Grizzly G8749 User Manual

MODEL G8749

DRUM/FLAP SANDER

OWNER'S MANUAL

COPYRIGHT © 2000 BY GRIZZLY INDUSTRIAL, INC., REVISED SEPTEMBER, 2014 (ST)

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#DS3216 PRINTED IN CHINA

This manual provides critical safety instructions on the proper setup,
operation, maintenance, and service of this machine/tool. Save this
document, refer to it often, and use it to instruct other operators.

Failure to read, understand and follow the instructions in this manual
may result in fire or serious personal injury—including amputation,
electrocution, or death.

The owner of this machine/tool is solely responsible for its safe use.
This responsibility includes but is not limited to proper installation in
a safe environment, personnel training and usage authorization,
proper inspection and maintenance, manual availability and compre­hension, application of safety devices, cutting/sanding/grinding tool
integrity, and the usage of personal protective equipment.

The manufacturer will not be held liable for injury or property damage
from negligence, improper training, machine modifications or misuse.

Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known to the State
of 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, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
Work in a well ventilated area, and work with approved safety equip­ment, such as those dust masks that are specially designed to filter
out microscopic particles.

Table of Contents

INTRODUCTION ............................................................................................................................... 2

Manual Accuracy ........................................................................................................................ 2

Contact Info ................................................................................................................................ 2

Functional Overview ................................................................................................................... 2

Identification ............................................................................................................................... 3

Machine Data Sheet ................................................................................................................... 4

SECTION 1: SAFETY ....................................................................................................................... 5

Safety Instructions for Machinery ............................................................................................... 5

Additional Safety Instructions Sanders ...................................................................................... 7

SECTION 2: CIRCUIT REQUIREMENTS ........................................................................................ 8

110V Operation .......................................................................................................................... 8

SECTION 3: SETUP ......................................................................................................................... 9

Setup Safety ............................................................................................................................... 9

Items Needed for Setup ............................................................................................................. 9

Unpacking .................................................................................................................................. 9

Inventory ................................................................................................................................... 10

Site Considerations .................................................................................................................. 10

Test Run ................................................................................................................................... 11

Mounting ................................................................................................................................... 12

Assembly .................................................................................................................................. 12

SECTION 4: OPERATIONS ........................................................................................................... 15

Operation Safety ...................................................................................................................... 15

Sanding Tips ............................................................................................................................ 15

ON/OFF Switch ........................................................................................................................ 16

Drum Sanding .......................................................................................................................... 16

Flap Sanding ............................................................................................................................ 16

SECTION 5: ACCESSORIES ......................................................................................................... 17

SECTION 6: MAINTENANCE......................................................................................................... 18

Schedule .................................................................................................................................. 18

Cleaning ................................................................................................................................... 18

Lubrication ................................................................................................................................ 18

Replacing Sanding Sleeves ..................................................................................................... 18

Replacing Flap Sandpaper/Brushes ........................................................................................ 19

SECTION 7: SERVICE ................................................................................................................... 20

Troubleshooting ........................................................................................................................ 20

SECTION 8: WIRING ...................................................................................................................... 22

Wiring Safety Instructions ........................................................................................................ 22

Wiring Diagram......................................................................................................................... 23

SECTION 9: PARTS ....................................................................................................................... 24

Parts Breakdown ...................................................................................................................... 24

Parts List .................................................................................................................................. 25

WARRANTY AND RETURNS ........................................................................................................ 29

INTRODUCTION

Functional OverviewManual Accuracy

We are proud to offer this manual with your new
machine! We've made every effort to be exact
with the instructions, specifications, drawings, and
photographs of the machine we used when writ­ing this manual. However, sometimes errors do
happen and we apologize for them.

Also, owing to our policy of continuous improve­ment, your machine may not exactly match
the manual. If you find this to be the case, and
the difference between the manual and machine
leaves you in doubt, immediately call our techni­cal support for updates or clarification.

For your convenience, we always keep current
Grizzly manuals and most updates available on
our website at www.grizzly.com. Any updates to
your machine will be reflected in these documents
as soon as they are complete. Visit our site often
to check for the latest updates!

The Model G8749 Drum/Flap Sander is generally
used for edge contour sanding using the sand­ing drums, as shown in Figure 1, or for round or
spherical sanding using the flap sander, as shown
in Figure 2.

Figure 1. Typical drum sanding operation.

Contact Info

We stand behind our machines. If you have any
service questions, parts requests or general ques­tions about the machine, please call or write us at
the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: [phone]

Fax: [phone]

E-Mail: [e-mail]

If you have any comments regarding this manual,
please write to us at the address below:

C

/O Technical Documentation Manager

Grizzly Industrial, Inc.

P.O. Box 2069

Bellingham, WA 98227-2069

Email: [e-mail]

Figure 2. Typical flap sanding operation.

-2-

G8749 Drum/Flap Sander

Flap Sander

Identification

Motor

Sanding Drum

ON/OFF Switch

Mounting Holes

Figure 3. Model G8749 identification.

G8749 Drum/Flap Sander

-3-

Machine Data Sheet

MACHINE DATA

SHEET

Customer Service #: [phone] · To Order Call: [phone] · Fax #: [phone]

MODEL G8749 DRUM / FLAP SANDER

Product Dimensions:

Weight................................................................................................................................................................ 57 lbs.

Width (side-to-side) x Depth (front-to-back) x Height................................................................. 30 x 7-1/2 x 10-1/2 in.

Footprint (Length x Width)......................................................................................................................... 9 x 6-1/2 in.

Shipping Dimensions:

Type..................................................................................................................................................... Cardboard Box

Content........................................................................................................................................................... Machine

Weight................................................................................................................................................................ 69 lbs.

Length x Width x Height....................................................................................................................... 15 x 31 x 10 in.

Electrical:

Power Requirement........................................................................................................... 110V, Single-Phase, 60 Hz

Prewired Voltage.................................................................................................................................................. 110V

Full-Load Current Rating........................................................................................................................................ 10A

Minimum Circuit Size.............................................................................................................................................. 15A

Connection Type....................................................................................................................................... Cord & Plug

Power Cord Included.............................................................................................................................................. Yes

Power Cord Length................................................................................................................................................. 5 ft.

Power Cord Gauge......................................................................................................................................... 16 AWG

Plug Included.......................................................................................................................................................... Yes

Included Plug Type................................................................................................................................................ 5-15

Switch Type.................................................................................................. Paddle Safety Switch w/Removable Key

Motors:

Main

Type................................................................................................................. TEFC Capacitor-Start Induction

Horsepower................................................................................................................................................ 1 HP

Phase............................................................................................................................................ Single-Phase

Amps............................................................................................................................................................ 10A

Speed................................................................................................................................................ 1725 RPM

Power Transfer ............................................................................................................................... Direct Drive

Bearings..................................................................................................... Shielded & Permanently Lubricated

Other Specifications:

Country of Origin ................................................................................................................................................ China

Warranty ........................................................................................................................................................... 1 Year

Approximate Assembly & Setup Time ........................................................................................................ 30 Minutes

Serial Number Location .............................................................................................. ID Label on Front of Top Cover

ISO 9001 Factory .................................................................................................................................................... No

CSA, ETL, or UL Certified/Listed ............................................................................................................................ No

Features:

Flap Sander Supplied with 120 Grit Paper
Includes 3-1/4" and 4-3/4" Inflatable Sanding Drums
Toggle On/Off Switch with Safety Lock

-4-

G8749 Drum/Flap Sander

SECTION 1: SAFETY

For Your Own Safety, Read Instruction
Manual Before Operating this Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This
manual uses a series of symbols and signal words intended to convey the level of importance
of the safety messages. The progression of symbols is described below. Remember that safety
messages by themselves do not eliminate danger and are not a substitute for proper accident
prevention measures.

Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.

This symbol is used to alert the user to useful information about

NOTICE

proper operation of the machine.

Safety Instructions for Machinery

Safety Instructions for Machinery

OWNER’S MANUAL. Read and understand

this owner’s manual BEFORE using machine.
Untrained users can be seriously hurt.

EYE PROTECTION. Always wear ANSI­approved safety glasses or a face shield when
operating or observing machinery. to reduce
the risk of eye injury or blindness from fly­ing particles Everyday eyeglasses are not
approved safety glasses.

HAZARDOUS DUST. Dust created while using
machinery may cause cancer, birth defects,
or long-term respiratory damage. Be aware of
dust hazards associated with each workpiece
material, and always wear a NIOSH-approved
respirator to reduce your risk.

WEARING PROPER APPAREL. Do not wear
clothing, apparel, or jewelry that can become
entangled in moving parts. Always tie back or
cover long hair. Wear non-slip footwear to avoid
accidental slips which could cause a loss of
workpiece control.

HEARING PROTECTION. Always wear hear­ing protection when operating or observiing loud
machinery. Extended exposure to this noise
without hearing protection can cause permanent
hearing loss.

MENTAL ALERTNESS. Be mentally alert when
running machinery. Never operate under the
influence of drugs or alcohol, when tired, or when
distracted.

G8749 Drum/Flap Sander

-5-

Safety Instructions for Machinery

DISCONNECTING POWER SUPPLY. Always

disconnect machine from power supply before
servicing, adjusting, or changing cutting tools
(bits, blades, cutters, etc.). Make sure switch is
in OFF position before reconnecting to avoid an
unexpected or unintentional start.

INTENDED USE. Only use the machine for its
intended purpose and only use recommended
accessories. Never stand on machine, modify
it for an alternative use, or outfit it with non­approved accessories.

STABLE MACHINE. Unexpected movement
during operations greatly increases the risk of
injury and loss of control. Verify machines are
stable/secure and mobile bases (if used) are
locked before starting.

FORCING MACHINERY. Do not force machine.
It will do the job safer and better at the rate for
which it was designed.

GUARDS & COVERS. Guards and covers can
protect you from accidental contact with mov­ing parts or flying debris. Make sure they are
properly installed, undamaged, and working
correctly before using machine.

REMOVING TOOLS. Never leave adjustment
tools, chuck keys, wrenches, etc. in or on
machine—especially near moving parts. Verify
removal before starting!

AWKWARD POSITIONS. Keep proper foot­ing and balance at all times when operating
machine. Do not overreach! Avoid awkward
hand positions that make workpiece control dif­ficult or increase the risk of accidental injury.

DANGEROUS ENVIRONMENTS. Do not use
machinery in wet locations, cluttered areas,
around flammables, or in poorly-lit areas. Keep
work area clean, dry, and well lighted to mini­mize risk of injury.

APPROVED OPERATION. Untrained operators
can be seriously hurt by machinery. Only allow
trained or properly supervised people to use
machine. When machine is not being used, dis­connect power, remove switch keys, or lock-out
machine to prevent unauthorized use—especially
around children. Make workshop kid proof!

CHILDREN & BYSTANDERS. Keep children
and bystanders a safe distance away from work
area. Stop using machine if children or bystand­ers become a distraction.

FEED DIRECTION. Unless otherwise noted, feed
work against the rotation of blades or cutters.
Feeding in the same direction of rotation may pull
your hand into the cut.

SECURING WORKPIECE. When required, use
clamps or vises to secure workpiece. A secured
workpiece protects hands and frees both of them
to operate the machine.

UNATTENDED OPERATION. Never leave
machine running while unattended. Turn machine
Off and ensure all moving parts completely stop
before walking away.

MAINTENANCE & INSPECTION. A machine that
is not properly maintained may operate unpre­dictably. Follow all maintenance instructions and
lubrication schedules to keep machine in good
working condition. Regularly inspect machine for
loose bolts, alignment of critical parts, binding, or
any other conditions that may affect safe opera­tion. Always repair or replace damaged or mis­adjusted parts before operating machine.

EXPERIENCING DIFFICULTIES. If at any time
you are experiencing difficulties performing the
intended operation, stop using the machine!
Contact our Technical Support Department at
[phone].

-6-

G8749 Drum/Flap Sander

Additional Safety Instructions Sanders

1. FEEDING WORKPIECE. To avoid the risk

of your hands being pulled into the machine,
do not jam workpiece into the sanding
attachment during operation. Firmly grasp
the workpiece in both hands and ease it into
the machine using light pressure.

2. ENTANGLEMENT HAZARD. To avoid
entanglement injuries, do not wear loose
clothing, jewelry, or gloves when using this
machine. Roll up long sleeves and tie back
long hair.

3. HAND PROTECTION. Do not place your
hands near or in contact with the sand­ing attachments during operation. Never
put your hands or fingers between the
workpiece and the sander during opera­tion.

4. INSPECTING WORKPIECES. Always
inspect the workpiece for nails, staples,
knots, and other imperfections that could
be dislodged and thrown from the machine
during operation, which could cause seri­ous personal injury.

5. PROTECTIVE EQUIPMENT. Dust and
chips become airborne at a high rate of
speed during operation, becoming haz­ards to eyes and lungs. Always wear ANSI
approved safety glasses or a face shield
and a respirator when using this sander.

6. ROTATION DIRECTION. To avoid entan­glement injuries, always be aware of the
rotation direction of the sanding attach­ments.

7. UNATTENDED OPERATION. To avoid the
risk of unauthorized use or accidental con­tact with the sanding attachments, never
leave the machine running unattended.
Turn the machine OFF after every use and
remove the switch disabling key.

8. ADJUSTMENT, MAINTENANCE, AND
SERVICE. Perform machine inspections

and maintenance service promptly and when
needed. Always disconnect the machine
from power when performing adjustments,
maintenance, or service to avoid injuries
from accidental start-up or electrocution.

9. SANDING ATTACHMENTS. Always make
sure the sanding attachments are correctly
mounted and secure before turning the
machine on. Keep these components in
good working order.

10. EXPERIENCING DIFFICULTIES. If at any
time you are experiencing difficulties per­forming the intended operation, stop using
the machine and contact Tech Support at
[phone].

Like all machinery there is potential danger
when operating this machine. Accidents are
frequently caused by lack of familiarity or
failure to pay attention. Use this machine
with respect and caution to decrease the
risk of operator injury. If normal safety pre­cautions are overlooked or ignored, serious
personal injury may occur.

G8749 Drum/Flap Sander

No list of safety guidelines can be complete.
Every shop environment is different. Always
consider safety first, as it applies to your
individual working conditions. Use this and
other machinery with caution and respect.
Failure to do so could result in serious per­sonal injury, damage to equipment, or poor
work results.

-7-

SECTION 2: CIRCUIT REQUIREMENTS

110V Operation

Serious personal injury could occur if you
connect the machine to power before com­pleting the setup process. DO NOT connect
the machine to the power until instructed
later in this manual.

Electrocution or fire could
result if machine is not
grounded and installed in
compliance with electrical
codes. Compliance MUST
be verified by a qualified
electrician!

Power Connection Device

The Model G8749 comes with a 5-15 plug, similar
to Figure 4, to connect the machine to power.

GROUNDED

5-15 RECEPTACLE

Grounding Prong

5-15 PLUG

Neutral Hot

Figure 4. Typical 5-15 plug and receptacle.

Full Load Amperage Draw

This machine draws the following amps under
maximum load:

Amp Draw .............................................. 10 Amps

Power Supply Circuit Requirements

You MUST connect your machine to a grounded
circuit that is rated for the amperage given below.
Never replace a circuit breaker on an existing cir­cuit with one of higher amperage without consult­ing a qualified electrician to ensure compliance
with wiring codes. If you are unsure about the

wiring codes in your area or you plan to con­nect your machine to a shared circuit, consult
a qualified electrician.

Minimum Circuit Size ............................. 15 Amps

This machine MUST have a ground prong in
the plug to help ensure that it is grounded.
DO NOT remove ground prong from plug
to fit into a two-pronged outlet! If the plug
will not fit the outlet, have the proper outlet
installed by a qualified electrician.

Extension Cords

We do not recommend using extension cords, but
if you find it absolutely necessary:

• Use at least a 14 gauge cord that does not
exceed 50 feet in length!

• The extension cord must have a ground wire
and plug pin.

-8-

• A qualified electrician MUST size cords over
50 feet long to prevent motor damage.

G8749 Drum/Flap Sander

SECTION 3: SETUP

Setup Safety

This machine presents
serious injury hazards
to untrained users. Read
through this entire manu­al to become familiar with
the controls and opera­tions before starting the
machine!

Wear safety glasses dur­ing the entire setup pro­cess!

Items Needed for

Setup

The following items are needed to complete the
setup process, but are not included with your
machine:

Description Qty

• Wrenches 14, 19mm ..........................1 Each

• Mounting Hardware (Page 11) ... As Needed

Unpacking

Your machine was carefully packaged for safe
transportation. Remove the packaging materials
from around your machine and inspect it. If you
discover the machine is damaged, please imme-

diately call Customer Service at [phone]
for advice.

Save the containers and all packing materials for
possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the condi­tion of your shipment, inventory the contents.

G8749 Drum/Flap Sander

-9-

Inventory

Site Considerations

The following is a description of the main compo­nents shipped with your machine. Lay the compo­nents out to inventory them.

Note: If you can't find an item on this list, check
the mounting location on the machine or examine
the packaging materials carefully. Occasionally
we pre-install certain components for shipping
purposes.

Component Inventory: (Figure 5) Qty
A. Sanding Drum 3

B. Flap Sander ................................................ 1

C. Sanding Drum 4

D. Arbor Bolt & Flat Washer (LH) ..........1 Each

E. Arbor Bolt & Flat Washer (RH) .......... 1 Each

F. Flap Sander Arbor Bolt & Flange ......1 Each

G. End Caps .................................................... 2

A

1

⁄4" x 8" .............................. 1

3

⁄4" x 8".............................. 1

B

C

Workbench Load

Refer to the Machine Data Sheet for the weight
and footprint specifications of your machine.
Some workbenches may require additional rein­forcement to safely support the machine.

Placement Location

Consider existing and anticipated needs, size of
material to be processed through each machine,
and space for auxiliary stands, work tables or
other machinery when establishing a location for
your new machine. See Figure 6 for the minimum
working clearances.

9"

30"

G

Figure 5. Model G8749 inventory.

If any nonproprietary parts are missing (e.g. a
nut or a washer), we will gladly replace them; or
for the sake of expediency, replacements can be
obtained at your local hardware store.

F

SUFFOCATION HAZARD!
Immediately discard all plas­tic bags and packing materi­als to eliminate choking/suf­focation hazards for children
and animals.

E

D

Figure 6. Minimum working clearances.

Children and visitors may be
seriously injured if unsuper­vised around this machine.
Lock entrances to the shop
or disable start switch or
power connection to prevent
unsupervised use.

-10 -

G8749 Drum/Flap Sander

Mounting

Test Run

Due to the significant forces exerted on the
sander during operation, you must mount it to a
workbench. We recommend that you use one of
the following methods to secure your sander to
the workbench before using it.

The strongest mounting option is a "Through
Mount" where holes are drilled all the way through
the workbench, and hex bolts, washers, and
hex nuts are used to secure the sander to the
workbench.

Hex
Bolt

Flat Washer

Machine Base

Workbench

Flat Washer

Lock Washer

Hex Nut

Figure 7. Example of a through mount setup.

Another option for mounting is a "Direct Mount"
where the machine is simply secured to the work­bench with a lag screw.

Once the assembly is complete, test run your
machine to make sure it runs properly and is
ready for regular operation.

The test run consists of verifying the following: 1)
The motor powers up and runs correctly, and 2)
the safety disabling mechanism works correctly.

If, during the test run, you cannot easily locate
the source of an unusual noise or vibration, stop
using the machine immediately, then review
Troubleshooting on Page 20.

If you still cannot remedy a problem, contact our
Tech Support at [phone] for assistance.

To test run the machine:

1. Make sure you have read the safety instruc-

tions at the beginning of the manual and that
the machine is set up properly.

2. Make sure all tools and objects used during
setup are cleared away from the machine.

3. Connect the machine to the power source.

4. Verify that the machine is operating correctly

by turning the it ON.

—When operating correctly, the machine

runs smoothly with little or no vibration or
rubbing noises.

Lag Screw

Flat Washer

Machine Base

Workbench

Figure 8. Example of a direct mount setup.

G8749 Drum/Flap Sander

— Investigate and correct strange or unusual

noises or vibrations before operating the
machine further. Always disconnect the
machine from power when investigating or
correcting potential problems.

-11-

5. Turn the machine OFF.

6. Remove the switch disabling key, as shown
in Figure 9.

Figure 9. Removing switch key from paddle

switch.

7. Try to start the machine by flipping the paddle
switch up to the ON position.

—If the machine does not start, the switch

disabling feature is working as designed.

—If the machine starts, immediately stop it.

The switch disabling feature is not working
correctly. This safety feature must work
properly before proceeding with regular
operations. Call Tech Support for help.

Assembly

The flap sander is designed to be mounted only
on the left side of the machine, whereas the drum
sanders can be mounted on either side.

Attaching Flap Sander

1. DISCONNECT SANDER FROM POWER!

2. When removed from the shipping box, the

flap sander is held together by two tie wraps.
Hold the assembly together from top to bot­tom, then remove the ties and store them for
future use.

Note: If the brushes should come loose

from the end plates during this step, refer
to Replacing Flap Sandpaper/Brushes on
Page 19 for detailed instructions on how to
put the assembly back together.

3. Position the flap sander so the sanding sur­face of the paper is facing you, then carefully
slide it onto the left hand arbor, as shown in
Figure 10.

-12-

Figure 10. Installing flap sander.

4. Secure the flap sander by threading the flap

sander arbor bolt and flange into the spindle,
as shown in Figure 10. Make sure to fully
tighten the bolt.

Note: This arbor bolt has left-hand threads

and tightens by rotating it counterclockwise.

G8749 Drum/Flap Sander

Reversing Sleeve Rotation

The sanding drums are shipped with 120 grit
sanding sleeves already installed. The sleeve
rotations are configured so that the large diameter
drum is mounted on the right side of the sander
and the smaller drum is mounted on the left.

If you want to change the mounting location of the
drums from the positions above, you must remove
the sanding sleeve and turn it around so that the
sleeve rotation matches the spindle rotation.

To reverse the sleeve rotation:

Always check the sanding
drum air pressure before
using it. Only use a
hand-operated air pump
to inflate the sanding
drum to 10 PSI. If the
drum is over-inflated,
the drum may burst with
considerable force, which
could cause serious
personal injury.

1. DISCONNECT SANDER FROM POWER!

2. Remove the protective cap on the air valve,

then push the valve stem to release all of the
air pressure from the drum (see Figure 11).

Air Valve

Spindle Rotation Arrow

Sleeve Rotation Arrow

Figure 11. Matching the sleeve rotation with the

spindle rotation.

Mounting Sanding Drum

It is important that the air pressure of the sanding
drum be maintained at 10 PSI to safely hold the
sanding sleeve in place.

To check air pressure and mount the sanding
drum:

1. DISCONNECT SANDER FROM POWER!

2. Remove the air valve protective cap, then

use a quality air pressure gauge to check the
drum air pressure, as shown in Figure 12.

— If the drum air pressure is more than 10

PSI, push the valve stem in to reduce the
air pressure. Use the gauge to recheck the
pressure.

— If the drum air pressure is less than 10 PSI,

use a hand-operated air pump to inflate the
sanding drum to 10 PSI.

3. Remove the sleeve from the drum, turn it
around, then slide it back onto the drum.

4. Hold the mounted sleeve up to the spindle
that you will be installing them on, then make
sure the sleeve rotation arrows and the rota­tion arrow on the spindle housing match.

G8749 Drum/Flap Sander

Figure 12. Checking sanding drum air pressure.

-13-

3. Replace the valve protective cap.

4. Slide the drum onto the spindle with the air

valve facing out, then secure it by threading
the arbor bolt with a flat washer through the
drum and into the spindle, as shown in Figure

13. Make sure to fully tighten the bolt.

Note: The left spindle uses the arbor bolt with

left-hand threads, which tightens by rotating it
counterclockwise. The right spindle arbor bolt
has right-hand threads and tightens by rotat­ing it clockwise.

Arbor Bolt &
Flat Washer

End Cap

Figure 13. Installing the sanding drum.

5. Fully thread the end cap onto the arbor bolt to

protect the valve stem during operation.

Note: One end cap also has left-hand threads

and is mounted on the left side of the machine.
The other cap has right-hand threads for the
right side of the machine.

-14-

G8749 Drum/Flap Sander

SECTION 4: OPERATIONS

Operation Safety

To reduce the risk of
serious injury when using
this machine, read and
understand this entire
manual before beginning
any operations.

Damage to your eyes and lungs could result
from using this machine without proper pro­tective gear. Always wear safety glasses and
a respirator when operating this machine.

Sanding Tips

Your sander is a safe tool when used properly. In
addition to the safety instructions in this manual,
the most important safety consideration is to use
common sense at all times.

Follow these rules when sanding:

• Make sure the sanding attachments are prop­erly installed and the spindle rotation of the
sandpaper and spindle match.

• Use both hands and engage the workpiece
with the spinning drum or flap sander slowly
and firmly. There can be considerable force
generated by the rotating device, causing the
workpiece to fly out of your hands.

• Check the sanding drum air pressure before
each use. Maintain the air pressure at 10 PSI.
Do not over-inflate the drums.

Loose hair, clothing, or
jewelry could get caught
in machinery and cause
serious personal injury.
Keep these items away
from moving parts at all
times to reduce this risk.

NOTICE

If you have never used this type of machine
or equipment before, WE STRONGLY REC­OMMEND that you read books, trade maga­zines, or get formal training before begin­ning any projects. Regardless of the con­tent in this section, Grizzly Industrial will
not be held liable for accidents caused by
lack of training.

• Always turn the sander ON and allow it
to reach full speed before engaging the
workpiece with the sandpaper.

• Use the correct sandpaper and grit for the job
to ensure good sanding results.

• Do not use the sander as a replacement for a
bandsaw or a planer. It is designed for finish
work, not rough dimensioning.

• Keep your workpiece moving across the face
of the drum or flap sander to prevent grooves
or ruts in the workpiece surface.

G8749 Drum/Flap Sander

-15-

ON/OFF Switch

This machine has a special safety ON/OFF pad­dle switch with a removable switch disabling key,
as shown in Figure 14.

Switch

Disabling

Key

Figure 15 shows a typical drum sanding opera­tion.

Spindle & Drum

Rotation Direction

Figure 15. Typical drum sanding operation.

Flap Sanding

Figure 14. Removing the ON/OFF switch

disabling key.

Turn the machine OFF, then remove the disabling
key when leaving the machine to prevent acciden­tal or unauthorized start-up.

If the key is removed while the machine is run­ning, the sander can still be turned OFF. However,
you need to re-install the key before turning the
sander back ON.

Drum Sanding

Drum sanding is perfect for performing sanding
operations on edge contours.

Use a soft sanding sleeve when sanding contours
with rounded or soft edges. A hard sleeve is desir­able when the sanded edge is to be sharp.

Flap sanding is useful for sanding rounded or
spherical shapes. With the flap sander mounted
on the left hand spindle, the abrasive side of the
sanding flaps will rotate toward the operator. It is
generally best to introduce the workpiece to the
bottom of the flap sander, as shown in Figure 16,
for the best control of the sanding forces.

Spindle & Flap Sander

Rotation Direction

Make sure the sanding sleeve is mounted on the
drum and sander so that the sleeve rotation and
spindle rotation match. The spindle will always
rotate toward the operator.

-16 -

Figure 16. Typical flap sanding operation.

G8749 Drum/Flap Sander

ACCESSORIES

SECTION 5: ACCESSORIES

G9956—Remote Controlled Heavy-Duty
Hanging Air Filter

Set the duration and speed with the remote con­trol from as far away as 45 feet, then hold on as
the fan spools up to draw a massive 1400 CFM
through the 1 micron filter. Changes the air in a
20' x 20' x 8' room 26 times an hour. Hangs eas­ily from the ceiling. A three pocket internal filter

1

bag simplifies cleaning. Motor is

1

amp. Dimensions: 30

⁄8"L x 19 7⁄8"W x 16 3⁄8"H and

⁄3 HP, 110V, 3

weighs 74 lbs.

Figure 17. Model G9956 Hanging Air Filter.

Aluminum Oxide Sanding Sleeves

1

G9196— 3
G9197—3
G9198— 3
G9199— 3
G9200—3
G9201—3
G9208—4
G9209—4
G9210—4
G9211— 4
G9212— 4
G9213— 4

⁄4" Diameter, 60 Grit

1

⁄4" Diameter, 80 Grit

1

⁄4" Diameter, 100 Grit

1

⁄4" Diameter, 120 Grit

1

⁄4" Diameter, 150 Grit

1

⁄4" Diameter, 180 Grit

3

⁄4" Diameter, 60 Grit

3

⁄4" Diameter, 80 Grit

3

⁄4" Diameter, 100 Grit

3

⁄4" Diameter, 120 Grit

3

⁄4" Diameter, 150 Grit

3

⁄4" Diameter, 180 Grit

6" x 60" J Weight Aluminum Oxide Rolls for
Flap Sander
G9187—120 Grit
G9188—180 Grit
G9189—220 Grit

T20514—Small Half-Mask Respirator
T20515—Medium Half-Mask Respirator
T20516—Large Half-Mask Respirator

Wood and other types of dust can cause severe
respiratory damage. If you work around dust every­day, a half-mask respirator can greatly reduce
your risk. Compatible with safety glasses!

Figure 18. Half-mask respirator with disposable

cartridge filters.

T20501—Face Shield Crown Protector 4"
T20502—Face Shield Crown Protector 7"
T20503—Face Shield Window
T20448—Economy Clear Safety Glasses
T20452—"Kirova" Anti-Reflective Glasses
T20456—"Dakura" Clear Safety Glasses

®

H0736—Shop Fox

Safety Glasses

These glasses meet ANSI Z87.1-2003 specifica­tions. Buy extras for visitors or employees. You
can't be too careful with shop safety!

T20502

T20452

T20503

T20448

T20456

H0736

H2491—Replacement Flap Brushes, Set of 12

G8749 Drum/Flap Sander

Figure 19. Our most popular eye protection.

-17-

SECTION 6: MAINTENANCE

Replacing Sanding

Always disconnect power
to the machine before
performing maintenance.
Failure to do this may
result in serious person­al injury.

Schedule

For optimum performance from your machine,
follow this maintenance schedule and refer to any
specific instructions given in this section.

Daily Check:

• Loose mounting bolts.

• Damaged or worn sandpaper/brushes.

• Sanding drum air pressure.

• Worn or damaged wires.

• Any other unsafe condition.

Daily Maintenance:

• Clean machine.

Sleeves

Your sander is supplied with a large 4 3⁄4" x 8"
sanding drum and a smaller 3
drums will accept soft or hard sanding sleeves.

To replace the sanding sleeve:

1. DISCONNECT SANDER FROM POWER!

2. Remove the air valve protective cap, press

the valve stem to release the drum air pres­sure (see Figure 20), then slide the sleeve off
the drum.

Sanding Sleeve

Spindle Rotation Arrow

1

⁄4" x 8" drum. Both

Air Valve

Cleaning

Cleaning the Model G8749 is relatively easy.
Vacuum excess wood chips and sawdust, and
wipe off the remaining dust with a dry cloth. If any
resin has built up, use a resin dissolving cleaner
to remove it.

Lubrication

Bearings are sealed and permanently lubricated,
so simply leave them alone unless they need
replacement.

-18-

Sleeve Rotation Arrow

Figure 20. Replacing sanding sleeve.

3. Match the direction of the sleeve rotation

arrow with the spindle rotation arrow, then
slide the replacement sleeve onto the drum.

Note: Make sure the sanding sleeve does not

extend beyond either end of the drum.

4. Use a hand-operated air pump to inflate the
sanding drum to 10 PSI, then replace the
valve cap.

G8749 Drum/Flap Sander

Replacing Flap

Sandpaper/Brushes

6. Make sure the sandpaper pieces are even

with one another and are centered in the
retaining bar, then re-tighten the retaining bar
screws to hold them in place.

To replace the flap sandpaper or brushes:

1. DISCONNECT SANDER FROM POWER!

2. While holding the outside end plate of the

flap sander, remove the arbor bolt and flange,
then remove the flap sander and place it
upright on a flat surface.

3. Remove the top end plate, then remove one
or two brushes to gain access to the retaining
bars that secure the sandpaper.

Note: All of the replacement sandpaper

needs to be oriented and installed so that
the abrasive side faces the same direction
and will face forward and down when the flap
sander is properly mounted on the machine.

1

4. Each retaining bar holds two 4
of sandpaper. Loosen the two screws secur­ing the retaining bar, then pull the old sand­paper pieces away.

5. Cut two new pieces of sandpaper from the
selected grit, then slip them under the retain­ing bar so that the abrasive side faces away
from the center of the flap sander, as shown
in Figure 21.

⁄2" x 6" pieces

7. If a flap brush is worn out or damaged, replace
it with a new one. Insert each brush into the
lower end plate and between two sandpaper
pieces attached to the same retaining bar, as
shown in Figure 22.

Figure 22. Sandpaper and brushes properly

configured on the flap sander.

8. After replacing the sandpaper and positioning
the brushes, place the top end plate onto the
flap sander.

9. As you lightly push down on the top plate,
correctly position one brush to align with the
recessed slot in the top plate, then rotate the
flap sander and work on the one next to it.
Continue this process until all of the brushes
are correctly aligned and fully seated into the
top plate.

Retaining Bar

Figure 21. Replacing flap sandpaper.

G8749 Drum/Flap Sander

Note: When storing the flap sander in a dry,

protected place, secure the bottom and top
end plates with tie wraps or string so that the
end plates do not come loose and allow the
brushes to fall out.

-19 -

SECTION 7: SERVICE

Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel­ops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical
Support at [phone].

Troubleshooting

Motor & Electrical

Symptom Possible Cause Possible Solution

Machine does not
start or a breaker
trips.

Machine stalls or is
underpowered.

Machine has
vibration or noisy
operation.

1. Switch disabling key removed.

2. Power supply switched OFF or at fault.

3. Plug/receptacle at fault/wired wrong.

4. Start capacitor at fault.

5. Motor connection wired wrong.

6. Wall circuit breaker tripped.

7. Wiring open/has high resistance.

8. Motor ON/OFF switch at fault.

9. Motor at fault.

1. Workpiece material not suitable for
machine.

2. Motor wired incorrectly.

3. Plug/receptacle at fault.

4. Motor bearings at fault.

5. Machine undersized for task.

6. Motor overheated.

7. Motor at fault.

1. Motor or component loose.

2. Incorrectly mounted to workbench.

3. Motor mount bolts loose/broken.

4. Motor bearings at fault.

1. Install switch disabling key.

2. Ensure power supply is ON/has correct voltage.

3. Test for good contacts; correct the wiring.

4. Test/replace if faulty.

5. Correct motor wiring connections (Page 23).

6. Ensure circuit size is correct/replace weak breaker.

7. Check/fix broken, disconnected, or corroded wires.

8. Replace switch.

9. Test/repair/replace.

1. Only cut wood; ensure moisture is below 20%.

2. Wire motor correctly (Page 23).

3. Test for good contacts/correct wiring.

4. Test/repair/replace.

5. Clean/replace sandpaper; reduce feed rate/sanding
depth.

6. Clean motor, let cool, and reduce workload.

7. Test/repair/replace.

1. Inspect/replace damaged bolts/nuts, and re-tighten
with thread locking fluid.

2. Shim/tighten mounting hardware.

3. Tighten/replace.

4. Test by rotating shaft; rotational grinding/loose shaft
requires bearing replacement.

-20-

G8749 Drum/Flap Sander

Operation

Symptom Possible Cause Possible Solution

Deep sanding
groove or scars in
workpiece.

Abrasive grain rubs
off the sandpaper.

Sanding surfaces
clog quickly or burn.

Burn marks on
workpiece.

Glazed surface on
workpiece.

W o r k p i e c e
frequently pulled out
of your hands.

1. Sandpaper grit too coarse.

2. Workpiece sanded across grain.

3. Workpiece pressure against sanding
abrasive too great.

4. Workpiece held too still against sanding
abrasive.

1. Sandpaper has been stored in an incorrect
environment.

2. Sandpaper has been folded or smashed.

1. Workpiece pressure against sanding
abrasive too great.

2. Sanding softwood or stock with high
residue.

1. Sandpaper grit too fine.

2. Workpiece pressure against sanding
abrasive too great.

3. Workpiece held too still against sanding
abrasive.

1. Sanding wet stock.

2. Sanding stock with high residue.

1. Workpiece not correctly supported.

2. Engaging workpiece with the sander on a
leading corner.

3. Starting sander with workpiece against
sandpaper.

1. Use finer grit sandpaper.

2. Sand with the grain.

3. Reduce pressure applied to the workpiece against
the sanding abrasive.

4. Continuously move workpiece back-and-forth across
the sanding abrasive surface.

1. Store sandpaper products away from extremely
cold or hot temperatures and in a dry, protected
location.

2. Store sanding sleeves or rolls so they are not
smashed or bent; store sandpaper sheets flat.

1. Reduce pressure applied to the workpiece against
the sanding abrasive.

2. Use different stock or accept the characteristics of
the stock and plan on cleaning/replacing sandpaper
frequently.

1. Use coarser grit sandpaper.

2. Reduce pressure applied to the workpiece against
the sanding abrasive.

3. Continuously move workpiece back-and-forth across
the sanding abrasive surface.

1. Properly dry stock before sanding so moisture
content is less than 20%.

2. Use different stock or accept the characteristics of
the stock and plan on cleaning/replacing sandpaper
frequently.

1. Hold workpiece firmly with both hands and engage
with sander slowly; use additional holding/supporting
devices for larger workpieces.

2. Start sanding workpiece on a trailing corner.

3. Start sander before engaging it with the workpiece.

G8749 Drum/Flap Sander

-21-

SECTION 8: WIRING

These pages are current at the time of printing. However, in the spirit of improvement, we may make chang­es to the electrical systems of future machines. Study this section carefully. If there are differences between
your machine and what is shown in this section, call Technical Support at [phone] for assistance
BEFORE making any changes to the wiring on your machine.

Wiring Safety Instructions

1. SHOCK HAZARD. Working on wiring that

is connected to a power source is extremely
dangerous. Touching electrified parts will
result in personal injury including but not lim­ited to severe burns, electrocution, or death.
Disconnect the power from the machine
before servicing electrical components!

2. QUALIFIED ELECTRICIAN. Due to the
inherent hazards of electricity, only a quali­fied electrician should perform wiring tasks
on this machine. If you are not a quali­fied electrician, get help from one before
attempting any kind of wiring job.

3. WIRE CONNECTIONS. All connections
must be tight to prevent wires from loosen­ing during machine operation. Double-check
all wires disconnected or connected during
any wiring task to ensure tight connections.

4. MOTOR WIRING. The motor wiring shown
in these diagrams is current at the time of
printing, but it may not match your machine.
Always use the wiring diagram inside the
motor junction box.

5. MODIFICATIONS. Using aftermarket parts or
modifying the wiring beyond what is shown
in the diagram may lead to unpredictable
results, including serious injury or fire.

6. WIRE/COMPONENT DAMAGE. Damaged
wires or components increase the risk of seri­ous personal injury, fire, or machine damage.
If you notice that any wires or components
are damaged while performing a wiring task,
replace those wires or components before
completing the task.

7. CAPACITORS. Some capacitors store an
electrical charge for up to five minutes after
being disconnected from the power source.
To avoid being shocked, wait at least this
long before working on capacitors.

8. CIRCUIT REQUIREMENTS. You MUST fol-
low the requirements on Page 8 when con­necting your machine to a power source.

9. EXPERIENCING DIFFICULTIES. If you are
experiencing difficulties understanding the
information included in this section, contact
our Technical Support at [phone].

The photos and diagrams
included in this section are
best viewed in color. You
can view these pages in
color at www.grizzly.com.

-22-

G8749 Drum/Flap Sander

wiring diagram

Motor

Start Capacitor

400MFD 125VAC

Wiring Diagram

ON/OFF

Switch

Ground

Neutral

Ground

Hot

110VAC

NEMA 5-15 Plug

(As Recommended)

WARNING!

SHOCK HAZARD!

Disconnect power
before working on
wiring.

G8749 Drum/Flap Sander

Figure 23. Model G8749 wiring.

READ ELECTRICAL SAFETY

-23-

ON PAGE 22!

SECTION 9: PARTS

Parts Breakdown

18

11

10-1

13

12

17

7

10

7

19-1

19

20

24

25

2A

27

28

26-1

23

26

22

21

8

9

34

1

31

30

29

39

40

-24-

35-1

38

35

32

36

37

G8749 Drum/Flap Sander

Parts List

REF PART # DESCRIPTION REF PART # DESCRIPTION

1 P8749001 MOTOR 1HP 110V 60HZ 24 P8749024 LOCK BOLT M12-1.75 X 135 LH
2A P8749002A COMPLETE FLAP SANDER ASSY 25 P8749025 FLANGE WASHER 30MM
7 PW07 FLAT WASHER 5/16 26 P8749026 FLAP SANDER END CAP
8 P8749008 ARBOR BOLT RH M12-1.75 X 22 26-1 P8749026-1 FLAP SANDER SHAFT
9 P8749009 END CAP RH 27 P8749027 BRUSH
10 P8749010 SANDING DRUM ASSY 4-3/4 X 8 28 P8749028 SANDPAPER 4-1/2 X 6 120 GRIT
10-1 P8749010-1 DRUM BLADDER 4-3/4 X 8 29 P8749029 STRAIN RELIEF
11 G9211 SANDING SLEEVE 4-3/4 X 8 120G 30 PWRCRD100L POWER CORD 110V W/5-15 PLUG
12 P8749012 AIR VALVE 31 P8749031 BASE
13 P8749013 VALVE CAP 32 P8749032 S CAPACITOR 400M 125V 3 X 1-3/8
17 P8749017 ARBOR BOLT LH M12-1.75 X 22 34 P8749034 MACHINE ID LABEL
18 P8749018 END CAP LH 35 PS07M PHLP HD SCR M4-.7 X 8
19 P8749019 SANDING DRUM ASSY 3-1/4 X 8 35-1 PW05M FLAT WASHER 4MM
19-1 P8749019-1 DRUM BLADDER 3-1/2 X 8 36 P8749036 CAPACITOR BRACKET
20 G9199 SANDING SLEEVE 3-1/4 X 8 37 P8749037 COVER PLATE
21 P8749021 SWITCH MOUNTING PLATE 38 PS07M PHLP HD SCR M4-.7 X 8
22 PSW06 PADDLE SWITCH 110V WITH KEY 39 PW01M FLAT WASHER 8MM
23 PS38M PHLP HD SCR M4-.7 X 10 40 PB26M HEX BOLT M8-1.25 X 30

G8749 Drum/Flap Sander

-25-

-26-

G8749 Drum/Flap Sander

WARRANTY CARD

Name _____________________________________________________________________________

Street _____________________________________________________________________________

City _______________________ State _________________________ Zip _____________________

Phone # ____________________ Email _________________________________________________

Model # ____________________ Order # _______________________ Serial # __________________

The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop
better products and services. Of course, all information is strictly confidential.

1. How did you learn about us?
____ Advertisement ____ Friend ____ Catalog
____ Card Deck ____ Website ____ Other:

2. Which of the following magazines do you subscribe to?

____ Cabinetmaker & FDM
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____ Journal of Light Cont.
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3. What is your annual household income?
____ $20,000-$29,000 ____ $30,000-$39,000 ____ $40,000-$49,000
____ $50,000-$59,000 ____ $60,000-$69,000 ____ $70,000+

CUT ALONG DOTTED LINE

4. What is your age group?
____ 20-29 ____ 30-39 ____ 40-49
____ 50-59 ____ 60-69 ____ 70+

5. How long have you been a woodworker/metalworker?
____ 0-2 Years ____ 2-8 Years ____ 8-20 Years ____20+ Years

6. How many of your machines or tools are Grizzly?
____ 0-2 ____ 3-5 ____ 6-9 ____10+

____ Popular Science
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____ Wooden Boat
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____ Woodworker West
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____ Other:

7. Do you think your machine represents a good value? _____Yes _____No

8. Would you recommend Grizzly Industrial to a friend? _____Yes _____No

9. Would you allow us to use your name as a reference for Grizzly customers in your area?
Note: We never use names more than 3 times. _____ Yes _____No

10. Comments: _____________________________________________________________________

_________________________________________________________________________________

_________________________________________________________________________________

_________________________________________________________________________________

FOLD ALONG DOTTED LINE

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Place

Stamp

Here

GRIZZLY INDUSTRIAL, INC.
P.O. BOX 2069
BELLINGHAM, WA 98227-2069

Send a Grizzly Catalog to a friend:

Name_______________________________

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City______________State______Zip______

TAPE ALONG EDGES--PLEASE DO NOT STAPLE

WARRANTY AND RETURNS

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special,

WARRANTY AND RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from
the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse,
negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty
and any and all warranties that may be implied by law, including any merchantability or fitness, for any par­ticular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent
that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants.
In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and
any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

or consequential damages arising from the use of our products.

To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then
issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the
carton. We will not accept any item back without this number. Proof of purchase must accompany the
merchandise.

The manufacturers reserve the right to change specifications at any time because they constantly strive to
achieve better quality equipment. We make every effort to ensure that our products meet high quality and
durability standards and we hope you never need to use this warranty.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.