Operating Instructions & Parts Manual EN

Sander,6 x 10˝ Belt/Disc

Model 49G991A

9638112.01

49G991A_oipm_En022_9638112.01 07/26/17 4:38 PM Page 1

PLEASE READ AND SAVE THESE INSTRUCTIONS.

READ CAREFULLY BEFORE ATTEMPTING

TO ASSEMBLE, INSTALL, OPERATE OR MAINTAIN THE

PRODUCT DESCRIBED.

PROTECT YOURSELF AND OTHERS BY OBSERVING ALL

SAFETY INFORMATION. FAILURETO COMPLY WITH INSTRUCTIONS

COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY

DAMAGE! RETAIN INSTRUCTIONSFOR FUTURE REFERENCE.

PLEASE REFER TO BACK COVERFOR INFORMATION REGARDING

DAYTON’S WARRANTY AND OTHER IMPORTANT

INFORMATION.

Model #: ___________________

Serial #: ____________________

Purch. Date: ________________

Form 5S7479 / Printed in Taiwan04634 Version 0.1 06/2017

© 2014 Dayton Electric Manufacturing Co.All Rights Reserved

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GETTING STARTED

Structural requirements

Make sure all supporting structures and load attachingdevices are strong enough to hold your intended loads. Ifin doubt, consult a qualified structural engineer.

Electrical requirements

The power supply to the Sander needs to be 120 volt/13.5 amp or 240 volt/ 6.7 amp, single phase, 60 Hz. Thestandard allowable voltage variation is plus or minus 10%.

Tools Needed:

Standard mechanic’s hand tool set.

UNPACKINGBe careful not to touch overhead powerlines, piping, lighting, etc. if lifting

equipment is used. Sander weighs approximately 178 lbs,proper tools, equipment and qualified personnel should beemployed in all phases of unpacking and installation.

Crates should be handled with care to avoid damage fromdropping, bumping, etc. Store and unpack crates with correct sideup. After unpacking, inspect carefully for any damage that mayhave occurred during transit. Check for loose, missing or damagedparts. If any damage or loss has occurred, claim must be filed withcarrier immediately. Check for completeness. Immediately reportmissing parts to dealer.

Contents:

The sander comes assembled as one unit. Additional parts whichneed to be fastened to sander, should be located and accountedfor before assembling.

• Belt/Disc Sander (1)

• Abrasive disc (1)

• Belt table with trunnion (1)

• Miter gauge assembly (1)

• Workstop (1)

• Handle (2)

• Intake port cap (1)

• Operating Instructions & Parts Manual (1)

Parts bag includes: one 8mm flat washer, four foot rest assemblies,6mm hex wrench and 4mm long hex wrench.

Unpack:

• Unbolt sander from pallet and carefully lift sander frompallet using appropriate hoisting equipment. Do not

discard packing materials until after machine has been inspectedfor damage and completeness. Locate loose parts and set aside.

Inspect:

• After unpacking the unit, carefully inspect for anydamage that may have occurred during transit. Check forloose, missing or damaged parts. Shipping damageclaims must be filed with the carrier.

• All tools should be visually inspected before use, in addition toregular periodic maintenance inspections.

• Be sure that the voltage labeled on the unit matches yourpower supply.

• See General Safety Instructions, Cautions andWarnings as shown.

SAFETY RULESFor your own safety, read all of theinstructions and precautions before

operating tool.

PROPOSITION 65 WARNING: Some dust created byusing power tools contain chemicals known to the stateof California to cause cancer, birth defects or other

reproductive harm.

Some examples of these chemicals are:

• Lead from lead-based paints.

• Crystalline silica from bricks and cement and other masonryproducts.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often youdo this type of work. To reduce your exposure to these chemicals:work in a well ventilated area and work with approved safetyequipment. Always wear OSHA/NIOSH approved, properly fittingface mask or respirator when using such tools.

Always follow proper operatingprocedures as defined in this manual even

if you are familiar with the use of this or similar tools.Remember that being careless for even a fraction of asecond can result in severe personal injury.

Be prepared for job

• Wear proper apparel. Do not wear loose clothing, gloves,neckties, rings, bracelets or other jewelry which may getcaught in moving parts of machine.

• Wear protective hair covering to contain long hair.

• Wear safety shoes with non-slip soles.

• Wear safety glasses complying with United States ANSI Z87.1.Everyday glasses have only impact resistant lenses. They areNOT safety glasses.

• Wear face mask or dust mask if operation is dusty.

• Be alert and think clearly. Never operate power tools whentired, intoxicated or when taking medications that causedrowsiness.

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SAFETY RULES (CONTINUED)

Prepare work area for job

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

• Do not use power tools in dangerous environments. Do notuse power tools in damp or wet locations. Do not exposepower tools to rain.

• Work area should be properly lighted.

• Proper electrical receptacle should be available for tool. Three-prong plug should be plugged directly into properly grounded,three-prong receptacle.

• Extension cords should have a grounding prong and the threewires of the extension cord should be of the correct gauge.

• Keep visitors at a safe distance from work area.

• Keep children out of workplace. Make workshop childproof.Use padlocks, master switches or remove switch keys toprevent any unintentional use of power tools.

Tool should be maintained

• Always unplug tool prior to inspection.

• Consult manual for specific maintaining and adjustingprocedures.

• Keep tool lubricated and clean for safest operation.

• Remove adjusting tools. Form habit of checking to see thatadjusting tools are removed before switching machine on.

• Keep all parts in working order. Check to determine that theguard or other parts will operate properly and perform theirintended function.

• Check for damaged parts. Check for alignment of movingparts, binding, breakage, mounting and any other conditionthat may affect a tool’s operation.

• A guard or other part that is damaged should be properlyrepaired or replaced. Do not perform makeshift repairs. (Useparts list provided to order repair parts.)

Know how to use tool

• Use right tool for job. Do not force tool or attachment to do ajob for which it was not designed.

• Disconnect tool when changing the abrasive belt or disc.

• Avoid accidental start-up. Make sure that the switch is in theOFF position before plugging in.

• Do not force tool. It will work most efficiently at the rate forwhich it was designed.

• Keep hands away from moving parts and sanding surfaces.

• Never leave tool running unattended. Turn the power off anddo not leave tool until it comes to a complete stop.

• Do not overreach. Keep proper footing and balance.

• Never stand on tool. Serious injury could occur if tool is tippedor if belt or disc are unintentionally contacted.

• Know your tool. Learn the tool’s operation, application andspecific limitations.

• Use recommended accessories. Use of improper accessoriesmay cause risk of injury to persons.

• Handle workpiece correctly. Protect hands from possible injury.

• Turn machine off if it jams. Belt jams when it digs too deeplyinto workpiece. (Motor force keeps it stuck in the work.) Do notremove jammed or cut off pieces until the sander is turned off,unplugged and the belt has stopped.

• Support workpiece with miter gauge, belt platen or work table.

• Maintain 1/16˝ maximum clearance between table and sandingbelt or disc.

Think safety! Safety is a combination ofoperator common sense and alertness at

all times when tool is being used.

SPECIFICATIONS

Belt size 6 x 48˝Belt platen area 61⁄4 x 163⁄4˝Belt table dimensions 6 x 101⁄8˝Belt table tilts -20° to 45°Belt dust chute diameter 4˝Belt speed 1470 SFPMDisc diameter 10˝Disc table dimensions 7 x 14˝Disc table tilts 0 to 45º outward, 0 to 20° inwardDisc dust chute diameter 4˝Disc speed 1880 RPMBase dimensions 23 x 21 x 58˝Switch 120 Volts, SPMotor 1 HP, 3450 RPM,

120/240V, 13.5/6.7 Amps, 60 HzWeight 178 lbsShipping weight 207 lbs

ASSEMBLYDo not attempt assembly if parts aremissing.Use this manual to order

replacement parts.

Before sander is assembled, a suitable location should be chosen.The sander with cabinet weighs approximately 200 lbs whencompletely assembled. They should be assembled on location.

• Sander needs to be set on a flat, level surface.

• Make sure there is ample room for moving the workpiece.There must be enough room that neither the operator nor thebystanders will have to stand in line while using the tool. Allowroom so belt assembly can be positioned horizontally.

• Good lighting and correct power supply are also required for aproper work area.

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ASSEMBLY (CONTINUED)

Adjust belt housing to vertical position

Refer to Figures 10 and 11, pages 10 and 12.

1. Move to the front of the sander; loosen and remove four knobs(Figure 11, Ref. Nos. 18 and 21).

2. Remove dust hoods (Figure 11, Ref. Nos. 19 and 20).

3. Loosen both hex nuts (Figure 10, Ref. No. 8) on the belthousing casting (Figure 10, Ref. No. 34). Do not take out hexnut.

4. Move to the rear of the sander and gently lift the belt housingup supporting the housing from both sides.

5. Lift belt housing until it is adjusted to the vertical position.

6. Tighten both hex nuts (Figure 10, Ref. No. 8) from the rear ofthe sander.

7. Replace dust hood and tighten knobs.

Attach foot rests

Refer to Figure 11.

Required parts and hardware:

• Four foot rest assembliesSander with cabinet weighsapproximately 200 lbs. At least two

people are required to attach foot rests.

1. Carefully tip the sander to raise cabinet from the floor justenough so that one foot rest with bolt can be positioned underthe cabinet corner so that the bolt slides through the hole onthe cabinet base. Slowly set the sander back to the floor.Repeat three more times to position one foot rest with boltunder each of the cabinet corner.

2. Loosen knob (Ref. No. 52) and open cabinet door (Ref. No.53).

3. Using the cabinet door opening, secure foot rests to cabinetusing four flat washers and four hex nuts.

4. Make sure all the hex nuts are tight.

5. Close cabinet door and secure it with knob.

Attach belt table

Refer to Figures 1 and 10.

Required parts and hardware:

• Belt table with trunnion

• Handle

• 8mm Flat washer

1. Position belt table (Ref. No. 54) on the belt housing (Ref. No.34) so that the trunnion (Ref. No. 55) travels on the slide (Ref.No. 29).

2. Set the belt table position so that the 0° mark on the trunnion isaligned with the pointer (Ref. No. 26).

3. Secure belt table position using the handle and flat washer

(Ref. Nos. 57 and 58). Tighten handle into the threaded hole onthe belt housing.

4. Sander is shipped with the belt tension handle (Ref. No. 31) atthe released position. Pull down the handle toward the belttable to tension the belt.

• Make sure that the clearance between the belt and belt tabledoes not exceed 1/16˝.

• Wear protective glove and manually push the belt to verify thatbelt travels smoothly and without interference.

Position disc table

Refer to Figure 10.

Required part: Handle

Sander is shipped with the disc table (Ref. No. 4) attached to thedisc guard (Ref. No. 61) using a handle with flat washer (Ref. Nos.57 and 58) one side and a hex head bolt with flat washer on theother side.

1. Loosen and remove hex head bolt and flat washer from thedisc table.

2. Replace hex head bolt with the handle provided. Secure disctable to disc guard using the handle and flat washer.

Attach abrasive disc to aluminum disc

Refer to Figures 2, 3 and 10.

Sander is shipped with the abrasive (Ref. No. 67) not applied to thealuminum disc (Ref. No. 66).

1. Clean the aluminum disc if necessary prior to applying theabrasive.

2. Remove the adhesive cover from the back of the abrasive disc.

3. Slide the abrasive between the disc table and aluminum discand center abrasive on the aluminum disc.

4. Apply pressure on abrasive to paste.

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Figure 1 – Attach belt table

Belt tension handle

Table lock handle

Figure 2 – Attach abrasive disc

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ASSEMBLY (CONTINUED)5. Make sure abrasive is pasted evenly on the aluminum disc.

• Make sure that the clearance between disc table and abrasivedisc does not exceed 1/16˝.

• Use a straight edge or square to check if the disc table is atright angle to the disc.

• Wear a protective glove and manually turn the disc to verifythat the disc turns freely and without interference.

ATTACH MITER GAUGE

Refer to Figures 10 and 11.

Required part: Miter gauge assembly

• Miter gauge is shipped completely assembled (Fig. 11, Ref.No. 1) and can be used with the belt or disc tables (Fig. 10,Ref. Nos. 4 and 54).

• Slide miter gauge bar (Fig. 11, Ref. No. 15) into the slot on beltor disc table.

INSTALLATIONRefer to Figures 4, 5 and 6.

All electrical connections must beperformed by a qualified electrician.

Power source

The motor is designed for operation on the voltage and frequencyspecified. Normal loads will be handled safely on voltages not morethan 10% above or below the specified voltage.

Running the unit on voltages which are not within the range maycause overheating and motor burnout. Heavy loads require thatvoltage at motor terminals be no less than the voltage specified onnameplate. Power supply to the motor is controlled by a single polelocking rocker switch. Remove the key to prevent unauthorizeduse.

Grounding instructionsImproper connection of equipmentgrounding conductor can result in the risk

of electrical shock. Equipment should be grounded while inuse to protect operator from electrical shock.

• Check with a qualified electrician if grounding instructions arenot understood or if in doubt as to whether the tool is properlygrounded.

• This tool is equipped with an approved 3-conductor cord ratedat 300V and a 3-prong grounding type plug (See Figure 4) foryour protection against shock hazards.

• Grounding plug should be plugged directly into a properlyinstalled and grounded 3-prong grounding-type receptacle, asshown (Figure 4).

• Do not remove or alter grounding prong in any manner. In theevent of a malfunction or breakdown, grounding provides apath of least resistance for electrical shock.

Do not permit fingers to touch theterminals of plug when installing or

removing from outlet.

• Plug must be plugged into matching outlet that is properlyinstalled and grounded in accordance with all local codes andordinances. Do not modify plug provided. If it will not fit inoutlet, have proper outlet installed by a qualified electrician.

• Inspect tool cords periodically, and if damaged, have repairedby an authorized service facility.

• Green (or green and yellow) conductor in cord is the groundingwire. If repair or replacement of the electric cord or plug isnecessary, do not connect the green (or green and yellow) wireto a live terminal.

• Where a 2-prong wall receptacle is encountered, it must bereplaced with a properly grounded 3-prong receptacle installedin accordance with National Electric Code and local codes andordinances.

This work should be performed by aqualified electrician.

• A temporary 3-prong to 2-prong grounding adapter (See Figure5) is available for connecting plugs to a two pole outlet if it isproperly grounded.

• Do not use a 3-prong to 2-prong grounding adapter unlesspermitted by local and national codes and ordinances.

(A 3-prong to 2-prong grounding adapter is not permitted inCanada.) Where permitted, the rigid green tab or terminal onthe side of the adapter must be securely connected to apermanent electrical ground such as a properly groundedwater pipe, a properly grounded outlet box or a properlygrounded wire system.

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Figure 4 – 3-Prong receptacle

Properly grounded outlet

Grounding prong

3-Prong plug

Figure 5 – 2-Prong receptacle with adapter

Grounding lug

Adapter

3-Prong plug2-Prongreceptacle

Make sure this isconnected to a knowngrounded receptacle

Figure 3 - Check disc table

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INSTALLATION (CONTINUED)• Many cover plate screws, water pipes and outlet boxes are not

properly grounded. To ensure proper ground, grounding meansmust be tested by a qualified electrician.

Extension cords

• The use of any extension cord will cause some drop in voltageand loss of power.

• Wires of the extension cord must be of sufficient size to carrythe current and maintain adequate voltage.

• Running the unit on voltages which are not within ±10% of thespecified voltage may cause overheating and motor burn-out.

• Use the table to determine the minimum wire size (A.W.G.)extension cord.

• Use only 3-wire extension cords having 3-prong groundingtype plugs and 3-pole receptacles which accept the tool plug.

• If the extension cord is worn, cut or damaged in any way,replace it immediately.

Extension cord length (120 volts)

Wire Size A.W.G.Up to 25 ft. 1425 – 50 ft. 12

NOTE: Using extension cords over 50 ft. long is not recommended.

Extension cord length (240 volts)

Wire Size A.W.G.Up to 50 ft. 1850 – 100 ft. 16100 – 200 ft. 14200 – 300 ft. 12

NOTE: Using extension cords over 300 ft. long is notrecommended.

Electrical connectionsWARNING: All electrical connections must be performedby a qualified electrician. Make sure tool is off anddisconnected from power source while motor is mounted,connected, reconnected or anytime wiring is inspected.

• Motor and wires are installed as shown in wiring diagram (SeeFigure 6). Motor is assembled with approved, 3-conductor cordto be used at 120/240 volts. Motor is prewired at the factory for120 volts.

Sander has a locking rocker switch with removable key for safe andeasy operation

• Remove the key from the locking rocker to preventunauthorized use of the tool.To replace the key, press key intothe slot on the locking rocker.

• To use the sander witha 240V power supply, have a qualifiedelectrician rewire motor and attach a 240 volt three-prongplug onto sander line cord.

Recommended Dayton plugs, connectors and receptacles for 240volts:

20 Amps 250 Volts NEMA L6-20Plug Connector Receptacle5A081 5A082 5A080

Sander also has a thermal overload protector to prevent damage tomotor and other electrical components. The thermal overloadprotector will get activated when high temperature conditions areobserved while operating the tool. This will turn the tool off toprevent temperature buildup. If that occurs, give adequate time forthe sander to cool down and depress the reset button once. Thetool will be ready to operate.

OPERATIONRefer to Figure 7 – 11.

Operation of any power tool can result inforeign objects being thrown into eyes

which can result in severe eye damage. Always wear safetygoggles complying with United States ANSI Z87.1 (shown onpackage) before commencing power tool operation.

Always observe the following safetyprecautions:

• Whenever adjusting or replacing any parts on the tool, turnswitch OFF and remove the plug from power source.

• Recheck table handles. They must be tightened securely.

• Make sure all guards are properly attached and securelyfastened.

• Make sure all moving parts are free and clear of anyinterference.

• Make sure all fasteners are tight and have not vibrated loose.

• With power disconnected, test operation by hand to verifyclearance and adjust if necessary.

• Always wear eye protection or face shield.

• Make sure abrasive belt tracks properly. Correct tracking givesoptimum performance.

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Figure 6 – Wiring diagram

3-Red 2-Gray

4-Yellow1-Black

120V

240V

3-Red

1-Black

2-Gray

4-Yellow

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OPERATION (CONTINUED)• After turning switch ON, always allow belt to come up to full

speed before sanding or grinding.

• Be sure motor runs clockwise on disc side. Abrasive belt musttravel down.

• Keep your hands clear of abrasive belt, disc and all movingparts.

• For optimum performance, do not stall motor or reduce speed.Do not force the work into the abrasive.

• Support workpiece with belt table when sanding with belt, withdisc table when sanding with disc.

• Never push a sharp corner of workpiece rapidly against belt ordisc. Abrasive backing may tear.

• Replace abrasives when they become loaded (glazed) orfrayed.

• When grinding metal, move workpiece across abrasive toprevent heat build-up.

• Never attempt wet sanding. If workpiece becomes too hot tohandle, cool it in water.

Position belt table

Refer to Figures 7 and 10.

The belt table (Ref. No. 54) can be tilted from 0° (at right angle tothe table) to 45°. To adjust belt table position:

1. Unlock the handle (Ref. No. 58) on the right side of table.

2. Set the belt table to any angle between 0° and 45° using thescale.

3. Lock the handle to secure belt table position.

Work stop

Refer to Figure 10.

The work stop (Ref. No. 23) can be used instead of the belt table.

1. Remove belt table from the belt housing (Ref. No. 34) byloosening and removing handle (Ref. No. 58).

2. Mount workstop using bolt (Ref. No. 22) and washer (Ref. No.21) which are located on belt housing.

Adjusting belt housing

Refer to Figures 8, 10 and 11.

The belt housing (Figure 10, Ref. No. 34) can be positioned at a fullvertical position, a full horizontal position, or at any angle inbetween which is convenient for the sanding operation.

To adjust belt housing position:

1. Loosen and remove four knobs (Figure 11, Ref. Nos. 18 and21).

2. Remove dust hoods (Figure 11, Ref. Nos. 19 and 20).

3. Loosen hex nuts (Figure 10, Ref. No. 8).

4. Move to the rear of the sander.

5. Gently push belt housing to move to the desired angle.

6. A positive stop bolt (Figure 11, Ref. No. 26) is provided to stopthe belt housing at the full horizontal position.

7. Tighten both hex nuts (Figure 10, Ref. No. 8) to secure belthousing position.

8. Replace dust hoods using the knobs.

Horizontal belt sanding

Refer to Figures 8 and 10.

1. Adjust the belt housing to full horizontal position as describedin the above section, “Adjusting Belt Housing˝.

2. Remove the belt table by removing handle (Ref. No. 58).

3. Install work stop as described in “Work Stop˝.

4. Idler drum (Ref. No. 44) can be used as a contact drum tosand curved surfaces. (Removing belt guard [Ref. No. 50] willbe required.)

Abrasive belt finishing

• Finishing flat surfaces: Hold workpiece firmly with both hands;keep fingers away from abrasive belt.

• Use work stop. Work stop is used to position and secure workbeing sanded. Keep end butted against work stop and movework evenly across abrasive belt. Use extra caution whenfinishing very thin pieces.

• Finishing long pieces: remove work stop. Apply only enoughpressure to allow abrasive belt to remove material.

• Finishing curved edges: Finish outside curves on flat portion ofabrasive belt. Finish inside curves on idler drum portion ofabrasive belt.

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Figure 8 - Horizontal belt sanding

Figure 7 - Position belt table

Table lock handle

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OPERATION (CONTINUED)• Finishing end grain: It is more convenient to finish ends of long

workpieces with the abrasive belt in a vertical position.

• Move work evenly across the belt.

• For accuracy use miter gauge.

• Adjust belt table angle for beveled work.

Using miter gauge

Refer to Figure 11.

The miter gauge is used on either the disc or belt table. Use themiter gauge for securing the work and holding the proper anglewhile sanding.

• Adjust angle by repositioning the miter gauge (Ref. No. 5).

1. Loosen the knob (Ref. No. 2) to reposition miter gauge.

2. Tighten the knob to secure miter gauge position.

• Miter gauge assembly has a positive stop set-up for 90° and45° on either side. To use the positive stop:

1. Loosen the knob, retract the indexing pin (Ref. No. 16),turn the miter gauge slightly, slide in indexing pin and turnthe miter gauge until the edge of the screw (Ref. No. 12) isstopped by the indexing pin.

• Check accuracy of miter gauge scale (Ref. No. 9).

1. Use a combination square to adjust miter gauge square todisc. Scale should be at zero. Loosen screw (Ref. No. 7)and reposition scale if necessary.

Belt tracking

Refer to Figures 9 and 10.

Belt (Ref. No. 1) should ride centered on drive and idler drums(Ref. Nos. 11 and 44). The sander is shipped with the trackingmechanism properly adjusted. However, if adjustment is necessary:

1. Loosen knob (Ref. No. 33) on either side of belt housing (Ref.No. 34).

2. Turn the unit on.

3. Insert a 1/8˝ or 5/32˝ hex wrench into the hole on adjusting nut(Ref. No. 42 or 47) on either side.

4. Turn the adjusting nut to the right to move belt toward you orturn the adjusting nut to the left to move belt away from you.

5. Make sure belt rides on the center of drive and idler drums.

6. Turn the unit off.

7. Tighten knobs on both sides of belt housing to secure trackingadjustment.

Replacing belt

Refer to Figure 10.

Sanding belt must be replaced when worn, torn, or glazed.

1. Push up the belt tension handle (Ref. No. 31) to release belt tension.

2. Loosen knob (Ref. No. 46) securing belt guard (Ref. No. 50).

3. Loosen and remove four knobs (Ref. No. 49) from the rear ofthe sander.

4. Remove belt cover (Ref. No. 48).

5. Remove knob and bracket (Ref. Nos. 2 and 3).

6. Slide old belt off the drive and idler drums (Ref. Nos. 11 and44).

NOTE: There may be an arrow on the inside of the belt. The arrowshould point down toward the belt table to ensure that the splice inthe belt will not come apart.

7. Slide new belt over the drive and idler drums; center belt ondrums.

8. Push the belt tension handle toward the drive drum to tensionbelt.

9. Replace belt cover using knobs.

10. Replace belt guard and bracket.

11. Wear a protective glove and manually rotate the belt by handto check tracking. If tracking needs to be adjusted, follow stepsdescribed in “Belt Tracking˝.

12. Make sure belt rides centered on drive and idler drums.

Position disc table

Refer to Figure 10.

Disc table (Ref. No. 4) is adjustable from 0° to 45° outward and 0°to 20° inward. To adjust the disc table position:

1. Loosen the two handles (Ref. No. 58) from either side of thedisc table.

2. Use the scale on disc table trunnions to set table at the desiredangle.

3. Secure disc table position by tightening the two handles.

Abrasive disc finishing

• Abrasive disc sanding is well suited for finishing small flatsurfaces and convex edges.

• Move workpiece across down side (left) of abrasive disc.

• Abrasive disc moves fastest and removes more material atouter edge.

• For accuracy, use miter gauge.

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Figure 9 - Belt tracking

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OPERATION (CONTINUED)

Replacing abrasive disc

Refer to Figures 10 and 11.

1. Loosen and remove four bolts (Figure 10, Ref. No. 24) fromdisc cover plate (Figure 10, Ref. No. 68).

2. Loosen two top bolts (Figure 11, Ref. No. 25) from dust collection port (Figure 11, Ref. No. 32).

3. Remove disc cover plate.

4. Remove old abrasive by peeling it from the aluminum disc.Removing aluminum disc is not necessary.

5. Clean aluminum disc if necessary. Select the proper abrasivedisc and apply to aluminum disc.

6. Additional abrasive discs are available.

7. Replace disc cover plate.

8. Tighten bolts on dust collection port.

9. Replace four bolts to secure disc cover plate.

MAINTENANCEMake certain that the unit isdisconnected from power source before

attempting to service or remove any component.

Replacing V-belt

Refer to Figures 10 and 11.

1. Turn sander off and disconnect it from power source.

2. Loosen and remove two handles (Figure 10, Ref. No. 58) fromeither side of the disc table (Figure 10, Ref. No. 4).

3. Slide out disc table from the disc guard (Figure 10, Ref. No. 61).

4. Loosen the set screw (Figure 10, Ref. No. 65) securing thealuminum disc (Figure 10, Ref. No. 66). Use the hole on thetop of disc guard to locate and loosen set screw. Do notremove set screw.

5. Loosen and remove four bolts (Figure 10, Ref. No. 24) fromdisc cover plate (Figure 10, Ref. No. 68).

6. Loosen and remove four bolts (Figure 11, Ref. No. 25) fromdust collection port (Figure 11, Ref. No. 32).

7. Remove disc cover plate and dust collection port.

8. Slide out and remove aluminum disc.

9. Open cabinet door (Figure 11, Ref. No. 53).

10. Turn knob (Figure 11, Ref. No. 52) on bracket (Figure 11, Ref.No. 51) to release tension on V-belt (Figure 10, Ref. No. 64).

11. Replace V-belt. Use parts list to order the appropriate V-belt.

12. Tighten knob on bracket to tension the V-belt.

13. Do not over tension the V-belt. Excessive tension on V-belt willreduce life of the belt and function of the tool. A belt is properlytensioned when light pressure applied to midpoint of the beltproduces about 1/2˝ deflection.

14. Close the cabinet door and secure it with the knob.

15. Replace aluminum disc and secure it by tightening the setscrew.

16. Replace dust collection port and disc cover plate and secure itwith bolts.

17 Replace disc table onto the disc guard and secure it using thetwo handles.

Cleaning

Keep machine and workshop clean. Do not allow sawdust toaccumulate on the tool. Keep the drums clean. Dirt on drums willcause poor tracking and belt slippage. Operate tool with dustcollector to keep dust from accumulating.

After sanding wood or nonmetallicmaterial, always clean dust collector and

guards of sawdust before grinding metal. Sparks couldignite debris and cause a fire.

Be certain motor is kept clean and is frequently vacuumed free ofdust.

Use soap and water to clean painted parts, rubber parts and plasticguards.

Lubrication

The shielded ball bearings in this tool are permanently lubricated atthe factory. They require no further lubrication.

• When operation seems stiff, a light coat of paste wax applied tothe belt and disc tables will make it easier to feed the workwhile finishing.

• Do not apply wax to the belt platen. Belt could pick up wax anddeposit it on the drums causing belt to slip.

Keep tool In repair

• If power cord is worn, cut, or damaged in any way, have itreplaced immediately.

• Replace worn abrasives when needed.

• Replace any damaged or missing parts. Use parts list to orderparts.

Any attempt to repair motor may create ahazard unless repair is done by a qualified

service technician.

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TROUBLESHOOTING GUIDESymptom Possible Cause(s) Corrective Action

Motor will not start

Motor will not start; fuses blownor circuit breakers tripped

Motor fails to develop full power(power output of motor decreases rapidly with decreasein voltage at motor terminals)

Motor overheats

Motor stalls(resulting in blown fuses ortripped circuit breakers)

Machine slows down while operatingAbrasive belt runs off top wheel

1. Low voltage2. Open circuit in motor or loose

connections1. Short circuit in line cord or plug

2. Short circuit in motor or looseconnections

3. Incorrect fuses or circuit breakers in power line

1. Power line overloaded with lights, appliances and other motors

2. Undersized wires or circuits too long3. General overloading of power

company’s facilities4. V-belt tension not correct

1. Motor overloaded2. V-belt tension not correct

1. Short circuit in motor or loose connections

2. Low voltage3. Incorrect fuses or circuit breakers in

power line4. Motor overloadedApplying too much pressure to workpiece

Not tracking properly

1. Check power line for proper voltage2. Inspect all lead connections on motor for loose

or open connection1. Insect line cord or plug for damaged insulation

and shorted wires2. Inspect all lead connections on motor for loose

or shorted terminals or worn insulation on wires.3. Install correct fuses or circuit breakers

1. Reduce load on power line

2. Increase wire sizes, or reduce length of wiring3. Request a voltage check from power company

4. Correct V-belt tension as stated in “Replacing V-belt” page 8 Step No. 13.

1. Reduce load on motor.2. Correct V-belt tension as stated in “Replacing

V-belt” page 8 Step No. 13.1. Inspect connections in motor for loose or

shorted terminals or worn insulation on leadwires

2. Correct the low line voltage conditions3. Install correct fuses or circuit breakers

4. Reduce load on motorEase up on pressure

See OPERATION “Belt Tracking”

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For Repair Parts, call 1-800-Grainger24 hours a day – 365 days a yearPlease provide following information:-Model number-Serial number (if any)-Part description and number as shown in parts list

REPAIR PARTS ILLUSTRATION FOR SANDER

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3031

55

5453

52

51

50

49

2292158

5756

2321

22

21

1819

20

171615 14

13 12

29

6 3233 34

66

32

6

48

2827

262524

11

109 8 567

36

4546

67 44

437

6 45

3738 39

4041

42

47

35

63

2

1

2292155 58

57

4

26

28 2961

5925 24

68

67

66

65 6362

64

60 57

24

Figure 10 – Replacement Parts Illustration for Sander

49G991A_oipm_En022_9638112.01 07/26/17 4:38 PM Page 10

REPAIR PARTS LIST FOR SANDERRef. PartNo. Description Number Qty.

Ref. PartNo. Description Number Qty.

11

1 Abrasive belt 9600511.00 12 Knob 9603314.00 13 Support bracket 9636130.00 14 Disc table 9636136.00 15 Bushing 9636008.00 16 3AMI-12 Retaining ring 9600519.00 97 6201zz Ball bearing 9600520.00 38 5/16˝-18 Hex nut * 29 5/16˝ Lock washer * 6

10 5/16-18 x 3/4˝ Set screw * 211 Driving roller 9603056.00 112 Driving roller shaft 9603057.00 113 5 x 5 x 65mm Key 9602591.00 114 6003zz Ball bearing 9604838.00 115 6003n Ball bearing 9603054.00 116 S35 Snap ring 9603053.00 117 3AMI-17 Retaining ring 9603052.00 118 Pivot bracket 9603050.00 119 Bolt liner 9603049.00 120 5/16-18 x 1-1/4˝ Carriage bolt * 221 5/16˝ Flat washer (N) * 1022 5/16-18 x 1˝ Socket head bolt * 923 Work stop 9636131.00 124 #10-24 x 3/8˝ Socket head bolt * 725 #10 Lock washer * 326 Pointer 9603045.00 127 Rivet 9603043.00 328 #10-24 x 3/8˝ Flat head screw * 629 Slide 9603044.00 330 Knob 9636009.00 131 Belt tension handle 9636010.00 132 Cam 9603063.00 233 Knob 9603059.00 234 Belt housing 9603061.00 1

35 Adjusting nut 9603067.00 236 5/16˝ Flat washer (R) * 337 Spring 9603068.00 238 1/4-20 x 1-1/4˝ Set screw * 239 1/4-20 Hex nut * 240 1/4˝ Lock washer * 241 5-0.8 x 6mm Set screw * 142 Right adjusting bar 9603070.00 143 Idler drum shaft 9603074.00 144 Idler drum 9608400.00 145 Drum cap 9603073.00 246 Knob 9636011.00 147 Left adjusting bar 9603071.00 148 Belt cover 9603062.00 149 Knob 9636012.00 650 Roller guard 9636013.00 151 3.5 x 10mm Tapping screw 9636014.00 252 Knob 9636015.00 253 Lower belt guard 9636016.00 154 Belt table 9603072.00 155 Trunnion 9603042.00 356 Angle label 9603046.00 257 5/16˝ Flat washer (W) 9605662.00 658 Lock handle assembly 9603041.00 359 Pointer 9603066.00 260 5/16-18 x 1˝ Hex head bolt * 461 Disc guard 9636132.00 162 1/4-20 x 3/8˝ Set screw * 163 Pulley 9602228.00 164 V-belt A33 9625476.00 165 5/16-18 x 3/8˝ Set screw * 166 Aluminum disc 9636133.00 167 Abrasive disc 10˝ 9636134.00 168 Disc cover plate 9636135.00 1

(∆) Not shown. (*) Standard hardware item, available locally.(N/A) Not available as replacement part.

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For Repair Parts, call 1-800-Grainger24 hours a day – 365 days a yearPlease provide following information:-Model number-Serial number (if any)-Part description and number as shown in parts list

REPAIR PARTS ILLUSTRATION FOR CABINET

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Figure 11 – Replacement Parts Illustration for Cabinet

34

1314

15 16

17

1211

10987

5

64

3

2

4623

47

51

2952

46

52

53

50

49

48

4746

34

23

44

45

2343

42

23

43

1

2922

32

33

31

1819

37

25

25

363839

4025

30

20

1821

2223

24

26

2728

29

55 54

41

35 23

49G991A_oipm_En022_9638112.01 07/26/17 4:38 PM Page 12

REPAIR PARTS LIST FOR CABINETRef. PartNo. Description Number Qty.

Ref. PartNo. Description Number Qty.

13

1 Miter gauge assy. 9636018.00 1(Inc. Ref. Nos. 2-17)

2 Knob 9636019.00 13 1/4˝ Flat washer * 14 #10 Fiber washer 9601370.00 15 Miter gauge 9608251.00 16 Threaded pin 9608255.00 17 #10-24 x 1/4˝ Pan head screw * 18 #10 Flat washer * 19 Scale 9608254.00 1

10 Indicator 9608253.00 111 #10-24 Hex nut * 312 #10-24 x 3/4˝ Pan head screw * 313 Guide washer 9636020.00 114 6-1.0 x 8mm Flat head screw 9636021.00 115 Miter gauge bar 9603075.00 116 Indexing pin 9608256.00 117 #10-24 x 1/4˝ Flat head screw 9606370.00 218 Knob 9603087.00 319 Belt side guard 9636022.00 120 Dust hood 9603088.00 121 Knob 9603314.00 222 5/16-18 x 1/2˝ Socket head bolt * 423 5/16˝ Flat washer (R) * 1824 Dust hood base 9603093.00 125 #10-24 x 3/8˝ Socket head bolt * 826 1/2-13 x 6 ½˝ Hex head bolt * 127 1/2-13 Hex nut * 1

28 5/16-18 x 3˝ Socket head bolt * 429 5/16˝ Flat washer (W) * 930 Base 9636138.00 131 Disk cover bracket 9603083.00 132 Dust collection nozzle 9603084.00 133 Dust port cover 9636023.00 134 5/16-18 Hex nut * 835 Switch box 9636139.00 136 Strain relief 9601413.00 137 Power cord 9606948.00 138 Switch 9600423.00 139 16A Circuit breaker 9603086.00 140 Connector 9636140.00 141 Cabinet 9636141.0042 Rubber foot 9636026.00 443 5/16-18 x 1˝ Socket head bolt * 844 Motor plate 9603079.00 145 Motor 9636142.00 146 5/16-18 Locking nut * 447 5/16-18 x 3/4 Hex head bolt * 348 5 x 5 x 30mm Key 9608438.00 149 1/4-20 x 3/8˝ Set screw * 150 Motor pulley 9636143.00 151 Hang up bracket 9603082.00 152 Knob 9636027.00 153 Door 9636028.00 154 #10-24 Hex nut * 155 #10 Serrated washer * 1

(∆) Not shown. (*) Standard hardware item, available locally.(N/A) Not available as replacement part.

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DAYTON ONE-YEAR LIMITED WARRANTYDAYTON ONE-YEAR LIMITED WARRANTY. All Dayton® product models covered in this manual are warranted by DaytonElectric Mfg. Co. (“Dayton”) to the original user against defects in workmanship or materials under normal use for one yearafter date of purchase. If the Dayton product is part of a set, only the portion that is defective is subject to this warranty. Anyproduct or part which is determined to be defective in material or workmanship and returned to an authorized service location,as Dayton or Dayton’s designee designates, shipping costs prepaid, will be, as the exclusive remedy, repaired or replacedwith a new or reconditioned product or part of equal utility or a full refund given, at Dayton’s or Dayton’s designee’s option, at no charge. For limited warranty claim procedures, see “Warranty Service” below. This warranty is void if there is evidenceof misuse, mis-repair, mis-installation, abuse or alteration. This warranty does not cover normal wear and tear of Daytonproducts or portions of them, or products or portions of them which are consumable in normal use. This limited warrantygives purchasers specific legal rights, and you may also have other rights which vary from jurisdiction to jurisdiction.

WARRANTY DISCLAIMERS AND LIMITATIONS OF LIABILITY RELATING TO ALL CUSTOMERS FOR ALLPRODUCTS

LIMITATION OF LIABILITY. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, DAYTON’S LIABILITY FORCONSEQUENTIAL AND INCIDENTAL DAMAGES IS EXPRESSLY DISCLAIMED. DAYTON’S LIABILITY IN ALL EVENTS ISLIMITED TO AND SHALL NOT EXCEED THE PURCHASE PRICE PAID.

WARRANTY DISCLAIMER. A DILIGENT EFFORT HAS BEEN MADE TO PROVIDE PRODUCT INFORMATION ANDILLUSTRATE THE PRODUCTS IN THIS LITERATURE ACCURATELY; HOWEVER, SUCH INFORMATION AND ILLUSTRATIONSARE FOR THE SOLE PURPOSE OF IDENTIFICATION, AND DO NOT EXPRESS OR IMPLY A WARRANTY THAT THE PRODUCTSARE MERCHANTABLE, OR FIT FOR A PARTICULAR PURPOSE, OR THAT THE PRODUCTS WILL NECESSARILY CONFORM TO THE ILLUSTRATIONS OR DESCRIPTIONS. EXCEPT AS PROVIDED BELOW, NO WARRANTY OR AFFIRMATION OF FACT,EXPRESSED OR IMPLIED, OTHER THAN AS STATED IN THE “LIMITED WARRANTY” ABOVE IS MADE OR AUTHORIZED BY DAYTON.

PRODUCT SUITABILITY. MANY JURISDICTIONS HAVE CODES AND REGULATIONS GOVERNING SALES, CONSTRUCTION,INSTALLATION, AND/OR USE OF PRODUCTS FOR CERTAIN PURPOSES, WHICH MAY VARY FROM THOSE IN NEIGHBORINGAREAS. WHILE ATTEMPTS ARE MADE TO ASSURE THAT DAYTON PRODUCTS COMPLY WITH SUCH CODES, DAYTON CANNOTGUARANTEE COMPLIANCE, AND CANNOT BE RESPONSIBLE FOR HOW THE PRODUCT IS INSTALLED OR USED. BEFOREPURCHASE AND USE OF A PRODUCT, REVIEW THE SAFETY/SPECIFICATIONS, AND ALL APPLICABLE NATIONAL AND LOCALCODES AND REGULATIONS, AND BE SURE THAT THE PRODUCT, INSTALLATION, AND USE WILL COMPLY WITH THEM.

CONSUMERS ONLY. CERTAIN ASPECTS OF DISCLAIMERS ARE NOT APPLICABLE TO CONSUMER PRODUCTS SOLD TO CONSUMERS; (A) SOME JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL ORCONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU; (B) ALSO, SOMEJURISDICTIONS DO NOT ALLOW A LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONMAY NOT APPLY TO YOU; AND (C) BY LAW, DURING THE PERIOD OF THIS LIMITED WARRANTY, ANY IMPLIED WARRANTIESOF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE APPLICABLE TO CONSUMER PRODUCTS PURCHASEDBY CONSUMERS, MAY NOT BE EXCLUDED OR OTHERWISE DISCLAIMED.

THIS LIMITED WARRANTY ONLY APPLIES TO UNITED STATES PURCHASERS FOR DELIVERY IN THE UNITED STATES.

WARRANTY SERVICE

To obtain warranty service if you purchased the covered product directly from W.W. Grainger, Inc. (“Grainger”), (i) write or call or visit the local Grainger branch from which the product was purchased or another Grainger branch near you (seewww.grainger.com for a listing of Grainger branches); or (ii) contact Grainger by going to www.grainger.com and clicking on the “Contact Us” link at the top of the page, then clicking on the “Email us” link; or (iii) call Customer Care (toll free) at 1-888-361-8649. To obtain warranty service if you purchased the covered product from another distributor or retailer, (i) go to www.grainger.com for Warranty Service; (ii) write or call or visit a Grainger branch near you; or (iii) call Customer Care (toll free) at 1-888-361-8649. In any case, you will need to provide, to the extent available, the purchase date, the originalinvoice number, the stock number, a description of the defect, and anything else specified in this Dayton One-Year LimitedWarranty. You may be required to send the product in for inspection at your cost. You can follow up on the progress ofinspections and corrections in the same ways. Title and risk of loss pass to buyer on delivery to common carrier, so if product was damaged in transit to you, file claim with carrier, not retailer, Grainger or Dayton. For warranty information for purchasers and/or delivery outside the United States, please use the following applicable contact information:

Dayton Electric Mfg. Co.,100 Grainger Parkway, Lake Forest, IL 60045 U.S.A.or call +1-888-361-8649

DM_US 44930530-6.019350.0029

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