13

Replacement parts ............................................................................................................. 15

Belt Sander Parts - Exploded View ................................................................................. 16

Belt Sander Parts - Parts List.......................................................................................... 17

Disc Sander Parts - Exploded View................................................................................. 18

Disc Sander Parts - Parts List......................................................................................... 19

2

General Specifications

The Wilton Model 4002 sander is designed to serve the varying sanding needs of the professional or the
home hobbyist. The sander features both a belt and a disc sanding surface.

Specifications

Belt 1-inch wide x 42-inches long

Disc 8-inches diameter

Motor 1/3 horsepower, 1725 rpm

Power requirements 1 15 volts

Dimensions: Sander (LWH) 25.50 x 15.50 x 19.50 inches

3

WARNING

- Misuse of this machine can cause serious injury .

- For safety, machine must be set up, used and
serviced properly .

- Read, understand and follow instructions in the
Operating Instructions and Parts Manual which
was shipped with your machine.

When setting up machine:

- Always avoid using machine in damp or poorly
lighted work areas.

- Always be sure the machine support is securely
anchored to the floor or the work bench.

When using machine:

- Always wear safety glasses with side shields (See
ANSI Z87.1)

- Never wear loose clothing or jewelry .

- Never overreach - you may slip and fall.

When servicing machine:

- Always disconnect the machine from its electrical
supply while servicing.

- Always follow instructions in Operating Instructions
and Parts Manual when changing accessory tools
or parts.

- Never modify the machine without consulting
Wilton Corporation.

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 ,
Wilton’s 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 Operating Instruc­tions and Parts Manual as well as all labels affixed to
the machine. Failure in following all of these warn­ings can cause serious injuries.

Machinery general safety warnings

4

1. Always wear protective eye wear when operating
machinery . Eye wear shall be impact resist ant,
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
breakage of eye protection.

2. Wear proper apparel. No loose clothing or
jewelry which can get caught in moving parts.
Rubber soled footwear is recommended for best
footing.

3. Do not overreach. Failure to maintain 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 guards in place and in proper working
order. Do not operate the machine with 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. Avoid accidental starts by being sure the start
switch is “OFF” before plugging in the machine.

7. Never leave the machine running while unat­tended. Machine shall be shut off whenever it is
not in operation.

8. Disconnect electrical power before servicing.

Whenever changing accessories or general
maintenance is done on the machine, electrical
power to the machine must be disconnected
before work is done.

9. 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.

10. Machinery must be anchored to the floor.

1 1. Secure work. Use clamps or a vise to hold work,

when practical. It is safer than using your hands
and it frees both hands to operate the machine.

12. Never brush away chips while the machine is in
operation.

13. Keep work area clean. Cluttered areas invite
accidents.

14. Remove adjusting keys and wrenches before
turning machine on.

15. Use the right tool. Don’t force a tool or attach­ment to do a job it was not designed for.

16. Use only recommended accessories and follow
manufacturers instructions pertaining to them.

17. Keep hands in sight and clear of all moving parts
and cutting surfaces.

18. All visitors should be kept at a safe distance from
the work area. Make workshop completely safe
by using padlocks, master switches, or by

General electrical cautions

removing starter keys.

19. Know the tool you are using its application,
limitations, and potential hazards.

This sander should be grounded in accordance
with the National Electrical Code and local codes
and ordinances. This work should be done by a
qualified electrician. The sander should be
grounded to protect the user from electrical shock.

WARNING: Do not connect the sander to a
240 volt power source. The sander motor requires
120 volts alternating current.

AWG (American wire gauge) number

Conductor length 240 volt lines 120 volt lines
0-50 feet NOT APPLICABLE No. 14

50-100 feet NOT APPLICABLE No. 12
Over 100 feet NOT APPLICABLE No.8

Wire sizes

Caution: For circuits which are far away from the

electrical service box, the wire size must be in­creased in order to deliver ample voltage to the motor.
T o 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 instructions for the 1-Inch belt / 8-Inch disc sander

WARNING: Do not operate your machine until it is
completely assembled and installed according to the
instructions.

WARNING: The dust generated by cert ain woods
and wood products can be injurious to your health.
Always operate machinery in well ventilated areas and
provide for proper dust removal. Use wood dust
collection systems whenever possible.

WARNING: This machine can be use for pro­cessing wood or metal products. However , combining
wood dust and metal filings can create a fire hazard.
Make sure that the dust collector is free of wood dust
deposits before processing metal products.

1. If you are not thoroughly familiar with the opera-

tion of belt and disc sanders, obtain advice from

your supervisor, instructor or other qualified

person.

2. If there is a tendency for the machine to tip over

or move during operation such as when sanding

long or heavy boards, the machine must be

securely fastened to a supporting surface.

3. Make sure the sanding belt is running in the

proper direction. The sanding belt must travel

downward when viewed from the front of the

machine.

4. Make sure the sanding belt is tracking correctly

in order that it does not run off the pulleys.

5. Make sure the sanding belt or disc is not torn or

loose.

6. Hold the work firmly when sanding.

7. Always hold the work firmly on the table when
sanding on the belt or disc. The only exception is
curved work performed on the top wheel of the
belt.

8. Always sand on the downward side of the disc
when using the disc portion of the machine, so
that the work is held securely on the table.
Sanding on the upward side of the disc could
cause the workpiece to fly up which could be
hazardous.

9. Always maintain a minimum clearance of 1/16­inch or less between the table and the sanding
belt or disc.

10. Never wear gloves or hold the work with a rag
when sanding.

1 1. Sand with the grain of the wood.

12. Do not sand pieces of material that are too small
to be safely supported.

13. Avoid awkward hand positions where a sudden
slip could cause a hand to move into the sanding
belt or disc.

14. When sanding a large workpiece, provide
additional support at table height.

15. Never force the work. Slowing or stalling the
motor will cause overheating.

16. When sanding metal, never use a steady stream
of water on the work piece. Dip the workpiece in
water to cool it.

5

17. Do not sand or polish magnesium. It could catch
fire.

18. Always remove scrap pieces and other objects
from the belt and disc tables before turning the
machine ON.

19. Never perform layout, assembly or set-up work

on the tables while the sander is operating.

20. Always turn the machine OFF and disconnect the
cord from the power source before installing or
removing accessories.

21. Never leave the machine work area when the
power is ON or before the machine has come to
a complete stop.

Setting up the sander

WARNING: For your own safety, do not connect the sander to the
power source until the machine is completely assembled and you
have read and understood the entire Operating Instructions and Parts
Manual.

Unpacking

The sander is shipped complete in one carton. Carefully unpack the
machine and all loose items from the carton. If any parts are missing,
do not attempt to operate your sander until the missing parts are
obtained and installed correctly .

Cleaning

6

Remove the protective coating from the surfaces of the sander and
from any loose parts. This coating may be removed with a soft cloth
moistened with kerosene (do not use acetone, gasoline or lacquer
thinner for this purpose). After cleaning, cover the table surfaces with
a good quality paste wax.

Assembly

Assembly of the sander is limited to the installation of the disc table
and the belt table. Proceed as described in the following paragraphs.

Assembling sanding disc table

WARNING: When assembling the sanding disc table, make certain

the motor is disconnected from the power source.

1. The sanding disc table is secured with two cap screws and nuts.
A hex wrench is required to tighten the screws.

2. Set the table on the rounded pockets in the support casting.
Install the nuts in the channel on the back side of the pockets.

3. Install the screws through the table and base casting into the nuts.
Tighten the screws.

4. Check for 1/16-inch clearance between the edge of the table and
the face of the disc. Adjust the clearance if required

Removal/Installation of the Disc)

.

Installing belt sander table

WARNING: When assembling the belt sander table, make cert ain the

motor is disconnected from the power source.

1. The belt table is secured with a spring-loaded locking handle
assembly . The handle assembly is disassembled for ease of
installation.

(see

Figure 1. Installing the disc sander
table

Figure 2. Securing the disc sander
table