Belt Disc Sander: Important
Belt Disc Sander: Important
Model # 6502
bit.ly/wenvideo
IMPORTANT:
Your new tool has been engineered and manufactured to WEN’s highest standards for dependability,
ease of operation, and operator safety. When properly cared for, this product will supply you years
of rugged, trouble-free performance. Pay close attention to the rules for safe operation, warnings,
and cautions. If you use your tool properly and for intended purpose, you will enjoy years of safe,
reliable service.
TECHNICAL DATA
Model Number: 6502
Motor: 120 V, 60 Hz, 4.3 A, 1/2 HP
Speed: 3600 RPM (no load)
Disc Diameter: 6˝
Belt Size: 4˝ x 36˝
Belt Speed: 1900 SFM
Belt Bed Tilt: 0 to 90°
Belt Grit: A80
Dust Port Size: 2-1/4˝
Net Weight: 41 lb
2
Downloaded from www.Manualslib.com manuals search engine
GENERAL SAFETY RULES
Safety is a combination of common sense, staying alert and knowing how your item works. SAVE THESE
SAFETY INSTRUCTIONS.
WARNING: To avoid mistakes and serious injury, do not plug in your tool until the following
steps have been read and understood.
1. READ and become familiar with this entire instruction manual. LEARN the tool’s applications, limitations,
and possible hazards.
2. AVOID DANGEROUS CONDITIONS. Do not use power tools in wet or damp areas or expose them to
rain. Keep work areas well lit.
4. ALWAYS keep your work area clean, uncluttered, and well lit. DO NOT work on floor surfaces that are
slippery with sawdust or wax.
5. KEEP BYSTANDERS AT A SAFE DISTANCE from the work area, especially when the tool is operating.
NEVER allow children or pets near the tool.
6. DO NOT FORCE THE TOOL to do a job for which it was not designed.
7. DRESS FOR SAFETY. Do not wear loose clothing, gloves, neckties, or jewelry (rings, watches, etc.) when
operating the tool. Inappropriate clothing and items can get caught in moving parts and draw you in. ALWAYS
wear non-slip footwear and tie back long hair.
8. WEAR A FACE MASK OR DUST MASK to fight the dust produced by sawing operations.
WARNING: Dust generated from certain materials can be hazardous to your health. Always
operate the tool in a well-ventilated area and provide for proper dust removal. Use dust collection
systems whenever possible.
9. ALWAYS remove the power cord plug from the electrical outlet when making adjustments, changing parts,
cleaning, or working on the tool.
11. AVOID ACCIDENTAL START-UPS. Make sure the power switch is in the OFF position before plugging
in the power cord.
12. REMOVE ADJUSTMENT TOOLS. Always make sure all adjustment tools are removed from the saw
before turning it on.
13. NEVER LEAVE A RUNNING TOOL UNATTENDED. Turn the power switch to OFF. Do not leave
the tool until it has come to a complete stop.
3
Downloaded from www.Manualslib.com manuals search engine
GENERAL SAFETY RULES
14. NEVER STAND ON A TOOL. Serious injury could result if the tool tips or is accidentally hit. DO NOT store
anything above or near the tool.
15. DO NOT OVERREACH. Keep proper footing and balance at all times. Wear oil-resistant rubber-soled foot-
wear. Keep the floor clear of oil, scrap, and other debris.
16. MAINTAIN TOOLS PROPERLY. ALWAYS keep tools clean and in good working order. Follow instruc-
tions for lubricating and changing accessories.
17. CHECK FOR DAMAGED PARTS. Check for alignment of moving parts, jamming, breakage, improper
mounting, or any other conditions that may affect the tool’s operation. Any part that is damaged should be properly
repaired or replaced before use.
18. MAKE THE WORKSHOP CHILDPROOF. Use padlocks and master switches and ALWAYS remove start-
er keys.
19. DO NOT operate the tool if you are under the influence of drugs, alcohol, or medication that may affect your
ability to properly use the tool.
20. USE SAFETY GOGGLES AT ALL TIMES that comply with ANSI Z87.1. Normal safety glasses only have
impact resistant lenses and are not designed for safety. Wear a face or dust mask when working in a dusty environ-
ment. Use ear protection such as plugs or muffs during extended periods of operation.
1. This sander is designed to sand wood or wood-like products only. Sanding or grinding other materials could
result in fire, injury, or damage to the workpiece.
2. Use the sander on horizontal surfaces only. Operating the sander when mounted on non-horizontal surfaces may
result in motor damage or injury.
3. Fasten the sander securely to a bench top or supporting surface in order to stop it from tipping over or moving
when in use.
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.
7. Always hold the workpiece firmly when sanding. Keep hands away from sanding belt or disc. Sand only one
workpiece at a time.
4
Downloaded from www.Manualslib.com manuals search engine
SPECIFIC RULES FOR THE BELT/DISC SANDER
8. Always hold the workpiece firmly on the table when using the disc sander and when using the belt sander.
9. Always sand on the downward side of the sanding disc when using the disc sander. Sanding on the upward side
of the disc can cause the workpiece to fly out of position, resulting in injury.
10. Always maintain a minimum clearance of 1/16 inch (1.6 mm) or less between the table or backstop and the
sanding belt or disc.
11. Do not sand pieces of material that are too small to be safely supported.
12. When sanding a large workpiece, provide additional table height support.
13. Do not sand with the workpiece unsupported. Support the workpiece with the backstop or table. The only ex-
ception is curved work performed on the outer sanding drum.
14. Always remove scrap pieces and other objects from the table, backstop, or belt before turning the sander ON.
15. Never perform layout, assembly or set-up work on the table while the sander is operating.
16. Never use solvents to clean plastic parts. Solvents could dissolve or otherwise damage the material. Use only a
soft damp cloth to clean plastic parts.
17. Should any component of your sander be missing/damaged or fail in any way, shut off switch and remove plug
from power supply outlet. Replace the missing, damaged, or failed parts before resuming operation.
18. Never pull the power cord out of the receptacle. Keep cords away from heat, oil, and sharp edges.
ELECTRICAL INFORMATION
GROUNDING INSTRUCTIONS
IN THE EVENT OF A MALFUNCTION OR BREAKDOWN, grounding provides the path of least resistance
for an electric current and reduces the risk of electric shock. This tool is equipped with an electric cord that has an
equipment grounding conductor and a grounding plug. 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
licensed electrician.
IMPROPER CONNECTION of the equipment grounding conductor can result in electric shock. The conduc-
tor with the green insulation (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.
5
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL INFORMATION
CHECK with a licensed electrician or service personnel if you do not completely understand the grounding
instructions or whether the tool is properly grounded.
WARNING: This tool is for indoor use only. Do not expose to rain or use in damp locations.
Guidelines for using 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 cause a drop in line
voltage resulting in loss of power and overheating. The table below shows the correct size to be used ac-
cording to cord length and nameplate ampere rating. When in doubt, use a heavier cord. The smaller the
gauge number, the heavier the cord.
Make sure your extension cord is properly wired and in good condition. Always replace a damaged exten-
sion cord or have it repaired by a qualified person before using it.
REQUIRED GAUGE FOR EXTENSION CORDS
AMPERAGE
25 ft. 50 ft. 100 ft. 150 ft.
4.3 A 18 gauge 16 gauge 16 gauge 14 gauge
Protect your extension cords from sharp objects, excessive heat and damp/wet areas.
Use a separate electrical circuit for your tools. This circuit must not be less than a #12 wire and should be
protected with a 15 A time-delayed fuse. Before connecting the motor to the power line, make sure the
switch is in the OFF position and the electric current is rated the same as the current stamped on the motor
nameplate. Running at a lower voltage will damage the motor.
WARNING: This tool must be grounded while in use to protect the operator from electric shock.
6
Downloaded from www.Manualslib.com manuals search engine
KNOW YOUR BELT/DISC SANDER
SANDING
BELT
DRIVE
DRUM
WORK SUPPORT
BELT SANDING
BELT TENSION
AREA
LEVER TRACKING
CONTROL
KNOB
TABLE ANGLE
ADJUSTMENT
DUST PORT
KNOB
BASE BOLD-DOWN
AREA
MITER
GAUGE
SANDING
DISC SANDING DISC ON/OFF
AREA SWITCH
UNPACKING
WARNING: To avoid injury from accidental startups, turn switch OFF and remove the plug
from the power source outlet before making any adjustments.
Carefully unpack the belt/disc sander and all its parts, and compare against the list below. Do not discard
the carton or any packaging until the belt/disc sander is completely assembled.
INCLUDES (Fig. 1)
7
Downloaded from www.Manualslib.com manuals search engine
ASSEMBLY AND ADJUSTMENTS
ASSEMBLY
1. With the table in a horizontal position, line up and insert the pivot indexing pin with the pivot hole on the
frame. Hold in place.
3. Adjust the table so that the edge is a maximum of 1/16 inch from the disc. Holding the table in this position,
tighten the three bolts on the top of the table.
WARNING: To avoid trapping the workpiece or fingers between the table and the sanding disc, the
table edge should be adjusted to a maximum of 1/16 inch from the sanding disc.
8
Downloaded from www.Manualslib.com manuals search engine
ASSEMBLY AND ADJUSTMENTS
MOUNTING THE WORK SUPPORT
WRENCH
1. Align the Work Support with the hole.
3. Insert the Hex Screw into the Work Support hole. Tighten.
Note: All bolts should be inserted from the top. Washers and
hex nuts should be fastened from the underside of the work-
bench.
4. Place the sanding belt over the drums with the direc-
tional arrow pointing towards the dust chute.
The sanding bed can be used in the horizontal or vertical positions or any angle in between. To use in the vertical
position, do the following:
1. Loosen the bed locking screw with hex key, move the bed to the desired vertical position.
2. Tighten the locking screw when at desired position.
The dust port can be easily connected to a large diameter shop vacuum hose.
Sanding operations are inherently dusty. To help minimize the amount of dust that escapes into the surrounding
air, this sander is equipped with a 2-1/4” dust chute that can be easily connected to a dust-collection system. It is
strongly recommended that users employ a dust-collection system when using this belt & disc sander.
Use of a mask or respirator is still recommended even when a dust-collection system is in use.
1. Remove the two screws from the sanding disc guard and remove the guard.
4. Peel the backing from the new sanding disc, align the disc with the
plate and press the sanding disc firmly on to the plate.
3. If the table is not 90° to the sanding surface, loosen the han-
dle (4), adjust the table, tighten the handle and recheck with the
square.
The work support (2) must be square to the sanding belt when
using the belt sander in a horizontal position. To keep the work-
piece from being carried along the belt:
1. Make sure the sanding belt is tight; also check that the tension
lever is fully tightened.
2. Place the combination square (1) on the belt with the ruler
against the work support (2).
11
Downloaded from www.Manualslib.com manuals search engine
OPERATION
ON/OFF SWITCH
2. Push key firmly into the slot, then push switch to the ON
position to start the sander.
Hold the workpiece firmly with both hands. Keep fingers away from
sanding belt. Keep the workpiece end against the backstop and move
it slowly across the sanding belt. Apply enough pressure to remove
material; excessive pressure will reduce sanding efficiency.
Note: Use extra caution when sanding very thin pieces, and apply
only enough pressure to allow the sanding belt to remove the mate-
rial.
12
Downloaded from www.Manualslib.com manuals search engine
OPERATION
Use for sanding the ends of small and narrow workpieces and
outside curved edges. Always work on the left side of the disc
(downward rotation side), holding the workpiece firmly with
light pressure against the sanding disc.
Your belt & disc sander can sand vertically as well as horizontally. Depending on the operator’s needs and the
workpiece, the work-support can be used with either the horizontal or vertical position.
Operational Note: Sand long workpieces with the sanding belt in the vertical position by moving the work
evenly across the sanding belt.
BED-LOCKING SCREW
13
Downloaded from www.Manualslib.com manuals search engine
OPERATION
MITER GAUGE - DISC SANDER
A miter-gauge is supplied with your sander, and can be used on the disc table. The miter gauge head can be set
anywhere up to 60º (right or left) by loosening the lock-knob, setting the miter gauge head to the desired angle,
and retightening the lock-knob.
SANDING SMALL END GRAIN AND OTHER SMALL SURFACES USING MITER GAUGE
Use of the miter gauge is recommended for sanding small end surfaces on the sanding disc.
Note: Always move the workpiece across the sanding disc from the left side towards the right side, and be sure to
hold the workpiece down tightly onto the table surface.
MAINTENANCE
WARNING: For your own safety, turn the switch OFF and remove the plug from the electrical outlet before
adjusting or performing maintenance or lubrication work on the belt/disc sander.
Before using, check to make sure parts are not damaged, missing, or worn. Check for alignment of moving parts,
binding of moving parts, improper mounting, or any other conditions that may affect the sander operation. If any
of these conditions exist, do not use the sander until parts are replaced or the sander is properly repaired. Fre-
quently blow or vacuum dust from all sanding parts and motor housing.
WARNING: Any attempt to repair or replace electrical parts on this tool may be hazardous. Repairs should be
done by a qualified service technician.
LUBRICATION
Ball bearings are grease packed at the factory and require no further lubrication. Use a spray lubricant on all mov-
ing table parts to ensure smooth operation.
2. Loosen the 3 screws (2) allowing the pulley to slip and the drive belt (3) to
loosen. The drive belt should be seated correctly in the motor pulley and the
drive pulley.
3. Adjust the tension of the belt by putting a slotted screwdriver in the brac-
ing slot (4). Pushing up on the screwdriver will tighten the tension of the belt
between the pulleys.
5. Test belt tension by squeezing both sides of the belt. If properly adjusted,
the belt should “give” between 1/8–1/4 inch (3–6 mm). Make sure that the
belt teeth are properly seated in the pulley gears.
6. Carefully reinstall the drive belt housing cover (1). Insert and tighten screw.
Note: Excessive tightness on the pulley belt will cause increased noise and motor overload. Premature failure will
occur if belt is too loose.
14
Downloaded from www.Manualslib.com manuals search engine
TROUBLESHOOTING
15
Downloaded from www.Manualslib.com manuals search engine
TROUBLESHOOTING
16
Downloaded from www.Manualslib.com manuals search engine
EXPLODED VIEW AND PARTS LIST
17
Downloaded from www.Manualslib.com manuals search engine
EXPLODED VIEW AND PARTS LIST
18
Downloaded from www.Manualslib.com manuals search engine
LIMITED TWO YEAR WARRANTY
WEN Products is committed to building tools that are dependable for years. Our warranties are consistent with
this commitment and our dedication to quality.
LIMITED WARRANTY OF WEN CONSUMER POWER TOOLS PRODUCTS FOR HOME USE
GREAT LAKES TECHNOLOGIES, LLC (“Seller”) warrants to the original purchaser only, that all WEN con-
sumer power tools will be free from defects in material or workmanship for a period of two (2) years from date of
purchase. Ninety days for all WEN products, if the tool is used for professional use.
SELLER’S SOLE OBLIGATION AND YOUR EXCLUSIVE REMEDY under this Limited Warranty and, to
the extent permitted by law, any warranty or condition implied by law, shall be the repair or replacement of parts,
without charge, which are defective in material or workmanship and which have not been misused, carelessly
handled, or misrepaired by persons other than Seller or Authorized Service Center. To make a claim under this
Limited Warranty, you must make sure to keep a copy of your proof of purchase that clearly defines the Date of
Purchase (month and year) and the Place of Purchase. Place of purchase must be a direct vendor of Great Lakes
Technologies, LLC. Third party vendors such as garage sales, pawn shops, resale shops, or any other secondhand
merchant void the warranty included with this product. Contact [email protected] or 1-800-232-
1195 to make arrangements for repairs and transportation.
When returning a product for warranty service, the shipping charges must be prepaid by the purchaser. The prod-
uct must be shipped in its original container (or an equivalent), properly packed to withstand the hazards of ship-
ment. The product must be fully insured with a copy of the warranty card and/or the proof of purchase enclosed.
There must also be a description of the problem in order to help our repairs department diagnose and fix the
issue. Repairs will be made and the product will be returned and shipped back to the purchaser at no charge.
THIS LIMITED WARRANTY DOES NOT APPLY TO ACCESSORY ITEMS THAT WEAR OUT FROM
REGULAR USAGE OVER TIME INCLUDING BELTS, BRUSHES, BLADES, ETC.
ANY IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO TWO (2) YEARS FROM
DATE OF PURCHASE. SOME STATES IN THE U.S., SOME CANADIAN PROVINCES DO NOT AL-
LOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITA-
TION MAY NOT APPLY TO YOU.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE
IN CANADA AND FROM COUNTRY TO COUNTRY.
THIS LIMITED WARRANTY APPLIES ONLY TO PORTABLE ELECTRIC TOOLS, BENCH POW-
ER TOOLS, OUTDOOR POWER EQUIPMENT AND PNEUMATIC TOOLS SOLD WITHIN THE
UNITED STATES OF AMERICA, CANADA AND THE COMMONWEALTH OF PUERTO RICO. FOR
WARRANTY COVERAGE WITHIN OTHER COUNTRIES, CONTACT THE WEN CUSTOMER SUP-
PORT LINE.
19
Downloaded from www.Manualslib.com manuals search engine
Thanks for remembering