Bucktool BD4802 - 4x8 BELT DISC SANDER Manual

SPECIFICATIONS

For your own safety, read and follow all of the Safety Guidelines and Operating Instructions before operating this product.

SAFETY GUIDELINES - DEFINITIONS

• Always wear safety goggles or safety glasses with side shields.
• Always wear respiratory and hearing protection.
• To reduce the risk of injury, user and all bystanders must read and understand instruction manual before using this product.
• Failure to keep your hands away from the moving part and cutting surface will result in serious personal injury.
• No children or pregnant women should enter the work area where the paint sanding is being done until all clean up is completed.
• A dust mask or respirator should be worn by all persons entering the work area. The filter should be replaced daily or whenever the wearer has difficulty breathing.
• NO EATING, DRINKING or SMOKING should be done in the work area to prevent ingesting contaminated paint particles. Workers should wash and clean up BEFORE eating, drinking or smoking. Articles of food, drink, or smoking should not be left in the work area where dust would settle on them.
• Paint should be removed in such a manner as to minimize the amount of dust generated.
• Areas where paint removal is occurring should be sealed with plastic sheeting of 4 miles thickness.
• Sanding should be done in a manner to reduce tracking of paint dust outside the work area.
• All surfaces in the work area should be vacuumed and thoroughly cleaned daily for the duration of the sanding project. Vacuum filter bags should be changed frequently.
• Plastic drop cloths should be gathered up and disposed of along with any dust chips or other removal debris. They should be placed in sealed refuse receptacles and disposed of through regular trash pick-up procedures. During clean up, children and pregnant women should be kept away from the immediate work area.
• All toys, washable furniture and utensils used by children should be washed thoroughly before being used again.

Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

POWER TOOL SAFETY

1. READ and become familiar with the entire Instruction Manual. LEARN the tool's application, limitations and possible hazards.
2. KEEP GUARDS IN PLACE and in working order.
3. REMOVE ADJUSTING KEYS AND WRENCHES. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool before turning ON.
4. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.
5. DO NOT USE IN DANGEROUS ENVIRONMENTS. Do not use power tools in damp locations, or expose them to rain or snow. Keep work area well lit.
6. KEEP CHILDREN AWAY. All visitors and bystanders should be kept a safe distance from work area.
7. MAKE WORKSHOP CHILD PROOF with padlocks, master switches or by removing starter keys.
8. DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.
9. USE THE RIGHT TOOL. Do not force the tool or an attachment to do a job for which it was not designed.
10. USE PROPER EXTENSION CORDS. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will result in a drop in line voltage and in loss of power which will cause the tool to overheat. The table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.
11. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewelry which may get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair.
12. ALWAYS WEAR EYE PROTECTION. Any power tool can throw foreign objects into the eyes and could cause permanent eye damage. ALWAYS wear Safety Goggles (not glasses) that comply with ANSI Safety standard Z87.1. Everyday eyeglasses have only impact–resistant lenses. They ARE NOT safety glasses.
    NOTE: Glasses or goggles not in compliance with ANSI Z87.1 could seriously injure you when they break.
13. WEAR A FACE MASK OR DUST MASK. Sanding operation produces dust.
14. SECURE WORK. Use clamps or a vise to hold work when practical. It is safer than using your hand and it frees both hands to operate the tool.
15. DISCONNECT TOOLS FROM POWER SOURCE before servicing, and when changing accessories such as blades, bits and cutters.
16. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in the OFF position before plugging the tool in.
17. USE RECOMMENDED ACCESSORIES. Consult this Instruction Manual for recommended accessories. The use of improper accessories may cause risk of injury to yourself or others.
18. NEVER STAND ON THE TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted.
19. CHECK FOR DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function – check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.
20. NEVER LEAVE THE TOOL RUNNING UNATTENDED. TURN THE POWER "OFF". Do not walk away from a running tool until the blade comes to a complete stop and the tool is unplugged from the power source.
21. DO NOT OVERREACH. Keep proper footing and balance at all times.
22. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.
23. DO NOT use power tool in presence of flammable liquids or gases.
24. DO NOT operate the tool if you are under the influence of any drugs, alcohol or medication that could affect your ability to use the tool properly.
25. Dust generated from certain materials can be hazardous to your health. Always operate saw in well-ventilated area and provide for proper dust removal.
26. WEAR HEARING PROTECTION to reduce the risk of induced hearing loss.

People with electronic devices, such as pacemakers, should consult their physician(s) before using this product. Operation of electrical equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker.

POWER TOOL SAFETY

1. USE sander on horizontal surfaces only. Operating the sander when mounted on non-horizontal surfaces might result in motor damage.
2. TO STOP it from tipping over or moving when in use, the sander must be securely fastened to a bench top or supporting surface.
3. PLACE the sander so neither the user nor bystanders are forced to stand in line with the abrasive belt or disc.
4. MAKE SURE the sanding belt is installed in the correct direction. See directional arrow on back of belt.
5. ALWAYS have the tracking adjusted properly so the belt does not run off the pulleys.
6. DO NOT USE sanding belts or discs that are damaged, torn or loose. Use only correct size sanding belt and disc. Narrower belts uncover parts that could trap fingers.
7. MAKE SURE there are no nails or foreign objects in the part of the workpiece to be sanded.
8. ALWAYS HOLD the workpiece firmly when sanding. Keep hands away from sanding belt or disc. Sand only one workpiece at a time.
9. ALWAYS HOLD the workpiece firmly on the table when using the disc sander and when using the belt sander.
10. ALWAYS SAND ON THE DOWNWARD SIDE of the sanding disc when using the disc sander. Sanding on the upward side of the disc could cause the workpiece to fly out of position, resulting in injury.
11. ALWAYS maintain a minimum clearance of 1/16 in. (1.6 mm) or less between the table or backstop and the sanding belt or disc.
12. DO NOT sand pieces of material that are too small to be safely supported.
13. KEEP fingers away from where the belt goes into the dust trap.
14. WHEN sanding a large workpiece, provide additional support at table height.

Electrical
A separate electrical circuit should be used for your machines. This circuit should not be less than #12 wire and should be protected with a 20-A time-lag fuse. If an extension cord is used, use only 3-wire extension cords which have 3-pronged grounding type plugs and matching receptacle which will accept the machine's plug. Before connecting the machine to the power line, make sure the switch is in the "OFF" position and be sure that the electric current is of the same characteristics as indicated on the machine. All line connections should make good contact. Running on low voltage will damage the machine.

MOTOR SPECIFICATIONS
Your machine is wired for 120 V, 60Hz alternating current. Before connecting the machine to the power source, make sure the switch is in the "OFF" position.

GROUNDING INSTRUCTIONS
All grounded, cord-connected machines: In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This machine is equipped with an electric cord having an equipment grounding conductor and a grounding plug.

DO NOT EXPOSE THE MACHINE TO RAIN OR OPERATE THE MACHINE IN DAMP LOCATIONS.
THIS MACHINE MUST BE GROUNDED WHILE IN USE TO PROTECT THE OPERATOR FROM ELECTRIC SHOCK
The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.
Do not modify the plug provided–if it will not fit the outlet, have the proper outlet installed by a qualified electrician.
Improper connection of the equipment-grounding conductor can result in risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.
Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the machine is properly grounded.
Use only 3-wire extension cords that have 3-pronged grounding type plugs and matching 3-conductor receptacles that accept the machine's plug, as shown in Fig. A. Repair or replace damaged or worn cord immediately.

MINIMUM GAUGE FOR CORD SETS
Use proper extension cords. Make sure your extension cord is in good condition and is a 3-wire extension cord which has a 3-pronged grounding type plug and matching receptacle which will accept the machine's plug. When using an extension cord, be sure to use one heavy enough to carry the current of the machine. An undersized cord will cause a drop in line voltage, resulting in loss of power and overheating. The table shows the correct gauge to use depending on the cord length. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

In all cases, make certain the receptacle in question is properly grounded.
If you are not sure, have a electrician check the receptacle.

Package contents

Key parts diagram

Operating instructions

To avoid injury, always keep the plug disconnected from the power source and the switch turned OFF until the sander is completely assembled and adjusted properly.

MOUNTING WORKTABLE ON DISC
The larger worktable is used with the sanding disc. It should be used to support workpieces in all sanding operations except inside curve applications.

1. Locate worktable handles (1) and washers (2) in parts bag.
2. Place the worktable (3) onto the sander frame, aligning the semi-circle slot (4) with the threaded hole (5).
3. Place a washer (2) on threaded shaft of each worktable handle (1), insert through semi-circular slot (4), and tighten into threaded hole (5). Repeat on other side of table.
4. Adjust worktable to level or any angle between 0° and 45° for sanding.
5. Mount the sanding disc cover (6) onto the metal frame that surrounds the sanding disc with the two Phillips Screws (7).
6. The cover guards the left, upward rotation side of the sanding disc to prevent any accidents from occurring. Always sand on the downward, right side of the rotating disc.

MOUNTING WORKTABLE ON BELT

1. Loosen the inner hex screw (1) using the 5 mm hex key, and raise the belt bed (2) in the vertical position. Tighten the inner hex screw (1).
2. Place the worktable (5) onto the belt sander frame, aligning the semi-circular slot (6) with the threaded hole (7).
3. Place washer (4) on the shaft of worktable lock knob (3), insert through semi-circular slot (6), and tighten into threaded hole (7).
4. Adjust worktable to level or any angle between 0° and 45° for sanding.

To avoid trapping the workpiece or fingers between the worktable (1) and sanding disc (2), the worktable edge should be positioned a maximum of 1/16 in. (1.6 mm) from sanding disc plate.

INSTALLING BELT BACKSTOP
The belt backstop prevents the workpiece from being pulled or dragged beyond the sanding belt surface. It should always be used to help control the workpiece when using the sanding belt.

1. Remove the belt worktable
2. Place the backstop (1) onto the sander frame, aligning the slot (2) on the fence with the threaded hole (3).
3. Insert two screws (4) through the slot (2) and tighten into threaded hole (3) with the 5 mm hex key.

INSTALLING DUST COLLECTION
The use of a dust collection system with the sander is strongly recommended. It will maintain shop cleanliness, and help prevent possible health hazards caused by wood dust.
The sander has two dust ports. Slide the hose of your dust collector over the outlet, and secure with a hose clamp.
NOTE: Dryer vent hoses are not acceptable for this purpose.

MITER GAUGE
A miter gauge (1) is supplied with your sander and can be used with the sanding table. The miter gauge body can be adjusted from 0° to 60° right or left for angle or miter sanding.

1. Install the miter gauge bar (2) into the table slot (3) as shown.
2. Loosen lock knob (4) and then rotate miter gauge body to the desired angle.
3. Tighten lock knob (4).

MOUNTING BELT / DISC SANDER TO WORKBENCH

1. Place the sander on a surface that is level but also provides enough room on all sides for the workpiece and for the operator (or bystanders) to not be standing in line with the wood while using the tool. Allow room for the belt to be positioned horizontally or vertically.
2. The hardware to mount this sander is NOT supplied with the sander.

ADJUSTING DISC TABLE SQUARE WITH SANDING DISC

1. Using a combination square (1), place one side of the square on the disc table (2) with the other side against the sanding disc (3), and check to see if the disc table is 90° to the disc.
2. If the disc table surface is not 90° to the disc, loosen the table lock knob (4), adjust table square with disc and tighten the table lock knob (4).
3. Loosen the screw (5) and secure the scale pointer (6) at 0°.

NOTE: The disc table (2) can be tilted from 0° to 45° by loosening the table lock knob (4). Tilt the disc table (2) to the desired angle. Tighten table lock knob (4).

ADJUSTING BELT TABLE SQUARE WITH SANDING BELT

1. Using a combination square (1), place one side of the square on the belt table (2) with the other side against the sanding belt (3), and check to see if the belt table is 90° to the belt.
2. If the belt table surface is not 90° to the belt, loosen the table lock knob (4), adjust table square with belt and tighten the table lock knob (4).
3. Loosen the screw (5) and secure the scale pointer (6) at 0°.

NOTE: The belt table (2) can be tilted from 0° to 45° by loosening the table lock knob (4). Tilt the belt table (2) to the desired angle. Tighten table lock knob (4).

OPERATING DUST EXHAUST
Sanding operations are inherently dusty. It is strongly recommended that users attach a dust collector when using this belt/disc sander. Use of a mask or respirator is still recommended even when a dust-collection system is in use.
NOTE: Do not operate the sander without first turning on the shop vacuum.

TO PROPERLY TRACK THE SANDING BELT

1. Plug in the sander.
2. Turn power switch ON, then immediately OFF, noting whether the belt (1) tends to slide off its track, and to which side (front or back) of the sander.
3. If the sanding belt does not slide to either side, it is tracking properly.
4. Viewed from the switch end, if the sanding belt runs toward the disc side, slightly turn the tracking knob (2) clockwise (down).
5. Viewed from the switch end, if the sanding belt runs away from the disc side, slightly turn the tracking knob (2) counterclockwise (up).
6. Turn power switch ON, then immediately OFF again, again taking note of any belt movement.
7. Readjust tracking knob (2) another 1/4 turn, necessary.

LEVELING THE SANDING BELT
The support rod is designed for adjusting the level of sanding belt. To adjust, please do the following.

1. Loosen the lock nut (1) on the upper end of the support rod (2) with the adjustable wrench.
2. Adjust the support rod (2) upward or downward to leveling the sanding belt (3).
3. When the level of the sanding belt (3) is achieved, tighten the lock nut (1).

ON/OFF SWITCH
The ON/OFF power switch is located on the front of the sander, and incorporates a removable safety key.
In situations where the sander may be left unattended, the operator has the option of removing the "black" safety key of the ON/OFF switch to render the sander inoperable. When the operator is ready to use the machine again, simply insert the "black" safety key into the slot in the switch and pushing it in until it "seats."

BELT HORIZONTAL SANDING
When using the sanding belt in the horizontal position, to perform surface or edge sanding, the belt worktable (1) must always be used. Always hold the workpiece (2) firmly keeping your fingers away from the sanding belt (3). Always keep the end of the workpiece against the belt worktable (1) and move the work evenly across the sanding belt (3). Apply only enough pressure to allow the sanding belt to remove material. Use extra caution when sanding very thin pieces.

SANDING INSIDE CURVES
With care, freehand sanding of inside curves can be accomplished on the idler drum (1). Never attempt to sand the ends of a workpiece on the idler drum (1).

BELT VERTICAL SANDING
Your belt/disc sander - belt station can sand vertically as well as horizontally. Depending on operator needs and the workpiece, the worktable can be used with either the horizontal or vertical position.
To change from one position to the other:

1. Loosen the inner hex screw (1) by turning it counterclockwise with the 5 mm hex key.
2. Manually move the work support station into the vertical or horizontal position, as required.
3. Retighten the inner hex screw (1) by turning it clockwise.

SANDING OUTSIDE CURVES
Freehand sanding of outside curves should be done on the sanding disc (1).
Keep fingers a minimum of 1 in. (25.4 mm) from the sanding disc.

Maintenance

For your safety, turn switch OFF and remove the power cord from the electrical outlet before adjusting or performing maintenance on your sander.
To avoid electric shock or fire, all repairs to the electrical components should be done by a qualified service technician. Before each use check for damaged, missing, or worn parts; check for alignment of moving parts, binding, improper mounting, or any other conditions that may affect the operation. Should any of these conditions exist, do not use the sander until properly repaired or parts are replaced.

REPLACING SANDING DISC
A sanding disc is pre-mounted at the factory. Use only sanding discs that measures 8 in. (200 mm) in diameter.

1. Remove the disc cover and worktable and then remove the disc cover (1) by removing four screws (2).
2. Remove the existing disc, and clean any residue left on disc plate (3). Only use mineral spirits to remove this residue.
3. Peel the plastic (4) back from new sanding disc (5) and carefully press sanding disc firmly in position around the sanding plate. Make sure the disc is centered on the plate.
4. Reinstall the disc cover (1), tighten four screws (2) and place sanding table back on unit.

REPLACING SANDING BELT

1. Remove the belt worktable.
2. Remove the belt sander support rod(9)
3. Position the belt work support frame horizontally as shown. Loosen the inner hex screw (1) by using a 5 mm hex wrench, turning it counterclockwise. Do not remove the screw.
4. Remove the two screws (2, 3) by using a phillips screwdriver, and pull out the tension lever (4) to release the tension of the sanding belt (5). Remove the belt exhaust cover (6).
5. Remove the sanding belt (5) from both sanding drums (7).
6. Place new sanding belt over sanding drums. Make sure the belt arrow located on the inside of the belt is pointed in the right direction.
7. Replace the belt exhaust cover (6) in position.

8. Replace and tighten the two screws (2, 3) and push the tension lever (4) in to apply belt tension.
9. Push the belt by hand and check if the sanding belt tends running to one side or the other of the two drums.
10. View from the switch end of sander, if the sanding belt runs toward disc, slightly turn the tracking knob (8) clockwise (down).
11. View from the switch end of sander, if the sanding belt runs away from the disc, slightly turn the tracking knob (8) counterclockwise (up).
12. Plug in the sander and turn the switch ON and OFF quickly to check if the sanding belt moves to either side. Re-adjust and fine-tune the belt tracking if necessary.

LUBRICATION
Ball bearings are grease packed at the factory and require no further lubrication. Use a paste wax to ensure smooth operation on all moving table parts. Do not use any lubrication on the belt plate as this might end up on the wheels, causing them to slip.

Troubleshooting

To avoid injury from an accidental start, turn the switch OFF and always remove the plug from the power source before making any adjustments.

Parts list