Wilton 4126AC, 4103, 4106 User Manual

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Operating Instructions — Parts Manual

Square Wheel Belt Grinder

Models: 4103, 4106, and 4126AC

WHM TOOL GROUP

2420 Vantage Drive Elgin, Illinois 60123

Ph.: 800-274-6848 www.wmhtoolgroup.com

Part No. 5507796

Revision C2 09/04

Cover Page .........................................................................................................................................1

General Specifications .........................................................................................................................4

Operating Precautions .........................................................................................................................5

Setup and Operation............................................................................................................................7

Maintenance ......................................................................................................................................10

Wiring Diagrams ................................................................................................................................12

Replacement Parts ............................................................................................................................13

Troubleshooting .................................................................................................................................13

Accessories ....................................................................................................................................... 17

General Specifications

The Wilton Square Wheel Belt Grinder, Models 4103, 4106 and 4126AC, are designed for grinding, deburring, chamfering, and internal/external grinding of small and large parts. The Square Wheel Belt Grinder can be used to polish or buff finished parts and grind small internal radii using available accessories. Accessory changeover is quick and easy. Belt tension and tracking are easily adjustable.

The Square Wheel Belt Grinder is available in either single speed (Models 4103 and

4106) or variable speed model (Model 4126AC). The variable speed model is controlled by an inverter that provides belt speeds ranging from 0 to 6000 SFPM.

Specifications Model 4103 Model 4106 Model 4126AC

Belt Width & Length 2 x 72 Inches 2 x 72 Inches 2 x 72 inches

Belt Speed 4600 SFPM 4600 SFPM 0 - 6000 SFPM

Motor 1 HP, Single Phase, 2 HP, Three Phase, 1 HP, 1,750 rpm

1750 rpm 1750 rpm

Contact Wheel Diameters 1-1/2, 3, & 8 inches 1-1/2, 3, & 8 inches 1-1/2, 3, & 8 inches

Weight 115-125 pounds 120 pounds 120 pounds

- 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 operator’s 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 machine is securely anchored to the floor.

- Always keep machine guards in place.

- Always put start switch in OFF position before plugging in machine.

When using machine:

- Never operate with machine 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 machine running while you are away from it.

- Always shut off the machine when not in use. When servicing machine:

- Always unplug machine from electrical power while servicing.

- Always follow instructions in operators 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 Operators 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

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 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.

11. 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 removing starter keys.

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

Wire sizes

General Electrical Cautions

This machine 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 machine should be grounded to protect the user from electrical shock.

AWG (American wire gauge) Number

Conductor Length 240 Volt Lines 120 Volt Lines

0 - 50 Feet No. 14 No. 14 50 - 100 Feet No. 14 No. 12 Over 100 Feet No. 14 No. 8

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. 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 grinding machines

Abrasive grinding can be hazardous to operators and bystanders. Grinding sparks, chips and dust particles thrown off by the grinding disc can cause serious injury by contact or inhalation. 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, protective 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 breakage of eye protection. See Figure A, below.

2. Wear leather safety gloves, arm guards, leather aprons and safety shoes.

3. A dust collection system is recommended, Operator shall also wear a dust mask at all times. See Figure B, below.

4. Additional precautions may be necessary for grinding materials which are flammable or have other hazardous properties. You should always consult the manufacturer of such materials for instructions on grinding and handling.

5. Do not force or jamb the workpiece into the grinding disc.

6. Before grinding, always allow the motor to come up to operating speed, then check the grinding disc for wobble, runout, or any unbalanced

A B C D

condition. If the disc is not operating accurately and smoothly, immediately stop the motor and make repairs before attempting any grinding 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 60 and 80 degrees Fahrenheit. Failure to do so could cause premature disc failure.

8. Examine the face of the grinding disc carefully. Excessive grinding which 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 shall be worn. See Figure C.

12. Personal hearing protection such as ear plugs or ear muffs shall be used to protect against the effect of noise exposure. See Figure D:

Introduction

This manual includes operating and maintenance instructions for the Wilton Model 4103, 4106 and 4126AC Square Wheel Belt Grinder. The manual also includes parts listings and illustrations of replaceable parts.

Refer to Figures 1 and 2 for key features of the Square Wheel Belt Grinder.

Setup and Operation

The Square Wheel Belt Grinder can be mounted on a work bench or an optional pedestal. The grinder should be secured to the work bench or pedestal using the four holes in the base of the grinder. (Refer to Assembly of Pedestal for machines that are to be pedestal-mounted.)

Installation of Work Rest

The work rest mounts on the left side of the head casting. Attach the work rest using the socket head cap screw provided with the machine.

The slot in the work rest has a lip against which the cap screw is tightened. Place the hole at the end of the slot over the cap screw. Then slide the rest inward until the work rest is in position in front of the contact wheel. Tighten the cap screw.

Belt Tension Lever

Motor

Switch

Belt Tracking Adjustment

Contact Wheel

Pedestal

Upper Guard

Work Rest

Inverter

ON/OFF Switch

Motor

Belt Tracking Adjustment

Upper Guard

Work Rest

Contact Wheel

Pedestal

Figure 1: Square Wheel Grinder Features

(single speed)

Figure 2: Square Wheel Grinder Features

(variable speed)

Vacuum Connection

Operating Controls

NOTE: A variety of vacuum system options are available. (Refer to Accessories section.)

The grinder uses a front mounted vacuum system. Refer to Fgure 3. Install the vacuum system components as follows:

1. Slide the support bracket into the channel secured to belt grinder base. Install one knob in the belt grinder base to secure the support bracket. NOTE: Refer to vacuum scoop exploded view, Figure 11 when installing channel.

2. Slide the ducted scoop onto the support bracket. Install remaining knob in the support bracket to secure the scoop.

3. Connect hose to exhaust duct and secure with a clamp.

Model 4103/4106

The ON/OFF switch for the Model 4103/4106 grinder is located in a switch box mounted on the drive motor.

Model 4126AC NOTE: Refer to Figure 4. Use only the inverter

controls defined in the following procedures. The inverter is pre-programmed at the factory and requires no further programming.The controls for the Model 4126AC grinder are located on the inverter. The ON/OFF switch is located on the left side of the inverter. Start the grinder by setting the ON/OFF switch to ON.

Press the FWD RUN pushbutton on the inverter and set the speed using the up/down arrow keys (to the right of the speed display). Press the up arrow to increase speed; press the down arrow to reduce speed. The display on the inverter shows drive motor speed in revolutions per minute. Press the STOP button on the inverter to stop the grinder. Then set the ON/OFF switch to OFF.

STOP Button

FWD (Forward) Button

On/Off Switch

Speed Display (RPM)

Down

Clamping Knob

Support Bracket

Scoop

Clamping Knob

Figure 3: Vacuum Connection

Figure 4: Operating Controls

(Model 4126AC)

Electrical Connection

Refer to the Wiring Diagram section for wiring information. Connection to electrical power should be made by a qualified electrician. Observe local electrical codes when connecting the machine.

Typical Uses for the Square Wheel Belt Grinder

Flat or angular stock — Platen

setting is the perfect angle for high speed, precision, flat and level grinding of tools, knives, plastics, and other materials. The platen allows working to very close tolerances. An adjustable work rest is standard on all models.

OPTIONAL FEATURES

Shaping — For grinding and finishing cylindrical shapes. The yoke surface conforms to the shape of the surface to produce an even, smooth finish without the danger of scarring. Excellent for tool post applications.

Roughing — Serrated contact wheel is used for removing heavy stock, cleaning up a weld or snagging a casting. This durable 8-inch diameter wheel is used extensively for hollow grinding and profiling knives and other culinary tools. It is standard equipment on all models.

Contouring — Grind difficult, hard to reach areas with the 3-inch by 2-inch or 11/2 inch by 2-inch diameter contact wheels. Contours and shapes unique parts like propellers and metal furniture.

Internal contouring

— The air-cushioned dead head is for use on very small radius grinding. When connected to a source of shop air (80-90 psi), the belt rides on a cushion of air to decrease head and belt wear. The dead head is easy to use, and adapts to any of the available radius tips.

Internal contouring with small wheel — This small

wheel accessory is designed for hard to reach places. Includes 5/8-inch, 70 durometer contact wheel. Available contact wheels are 1/2-inch, 3/4inch, and 1-inch.

Polishing — The buffing pad is perfect for satin finish or high gloss polishing. The fine, close stitched burring pads are ideal for metal and plastic

Finishing — The nylon reinforced, silicone carbide wheel is perfect for polishing and deburring. It applies a high luster finish on rough surfaces and is excellent for steel, iron, or aluminum.

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