Wilton 4200A, 4400A, 4300A User Manual
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Operating Instructions — Parts Manual
Disc, Belt, and Combination Disc/Belt Sanders
Models: 4200A, 4300A, 4400A
4200A Disc/Belt Sander 4300A 6 Inch Belt Sander 4400A 12 Inch Disc Sander
WHM TOOL GROUP
2420 Vantage Drive
Elgin, Illinois 60123 Part No. 5511365
Ph.: 800-274-6848 Revision E2 10/04
www.wmhtoolgroup.com Copyright © WMH Tool Group
This manual has been prepared for the owner and operators of a Wilton Sander. Its purpose, aside from
machine operation, is to promote safety using accepted operating and maintenance procedures. To obtain
maximum life and efficiency from your Sander and to aid in using it safely, please read this manual thoroughly
and follow instructions carefully.
Warranty and Service
WMH Tool Group warrants every product it sells. If one of our tools needs service or repair, one of our
Authorized Repair Stations located throughout the United States can provide quick service or information.
In most cases, a WMH Tool Group Repair Station can assist in authorizing repair work, obtaining parts, or
perform routine or major maintenance repair on your Wilton product.
For the name of an Authorized Repair Station in your area, please call 1-888-594-5866, or visit our web site at
www.wmhtoolgroup.com
More Information
Remember, WMH Tool Group is consistently adding new products to the line. For complete, up-to-date
product information, check with your local WMH Tool Group distributor, or visit our web site at
www.wmhtoolgroup.com
WMH Tool Group Warranty
WMH Tool Group makes every effort to assure that its products meet high quality and durability standards and
warrants to the original retail consumer/purchaser of our products that each product be free from defects in
materials and workmanship as follows: 1 YEAR LIMITED WARRANTY ON ALL PRODUCTS UNLESS
SPECIFIED OTHERWISE. This Warranty does not apply to defects due directly or indirectly to misuse,
abuse, negligence or accidents, normal wear-and-tear, repair or alterations outside our facilities, or to a lack
of maintenance.
WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD SPECIFIED ABOVE,
BEGINNING FROM THE DATE THE PRODUCT WAS PURCHASED AT RETAIL. EXCEPT AS STATED
HEREIN, ANY IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME
STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE
ABOVE LIMITATION MAY NOT APPLY TO YOU. IN NO EVENT SHALL WMH TOOL GROUP BE LIABLE
FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECIAL,
OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS. SOME STATES DO
NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
To take advantage of this warranty, the product or part must be returned for examination, postage prepaid, to
an Authorized Repair Station designated by our office. Proof of purchase date and an explanation of the
complaint must accompany the merchandise. If our inspection discloses a defect, we will either repair or
replace the product at our discretion, or refund the purchase price if we cannot readily and quickly provide a
repair or replacement. We will return the repaired product or replacement at WMH Tool Group’s expense, but
if it is determined there is no defect, or that the defect resulted from causes not within the scope of WMH Tool
Group’s warranty, then the user must bear the cost of storing and returning the product. This warranty gives
you specific legal rights; you may also have other rights, which vary from state to state.
WMH Tool Group sells through distributors only. Members of the WMH Tool Group reserve the right to effect
at any time, without prior notice, alterations to parts, fittings and accessory equipment, which they may deem
necessary for any reason whatsoever.
Table of Contents
Cover Page ......................................................................................................................................... 1
Warranty..............................................................................................................................................2
Table of Contents ................................................................................................................................3
Machine and Manual Overview ............................................................................................................4
General Specifications......................................................................................................................... 5
Warnings .............................................................................................................................................6
Operating Instructions ..........................................................................................................................8
Maintenance ......................................................................................................................................10
Setup and Installation ........................................................................................................................ 13
Troubleshooting .................................................................................................................................18
Wiring Diagrams ................................................................................................................................19
Replacement Parts ............................................................................................................................ 20
Accessories ....................................................................................................................................... 28
3
Machine and Manual Overview
Wilton Abrasive Finishing Machines are available in three
different configurations: disc, belt, and combination disc
and belt. Each configuration is a rugged, heavy-duty
machine designed for maximum high production work in
an industrial environment.
The speed of stock removal and the quality of finish
achieved is determined largely by the aggressiveness of
the abrasive disc or belt mounted on the machine. With
very aggressive grits, these machines are typically considered grinding machines. With very fine grits, these
machines are typically considered sanding machines.
Whatever you call them, and however you use them, the
instructions in this manual will help you use them safely
and productively.
You will note there are several types of electrical systems available for these machines. All of these systems
are equally effective in providing power to the grinding
mechanism -- however, local codes and the type of environment in which the machine is used will often be a
factor in your choice of system.
Instructions in this manual assume that you are using
one of the Model 4200A series Belt and Disc machines.
If you have a disc only, or belt only machine, you can
bypass those instructions which do not apply to you.
4
General Specifications
Table size
Table tilt
Miter gauge groove
Disc diameter
Disc Speed
Platen size
Belt size
Belt speed
Dimensions
(depth, W, H)
Dimensions w/platen
vertical (depth,W, H)
Dimensions w/platen
horizontal
(depth, W, H)
Motor options
Weight
Disc Sander
12x16 3/8 in. (254x416mm)
45° down, 20° up
3/8x3/4 in. (9.5x19mm)
12 in. (305mm)
1960 RPM
29x17x42 3/4 in.
(1070x725x4250mm)
Model 4400A 1 ph. 1.5HP
115/230V
Model 4401A 3 ph. 1.5HP
230V/460V
Model 4403A 3 ph. 1.5HP
230/460V (connected 460)
full JIC, 110V at the switch
unassembled
164 lbs. (74 kg.)
Belt Sander
7 3/8x14 3/4 in. (187x355mm)
45° down, 20° up
3/8x3/4 in. (9.5x19mm)
6 1/4x14 3/4 in. (159x375mm)
6x48 in. (152x1214mm)
2850 SFM
19x16x57 1/2 in.
(475x400x1437mm)
25 1/2x16x43 in.
(637x400x1075mm)
Model 4300A 1 ph. 1.5HP
115/230V
Model 4301A 3 ph. 1.5HP
230V/460V
Model 4303A 3 ph. 1.5HP 230/
460V (connected 460) full JIC,
110V at the switch
211 lbs. (96 kg.)
Disc/Belt Sander
Disc:12x16 3/8 in. (254x416mm)
Belt: 7 3/8x14 3/4 in.
(187x355mm)
(both) 45° down, 20° up
(both) 3/8x3/4 in. (9.5x19mm)
12 in. (305mm)
1960 RPM
6 1/4x14 3/4 in. (159x375mm)
6x48 in. (152x1214mm)
2850 SFM
19x16x57 1/2 in.
(475x400x1437mm)
25 1/2x16x43 in.
(637x400x1075mm)
Model 4200A 1 ph. 1.5HP
115/220V
Model 4202A 3 ph. 1.5HP
230V/460V
Model 4204A 3 ph. 1.5HP 230/
460V (connected 460) full JIC,
110V at the switch
250 lbs. (113 kg.)
5
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.
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.
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.
- Never modify the machine without consulting Wilton
Corporation.
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
6
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 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.
10. The machinery must be anchored to the floor.
11. 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.
12. Never brush chips away while the machine is in operation.
13. Keep work area clean. Cluttered areas invite accidents.
14. Remove adjusting keys and wrenches before turning
the 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 your 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.
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:
Conductor length
0-50 feet
50-100 feet
Over 100 feet
AWG (American Wire Gauge) number
240 volt lines 120 volt lines
No. 14
No. 14
No. 12
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.
No. 14
No. 12
No. 8
7. Abrasive discs must be stored in a controlled environment area. Relative humidity should be 35% to 50% and
the temperature should be between 60o and 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.
7
Figure A Figure B
Figure C
Figure D
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.
Figure 1: Locking handle for belt table
Using the Indexing Lock Handle
The lock handle is spring loaded and can be reposi-
tioned on its shaft to permit easy locking and unlocking.
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.
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
Adjusting the Belt Sander Table
You can tilt the table in a range between 20o upward
and 45o downward. 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 45o downward (essentially 90o + 45o or 135o total 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 re-
8
quired angle between 20o upward and 45o downward.
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.
CAUTION: NEVER ADJUST THE TABLE ANGLE
WHILE THE SANDER IS RUNNING. ALWAYS TURN
THE MOTOR OFF BEFORE ADJUSTING THE TABLE
ANGLE.
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.
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 20o upward and 45o downward.
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.
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.
CAUTION: NEVER ADJUST THE ARM ANGLE
WHILE THE SANDER IS RUNNING. ALWAYS TURN
OFF THE MOTOR BEFORE ADJUSTING THE ARM
ANGLE.
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 4: Disc sander table adjustment
9
Figure 5: Use of the miter system
10
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.
Figure 6: Top cover components
Figure 7: Belt adjustment components (Note top cover
removed for removal and replacement of belt.)
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