JET 577634, 577842, 578842 User Manual
Operating Instructions and Parts Manual
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Benchtop Belt and Disc Sanders
Models IBDG-248/248VS/436/436VS
JET
427 New Sanford Road
LaVergne, Tennessee 37086 Part No. M-578842
Ph.: 800-274-6848 Edition 1 01/2020
www.jettools.com Copyright © 2020 JET
IBDG-248 shown
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1.0 IMPORTANT SAFETY
INSTRUCTIONS
1.1 General safety rules
WARNING – To reduce risk of injury:
1. Read and understand the entire owner's
manual before attempting assembly or
operation.
2. Read and understand the warnings posted on
the machine and in this manual. Failure to
comply with all of these warnings may cause
serious injury.
3. Replace warning labels if they become
obscured or removed.
4. Know the tool you are using; its application,
limitations, and potential hazards.
5. Do not use this machine for other than its
intended use. If used for other purposes, JET
disclaims any real or implied warranty and holds
itself harmless from any injury that may result
from that use.
6. Always wear protective eye wear when
operating machinery. Eye wear shall be impact
resistant, protective safety glasses with side
shields which comply with ANSI Z87.1
specifications. Use of eye wear which does not
comply with ANSI Z87.1 specifications could
result in severe injury from breakage of eye
protection. (Everyday eyeglasses only have
impact resistant lenses; they are NOT safety
glasses.)
7. Wear proper apparel. Do not wear loose
clothing, neckties, rings, bracelets, or other
jewelry which may get caught in moving parts.
Non-slip footwear is recommended. Wear
protective hair covering to contain long hair.
8. Wear hearing protection (plugs or muffs) if the
particular work requires it.
9. Do not operate this machine while tired or under
the influence of drugs, alcohol or any
medication.
10. Make certain the switch is in the OFF position
before connecting the machine to the power
supply.
11. Make certain the machine is properly grounded.
12. Make all machine adjustments or maintenance
with the machine unplugged from the power
source.
13. Remove adjusting keys and wrenches. Form a
habit of checking to see that keys and adjusting
wrenches are removed from the machine
before turning it on.
14. Keep safety guards in place at all times when
the machine is in use. If removed for
maintenance purposes, use extreme caution
and replace the guards immediately after
completion of maintenance.
15. Check damaged parts. Before further use of the
machine, a guard or other part that is damaged
should be carefully checked to determine that it
will operate properly and perform its intended
function. Check for alignment of moving parts,
binding of moving parts, breakage of parts,
mounting and any other conditions that may
affect its operation. A guard or other part that is
damaged should be properly repaired or
replaced.
16. Provide for adequate space surrounding work
area and non-glare, overhead lighting.
17. Keep the floor around the machine clean and
free of scrap material, oil and grease.
18. Keep visitors a safe distance from the work
area. Keep children away.
19. Make your workshop child proof with padlocks,
master switches or by removing starter keys.
20. Give your work undivided attention. Looking
around, carrying on a conversation and “horseplay” are careless acts that can result in serious
injury.
21. Keep proper footing and balance at all times so
that you do not fall into or lean against the
sanding belt or other moving parts. Do not
overreach or use excessive force to perform
any machine operation.
22. Disconnect sander from power source before
servicing and when changing abrasive wheel or
sanding belt.
23. Use recommended accessories. The use of
improper accessories may cause risk of injury
to persons.
24. Turn off the machine before cleaning. Use a
brush to remove chips or debris — do not use
bare hands.
25. Never leave sander running unattended. Turn
power off and do not leave machine until belt
and disc have completely stopped
26. Remove loose items and unnecessary work
pieces from the area before starting the sander.
27. Don’t use in dangerous environment. Don’t use
power tools in damp or wet location, or expose
them to rain. Don’t use this machine in a
flammable environment. Keep work area well lit.
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28. Keep work area clean. Cluttered areas and
benches invite accidents.
29. Use the right tool. Don't force tool or attachment
to do a job for which it was not designed.
30. Use proper extension cord. An undersized cord
will cause a drop in line voltage resulting in loss
of power and overheating. Table 2 (see sect.
7.2) shows correct size to use depending on
cord length and nameplate ampere rating.
31. Maintain tools with care. Keep tools sharp and
clean for best and safest performance. Follow
instructions for lubricating and changing
accessories.
32. Direction of feed: Feed work into a blade or
cutter against the direction of rotation of the
blade or cutter only.
1.2 Specific rules for abrasive
sanding machines
Abrasive sanding can be hazardous to operators
and bystanders. Sanding sparks, chips and dust
particles thrown off by the sanding disc can cause
serious injury by contact or inhalation. In addition to
the general safety rules above, you must also
comply with the following specific requirements:
1. If you are not thoroughly familiar with the
operation of belt and disc sanders, obtain
advice from your supervisor, instructor or other
qualified person.
2. A dust collection system is recommended.
Operator shall also wear a dust mask at all
times.
3. Do not sand magnesium; it could catch fire.
Additional precautions may be needed for other
materials that are hazardous or flammable.
Always consult the material manufacturer for
instructions on sawing and handling.
4. Do not start the grinder while a workpiece is
contacting the grinding wheel or the sanding
belt.
5. If there is any risk of the machine tipping or
moving during operation, such as when sanding
long or heavy boards, the machine must be
securely fastened to a supporting surface.
6. Make sure the sanding belt is running in the
proper direction; it must travel downward when
viewed from front of machine.
7. Make sure sanding belt tracks correctly so that
it does not run off the wheels.
8. Make sure sanding belt or disc is not torn or
loose.
9. Before sanding, allow motor to reach operating
speed, then check the sanding disc for wobble,
runout or any unbalanced condition. If the disc
is not operating accurately and smoothly,
immediately stop the motor and make repairs
before attempting sanding operations.
10. Always hold the work firmly on the table when
sanding on the belt or disc. The only exception
is curved work performed on the bottom wheel.
11. Always sand on the downward side of the disc
so that the work is held securely on the table.
Sanding on the upward side of the disc can
cause the workpiece to fly upward, which may
be hazardous.
12. Always maintain a minimum clearance of 1/16inch between table and sanding belt or disc.
13. This machine can be used for processing wood
or metal products. However, combining wood
dust and metal filings can create a fire hazard.
Make sure that the dust collector is free of wood
dust deposits before processing metal
products.
14. Never wear gloves or hold the work with a rag
when sanding.
15. Sand with the grain of the wood when possible.
16. Do not sand pieces of material that are too small
to be safely supported.
17. When sanding a large workpiece, provide
additional support at table height.
18. Avoid awkward hand positions where a sudden
slip could cause a hand to move into the
sanding belt or disc.
19. Never force the work. Slowing or stalling the
motor will cause overheating.
20. Always remove scrap pieces and other objects
from the belt and disc tables before turning on
the machine.
21. When sanding metal, never use a steady
stream of water on the work piece. Dip the
workpiece in water to cool it.
22. Wear protective clothing such as apron, safety
shoes, or arm guards, where the sanding or
grinding activity presents a hazard to the
operator.
23. Abrasive discs must be stored in a controlled
environment area. Relative humidity should be
35% to 50% and the temperature should be
between 60 and 80 degrees Farenheit. Failure
to do so could cause premature disc failure.
24. Examine the face of the sanding disc carefully.
Excessive sanding which wears down to the
backing material can cause tearing of the disc.
Never use a disc which shows backing, nicks or
cuts on the surface or edge, or damage due to
creasing or poor handling.
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25. When installing a new disc, be certain the disc
is accurately centered on the drive wheel.
Failure to do so could cause an unbalanced
condition.
26. Always present the workpiece to the wheel
while resting the workpiece firmly on the table.
Failure to do so could result in damage to the
workpiece or throwing of the workpiece off the
wheel.
WARNING: This product can expose you to
chemicals including lead which is known to the
State of California to cause cancer and birth
defects or other reproductive harm. For more
information go to http://www.p65warnings.ca.
gov.
WARNING: Some dust, fumes and gases
created by power sanding, sawing, grinding,
drilling, welding and other construction activities
contain chemicals known to the State of
California to cause cancer and birth defects or
other reproductive harm. Some examples of
these chemicals are:
lead from lead based paint
crystalline silica from bricks, cement and
other masonry products
arsenic and chromium from chemically
treated lumber
Your risk of exposure varies, depending on how
often you do this type of work. To reduce your
exposure to these chemicals, work in a wellventilated area and work with approved safety
equipment, such as dust masks that are
specifically designed to filter out microscopic
particles. For more information go to
http://www.p65warnings.ca. gov/ and http://www
.p65warnings.ca.gov/wood.
SAVE THESE INSTRUCTIONS
Familiarize yourself with the following safety notices used in this manual:
This means that if precautions are not heeded, it may result in minor injury and/or possible
machine damage.
This means that if precautions are not heeded, it may result in serious, or possibly even fatal,
injury.
2.0 About this manual
This manual is provided by JET, covering the safe operation and maintenance procedures for a JET Model IBDG
series Belt and Disc Sander. This manual contains instructions on installation, safety precautions, general
operating procedures, maintenance instructions and parts breakdown. Your machine has been designed and
constructed to provide consistent, long-term operation if used in accordance with the instructions set forth in this
document.
If there are questions or comments, please contact your local supplier or JET. JET can also be reached at our
web site: www.jettools.com.
Retain this manual for future reference. If the machine transfers ownership, the manual should accompany it.
Read and understand the entire contents of this manual before attempting assembly or
operation! Failure to comply may cause serious injury!
Register your product using the provided mail-in card, or register online:
http://www.jettools.com/us/en/service-and-support/warranty/registration/
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3.0 Table of contents
Section Page
1.0 IMPORTANT SAFETY INSTRUCTIONS ....................................................................................................... 2
1.1 General safety rules ................................................................................................................................... 2
1.2 Specific rules for abrasive sanding machines ............................................................................................ 3
2.0 About this manual .......................................................................................................................................... 4
3.0 Table of contents ............................................................................................................................................ 5
4.0 Specifications ................................................................................................................................................. 6
4.1 Mounting hole dimensions .......................................................................................................................... 7
4.2 Machine dimensions/work area .................................................................................................................. 8
5.0 Carton contents .............................................................................................................................................. 9
6.0 Setup and assembly ..................................................................................................................................... 10
6.1 Tools required for assembly ..................................................................................................................... 10
6.2 Unpacking ................................................................................................................................................ 10
6.3 Securing the sander ................................................................................................................................. 10
6.4 Belt sanding table ..................................................................................................................................... 10
6.5 Stand-off ................................................................................................................................................... 10
6.6 Sanding tool rest ...................................................................................................................................... 11
6.7 Dust port ................................................................................................................................................... 11
6.8 Installing sanding disc .............................................................................................................................. 11
6.9 Installing disc table ................................................................................................................................... 11
6.10 Miter gauge ............................................................................................................................................ 11
7.0 Electrical connections .................................................................................................................................. 11
7.1 GROUNDING INSTRUCTIONS ............................................................................................................... 12
7.2 Extension cords ........................................................................................................................................ 12
7.3 Voltage conversion ................................................................................................................................... 13
8.0 Adjustments ................................................................................................................................................. 13
8.1 Sanding arm tilt ........................................................................................................................................ 13
8.2 Sanding belt tracking ................................................................................................................................ 13
9.0 Operation ..................................................................................................................................................... 13
9.1 Basic procedures ...................................................................................................................................... 13
9.2 Operating controls .................................................................................................................................... 14
10.0 User-maintenance ...................................................................................................................................... 15
10.1 Cleaning ................................................................................................................................................. 15
10.2 Installing/replacing sanding belt ............................................................................................................. 15
10.3 Tension lever tightness .......................................................................................................................... 15
10.4 Replacing sanding disc .......................................................................................................................... 15
10.5 Lubrication .............................................................................................................................................. 15
10.6 Additional servicing ................................................................................................................................ 15
11.0 Optional accessories .................................................................................................................................. 16
12.0 Troubleshooting IBDG series Belt/Disc Sander ......................................................................................... 17
12.1 General mechanical and electrical problems ......................................................................................... 17
12.2 Digital readout error codes (Variable speed models) ............................................................................. 19
13.0 Replacement Parts ..................................................................................................................................... 19
13.1.1 IBDG-248 Belt/Disc Sander – Exploded View ..................................................................................... 20
13.1.2 IBDG-248 Belt/Disc Sander – Parts List .............................................................................................. 21
13.2.1 IBDG-248VS Belt/Disc Sander – Exploded View ................................................................................ 23
13.2.2 IBDG-248VS Belt/Disc Sander – Parts List ......................................................................................... 24
13.3.1 IBDG-436 Belt/Disc Sander – Exploded View ..................................................................................... 26
13.3.2 IBDG-436 Belt/Disc Sander – Parts List .............................................................................................. 27
13.4.1 IBDG-436VS Belt/Disc Sander – Exploded View ................................................................................ 29
13.4.2 IBDG-436VS Belt/Disc Sander – Parts List ......................................................................................... 30
14.0 Electrical Connections ................................................................................................................................ 32
14.1 Wiring diagram for IBDG-248 and IBDG-436 ......................................................................................... 32
14.2 Wiring diagram for IBDG-248VS and IBDG-436VS ............................................................................... 32
15.0 Warranty and service ................................................................................................................................. 33
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4.0 Specifications
Table 1
Stock number
Model number IBDG-248 IBDG-248VS IBDG-436 IBDG-436VS
Motor and Electricals
Type
Horsepower 1HP
Phase 1 PH 3 PH 1 PH 3 PH
Motor
Input power required Single phase 115V (or 230V if rewired)
On/off switch toggle TACT toggle TACT
Power transfer Direct drive
Power cord SJT 16AWG x 3C, 6 ft. (183cm)
Power plug installed 5-15P, 125V/15A
Recommended minimum circuit size 1 15 A
Sound emission without load 2 75 dB at 3 ft. (92cm)
Disc sander
Disc diameter 9 in. (228.6m)
Sanding disc 80 Grit, Aluminum Oxide
Disc table size 11-13/16 x 5-29/32 in. (300 x 150 mm)
T-slot size (W x D) 3/4 x 3/8 in. (19 x 9.6 mm)
Disc table tilt 45 deg. down
Dust port diameter 2 in. (52mm)
Base
Foot print (W x D) 9-1/2 x 8-1/16 in. (240 x 205mm)
Mounting holes diameter 7/16 in. (11mm)
Distance between mounting hole
centers
Belt sander
Sanding belt size (L x W) 48 x 2 in. (1219 x 52) 36 x 4 in. (914 x 102 mm)
Sanding belt type 80 Grit, Aluminum Oxide
Belt speed (SFPM) 4,712 1,178 – 4,712 3,769 942-3,769
Belt table tilt 45 deg. down
Belt table size (L x W) 4-11/32 x 2-15/16 in. (110 x 75 mm) 6-5/16 x 2-15/16 in. (160 x 75 mm)
Tool rest tilt 45 deg. down
Tool rest size (L x W) 3-1/8 x 2-5/8 in. (79 x 67 mm) 5-1/8 x 3-1/8 in. (130 x 80 mm)
Drive wheel size (Dia. x W) 5 x 2-1/16 in. (127.5 x 53 mm) 4 x 4-1/16 (102.5 x 104 mm)
Dust port diameter 2 in. (52 mm)
Minimum dust extraction required
Weights
Net weight 74 lbs. (33.82 kg) 73 lbs. (33.32 kg)
Shipping weight 97 lbs. (44.25 kg) 92 lbs. (41.96 kg)
Voltage 115/230V, prewired 115V
Cycle 60 Hz
Listed FLA (full load amps) 11 / 5.5 A 7 / 3.5 A 11 / 5.5 A 7 / 3.5 A
Speed 3,600 RPM 900-3600 RPM 3,600 RPM 900-3600 RPM
Starting capacitor
Running capacitor 35µF, 250V n/a 35µF, 250V n/a
578842 577842 578634 577634
totally enclosed,
induction,
capacitor start
200MFD,
125VAC
totally enclosed,
induction,
with inverter
n/a
8-15/32 in. (215mm)
totally enclosed,
induction,
capacitor start
200MFD,
125VAC
totally enclosed,
induction,
with inverter
n/a
6
Dimensions
Overall
dimensions
(L x W x H)
Shipping dimensions (L x W x H)
Main materials
Disc sander
Belt sander
1
subject to local and national electrical codes.
2
The specified values are emission levels and are not necessarily to be seen as safe operating levels. As workplace
conditions vary, this information is intended to allow the user to make a better estimation of the hazards and risks
involved only.
L = length, W = width, H = height, D = depth
n/a = not applicable
The specifications in this manual were current at time of publication, but because of our policy of continuous
improvement, JET reserves the right to change specifications at any time and without prior notice, without incurring
obligations.
Sanding arm vertical
Sanding arm horizontal
Disc Aluminum
Disc guard Aluminum
Disc lower cover Aluminum
Disc table Cast iron
Trunnions Aluminum
Belt table Cast iron
Belt table bracket Sheet metal
Tool rest
Tool rest bracket
23-7/16 x 15-1/16 x 25-29/32 in.
(595 x 383 x 658 mm)
23-7/16 x 26-27/32 x 12-7/32 in.
(595 x 682 x 310 mm)
26-9/16 x 24-19/32 x 16-15/16 in.
(675 x 625 x 430 mm)
Sheet metal
Sheet metal
25-13/32 x 15-1/16 x 20-3/4 in.
(645 x 383 x 527 mm)
25-13/32 x 21-11/16 x 11-3/4 in.
(645 x 551 x 298 mm)
21-15/32 x 24-19/32 x 16-15/16
(545 x 625 x 430 mm)
4.1 Mounting hole dimensions
Figure 4-1 Base mounting holes, all models
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4.2 Machine dimensions/work area
Primary dimensions in millimeters. (Parentheses show imperial dimensions.)
Figure 4-2: dimensions for IBGB-248/-248VS
Figure 4-3: dimensions for IBGB-436/-436VS
8
5.0 Carton contents
Included accessories are shown on this page. The
identifying letters are used in the assembly
instructions.
Hardware package
Part no. IBGB248-HP or IBGB436-HP
K Tool rest (for sanding belt) 1
L Flat washer 3/8 1
M Adjustable handle 3/8 x 5/8L 1
N Stand-off 1
O Socket hd cap screw 5/16 x 1/2 1
P Flat washer 5/16 1
R Ext. tooth lock washer M8 1
S Bracket plate 1
T Flat washer 5/16 1
U Adjustable handle 5/16 x 1L 1
Qty.
W Belt Sanding Table 1
Hex (“Allen”) Wrench 6mm 1
Disc Table 1
Qty.
Qty.
B Dust port 1
Truss head screw 3/16 x 3/8 3
Miter gauge 1
Qty.
Qty.
9
Handles for disc table 1
Flat Washers 2
Hex (“Allen”) wrench 3mm 1
Sanding disc 80G, Ø9 in. 1
Qty.
Qty.
6.0 Setup and assembly
rubber pads be left on, as they allow air circulation
as well as vibration dampening.
6.1 Tools required for assembly
Cross-point (Phillips) screwdriver
3mm hex wrench – provided
6mm hex wrench – provided
Additional tools may be needed for securing sander
to a stand or workbench.
6.2 Unpacking
Separate all parts from the packing material. Check
each part against sect. 5.0, Carton contents, and
make certain that all items are accounted for.
(Check whether any parts have been pre-mounted
to the grinder.) Notify your dealer or JET if missing
or damaged items are discovered. Do not discard
packing material until grinder is assembled and
operating properly.
The IBDG Belt and Disc Sander requires minimal
assembly. For your safety, do not plug the sander
into a power source until all assembly and
adjustments are complete.
Make sure that sander is
unplugged and power switch is in OFF position.
Do not plug in the sander to power until it is
inspected for shipping damage and all
necessary assembly and adjustments are
performed. Failure to comply may cause serious
injury.
6.4 Belt sanding table
Install bracket plate, table and handles, as shown in
Figure 6-1. (You may prefer sanding arm in
horizontal position for this – see Figure 6-3.)
Figure 6-1: sanding belt table
TIP: The quickest method of installing a handle is to
start the handle into the threads of the hole, then pull
out on the handle while turning the screw with a
3mm hex wrench until tight. See Figure 6-2.
To reposition a handle for convenience without
affecting its tightness, pull out on it, rotate, then
release it, allowing it to resettle upon the screw.
Do not operate this machine
without all guards and shields in place and in
working order. Failure to comply may cause
serious injury.
6.3 Securing the sander
To prevent the machine from moving during
operation, it should be securely mounted to a work
bench or stand. Fasteners for mounting are not
included with the sander.
1. Align mounting holes on sander with predrilled
holes in bench or pedestal. Figure 4-1 shows
hole centers for mounting.
2. Insert M10 (or 3/8”) bolts through the holes and
secure with washers and nuts.
An optional JET pedestal stand (not included) is
available for your sander. See sect. 11.0.
IMPORTANT: The sander’s base plate contains
ventilation holes for heat dissipation. This is
especially important on the variable speed models,
as it helps keep the circuit board at an acceptable
temperature. These holes should not be obstructed.
If the rubber pads are removed for mounting to a
table, allow an opening in the table below the grinder
for air circulation. However, it is recommended the
Figure 6-2: installing handles
To avoid trapping the work or
fingers between table and sanding belt, the table
edge must be positioned 1/16-inch or less from
the sanding belt.
6.5 Stand-off
1. Install stand-off (shown installed in Figure 8-2)
into threaded hole in back of sanding arm.
2. Loosen screw (A, Figure 6-3) with 6mm hex
wrench and lower sanding arm to horizontal
position.
3. Turn stand-off in or out as needed until sanding
arm is level with workbench.
4. Tighten hex nut against sanding arm to secure
setting of stand-off.
10
6.6 Sanding tool rest
Loosen screw (A, Figure 6-3) with 6mm hex wrench
and lower sanding arm to horizontal position.
Install tool rest as shown in Figure 6-3, using a 6mm
hex wrench.
Note: The tool rest can remain installed when not in
use. Simply adjust it outward to allow opening and
closing of drive wheel cover. Adjust it inward before
raising arm to vertical position.
Figure 6-3: Sanding tool rest
Position table at 90° to disc, and check distance
between table edge and sanding disc. If gap is
greater than 1/16-inch, adjust as follows:
1. Look through top access hole and rotate disc
until set screw appears.
2. Insert provided 3mm hex wrench through hole
to loosen set screw. See Figure 6-4.
3. Bump disc toward the table to achieve 1/16-inch
gap. (Remove lower guard if needed.)
4. Tighten set screw. (Reinstall lower guard if
removed.)
6.7 Dust port
Install dust port (B, Figure 6-3) over exhaust hole in
sanding arm, with three screws.
It is recommended that a dust collection system
designed for metal dust and shavings be connected
to the two ports on both ends of the machine, using
2-1/2” inside-diameter hose with hose clamp (not
provided). An accessory hose kit is available from
JET; see sect. 11.0.
6.8 Installing sanding disc
1. Remove guard covering lower portion of disc.
2. Peel back about 1/2 of the backing on sanding
disc to expose the adhesive.
3. Carefully position upper part of sanding disc to
the machine disc, matching its outer edge with
that of the machine disc. Continue peeling away
the remainder of the backing as you work
downward to remove any entrapped air,
pressing the sanding disc to the machine’s disc.
4. Reinstall lower guard.
6.9 Installing disc table
Install disc table with two handles and flat washers
(see Figure 6-4). Loosen handles to tilt table
downward. Tighten handles before operating.
To avoid trapping the work or
fingers between table and sanding disc, the
table edge must be positioned 1/16-inch or less
from sanding disc.
Figure 6-4: disc table
6.10 Miter gauge
Insert the miter gauge bar into the end of the disc
table slot. Loosen handle to rotate gauge to desired
angle shown on scale. Always tighten handle before
operating.
If precise angles are needed, verify the miter gauge
setting by placing an angle measuring device
against miter gauge and sanding disc.
7.0 Electrical connections
Electrical connections should
be made by a qualified electrician in compliance
with all relevant codes. This tool must be
properly grounded. Failure to comply may cause
serious or fatal injury.
The IBDG Belt and Disc Sander is prewired for 115V
single phase power, and is supplied with a plug
designed for use on a circuit with a grounded outlet
that looks like the one pictured in A, Figure 7-1. The
sander may also be used with 230V single phase
input power, see sect. 7.3 for instructions.
Before connecting to power source, be sure switch
is in off position.
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