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OPERATOR’S MANUAL
4 x36
BELT/DISC SANDER
BD4600
Your belt/disc sander has been engineered and manufactured to our high standard for dependability, ease of operation,
and operator safety. When properly cared for, it will give you years of rugged, trouble-free performance.
WARNING: To reduce the risk of injury, the user must read and understand the operator’s manual before using
this product.
Thank you for your purchase.
SAVE THIS MANUAL FOR FUTURE REFERENCE
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TABLE OF CONTENTS
Introduction ..................................................................................................................................................................... 2
Warranty .......................................................................................................................................................................... 2
General Safety Rules .................................................................................................................................................... 3-4
Specific Safety Rules ....................................................................................................................................................... 4
Symbols ........................................................................................................................................................................5-6
Electrical .......................................................................................................................................................................... 7
Glossary of Terms ............................................................................................................................................................ 8
Features ......................................................................................................................................................................9-10
Loose Parts ................................................................................................................................................................... 11
Assembly ..................................................................................................................................................................11-13
Operation .................................................................................................................................................................. 14-15
Adjustments ................................................................................................................................................................... 16
Maintenance .................................................................................................................................................................. 17
Parts Ordering / Service ...................................................................................................................................Back Page
INTRODUCTION
This tool has many features for making its use more pleasant and enjoyable. Safety, performance, and dependability have
been given top priority in the design of this product making it easy to maintain and operate.
WARRANTY
RYOBI® POWER TOOL - LIMITED TWO YEAR WARRANTY AND 30 DAY EXCHANGE POLICY
One World Technologies, Inc., warrants its RYOBI® power tools with the following conditions:
30-DAY EXCHANGE POLICY: During the first 30 days after date of purchase, you may either request service under this
warranty or you may exchange any RYOBI® power tool which does not work properly due to defective workmanship or
materials by returning the power tool to the dealer from which it was purchased. To receive a replacement power tool
or requested warranty service, you must present proof of purchase and return all original equipment packaged with the
original product. The replacement power tool will be covered by the limited warranty for the balance of the two year period
from the date of the original purchase.
WHAT THIS WARRANTY COVERS: This warranty covers all defects in workmanship or materials in your RYOBI® power
tool for a period of two years from the date of purchase. With the exception of batteries, power tool accessories are
warranted for ninety (90) days. Batteries are warranted for two years.
HOW TO GET SERVICE: Just return the power tool, properly packaged and postage prepaid, to an Authorized Service
Center. You can obtain the location of the Service Center nearest you by contacting a service representative at One
World Technologies, Inc., P.O. Box 1207, Anderson, SC 29622-1207, by calling 1-800-525-2579 or by logging on to www.
ryobitools.com. When you request warranty service, you must also present proof of purchase documentation, which
includes the date of purchase (for example, a bill of sale). We will repair any faulty workmanship, and either repair or replace
any defective part, at our option. We will do so without any charge to you. We will complete the work in a reasonable time,
but, in any case, within ninety (90) days or less.
WHAT’S NOT COVERED: This warranty applies only to the original purchaser at retail and may not be transferred. This
warranty only covers defects arising under normal usage and does not cover any malfunction, failure or defects resulting
from misuse, abuse, neglect, alteration, modification or repairs by other than Authorized Service Centers. One World
Technologies, Inc. makes no warranties, representations or promises as to the quality or performance of its power tools
other than those specifically stated in this warranty.
ADDITIONAL LIMITATIONS: Any implied warranties granted under state law, including warranties of merchantability or
fitness for a particular purpose, are limited to two years from the date of purchase. One World Technologies, Inc. is not
responsible for direct, indirect, or incidental damages, so the above limitations and exclusions may not apply to you. This
warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
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GENERAL SAFETY RULES
WARNING:
Read and understand all instructions. Failure to follow
all instructions listed below, may result in electric shock,
fire and/or serious personal injury.
READ ALL INSTRUCTIONS
WORK AREA
KNOW YOUR POWER TOOL. Read the operator’s
manual carefully. Learn the applications and limitations
as well as specific potential hazards related to this tool.
GU AR D AG A IN ST ELE C TR IC AL S HO CK BY
PREVENTING BODY CONTACT WITH GROUNDED
SURFACES. For example: pipes, radiators, ranges, re-
frigerator enclosures.
KEEP GUARDS IN PLACE and in working order.
REMOVE ADJUSTING KEYS AND WRENCHES. Form
habit of checking to see keys and adjusting wrenches are
removed from tool before turning it on.
KEEP THE WORK AREA CLEAN. Cluttered work areas
and work benches invite accidents. DO NOT leave tools
or pieces of wood on the tool while it is in operation.
DO NOT USE IN DANGEROUS ENVIRONMENTS. Do
not use power tools in damp or wet locations or expose
them to rain. Keep the work area well lit.
KEEP CHILDREN AND VISITORS AWAY. All visitors
should wear safety glasses and be kept a safe distance
from work area. Do not let visitors contact tool or extension cord while operating.
MAKE WORKSHOP CHILDPROOF with padlocks,
master switches, or by removing starter keys.
DON’T FORCE THE TOOL. It will do the job better and
safer at the rate for which it was designed.
USE THE RIGHT TOOL. Do not force the tool or attach-
ment to do a job for which it was not designed.
USE THE PROPER EXTENSION CORD. Make sure your
extension cord is in good condition. Use only a cord heavy
enough to carry the current your product will draw. An
undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A wire gauge size
(A.W.G.) of at least 16 is recommended for an extension
cord 50 feet or less in length. If in doubt, use the next
heavier gauge. The smaller the gauge number, the heavier
the cord.
DRESS PROPERLY. Do not wear loose clothing, neckties,
or jewelry that can get caught and draw you into moving
parts. Rubber gloves and nonslip footwear are recommended when working outdoors. Also wear protective
hair covering to contain long hair.
ALWAYS WEAR SAFETY GLASS ES WITH SIDE
SHIELDS. Everyday eyeglasses have only impact-resis-
tant lenses, they are NOT safety glasses.
SECURE WORK. Use clamps or a vise to hold work when
practical, it is safer than using your hand and frees both
hands to operate the tool.
DO NOT OVERREACH. Keep proper footing and balance
at all times.
MAINTAIN TOOLS WITH CARE. Keep tools sharp and
clean for best and safest performance. Follow instructions
for lubricating and changing accessories.
DISCONNECT TOOLS. When not in use, before servic-
ing, or when changing attachments, blades, bits, cutters,
etc., all tools should be disconnected from power source.
AVOID ACCIDENTAL STARTING. Be sure switch is off
when plugging in any tool.
USE RECOMMENDED ACCESSORIES. Consult the
operator’s manual for recommended accessories. The
use of improper accessories may result in injury.
NEVER STAND ON TOOL. Serious injury could occur if
the tool is tipped.
CHECK DAMAGED PARTS. Before further use of the
tool, a guard or other part that is damaged should be
carefully checked to determine that it will operate properly
and perform its intended function. Check for alignment
of moving parts, binding of moving parts, breakage of
parts, mounting and any other conditions that may affect
its operation. A guard or other part that is damaged must
be properly repaired or replaced by an authorized service
center to avoid risk of personal injury.
USE THE RIGHT DIRECTION OF FEED. Feed work into
a blade, cutter, or sanding spindle against the direction
or rotation of the blade, cutter, or sanding spindle only.
NEVER LEAVE TOOL RUNNING UNATTENDED. TURN
THE POWER OFF. Don’t leave tool until it comes to a
complete stop.
PROTECT YOUR LUNGS. Wear a face or dust mask if
the cutting operation is dusty.
PROTECT YOUR HEARING. Wear hearing protection
during extended periods of operation.
DO NOT ABUSE CORD. Never carry tool by the cord or
yank it to disconnect from receptacle. Keep cord from
heat, oil, and sharp edges.
USE OUTDOOR EXTENSION CORDS. When tool
is used outdo ors, use only exten sion cords with
approved ground connection that are intended for use
outdoors and so marked.
KE EP BLA D ES C LE AN , SH A R P, AND WI T H
SUFFICIENT SET. Sharp blades minimize stalling
and kickback.
NEVER USE IN AN EXPLO SIVE ATMOSPHERE.
Normal sparking of the motor could ignite fumes.
INSPECT TOOL CORDS PERIODICALLY. If dam-
aged, have repaired by a qualified service technician at
an authorized service facility. The conductor with insulation having an outer surface that is green with or without
yellow stripes is the equipment-grounding conductor. If
repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor
to a live terminal. Repair or replace a damaged or worn
cord immediately. Stay constantly aware of cord location
and keep it well away from the rotating blade.
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GENERAL SAFETY RULES
INSPECT EXTENSION CORDS PERIODICALLY and
replace if damaged.
KEEP TOOL DRY, CLEAN, AND FREE FROM OIL AND
GREASE. Always use a clean cloth when cleaning. Never
use brake fluids, gasoline, petroleum-based products, or
any solvents to clean tool.
STAY ALERT AND EXERCISE CONTROL. Watch what
you are doing and use common sense. Do not operate
tool when you are tired. Do not rush.
DO NOT USE TOOL IF SWITCH DOES NOT TURN IT
ON AND OFF. Have defective switches replaced by an
authorized service center.
INSPECT FOR AND REMOVE ALL NAILS FROM LUM-
BER BEFORE USING THIS TOOL. Following this rule
will reduce the risk of serious personal injury.
SPECIFIC SAFETY RULES
FIRMLY CLAMP OR BOLT your tool to a workbench or
table at approximately hip height.
NEVER stand or have any part of your body in line with
the path of the workpiece.
PLAN YOUR WORK TO REDUCE THE RISK OF
THROWBACKS (when the workpiece catches the sand-
ing drum and is torn from your hands).
MAKE SURE THERE’S NO DEBRIS between the
workpiece and its supports.
WH EN S AN DI NG I RR EG UL AR LY S H A P E D
WORKPIECES, plan your work support so it will not slip
and be pulled from your hands.
USE EXTRA CAUTION WITH LARGE, very small or
awkward workpieces.
NEVER USE THIS TOOL to finish pieces too small to
hold by hand.
USE EXTRA SUPPORTS (TABLES, SAW HORSES,
BLOCKS, ETC.) for any workpieces large enough to tip
when not secured to the work surface.
NEVER sand more than one piece at a time. DO NOT
STACK more than one workpiece on the sander table at
a time.
ALWAYS FEED WORKPIECE FROM LEFT TO RIGHT
against the direction the drum sleeve is rotating.
NEVER START A TOOL WHEN ANY ROTATING COM-
PONENT IS IN CONTACT WITH THE WORKPIECE.
DO NOT OPERATE A TOOL WHILE UNDER THE
INFLUENCE OF DR U GS, ALCOHOL, OR AN Y
MEDICATION.
WHEN SERVICING use only identical replacement parts.
Use of any other parts may create a hazard or cause
product damage.
USE ONLY RECOMMENDED ACCESSORIES listed
in this manual or addendums. Use of accessories that
are not listed may cause the risk of personal injury.
Instructions for safe use of accessories are included
with the accessory.
DOUBLE CHECK ALL SETUPS. Make sure the spindle
or sanding belt assembly is tight and not making contact with sander or workpiece before connecting to
power supply.
DO NOT USE DRUMS, sanding sleeves or belts which
show visual signs of wear such as grooves, tears or
rips.
ALWAYS STAY ALERT! Do not allow familiarity (gained
from frequent use of your sander) to cause a careless
mistake. ALWAYS REMEMBER that a careless fraction
of a second is sufficient to inflict severe injury.
MAKE SURE THE WORK AREA HAS AMPLE LIGHTING
to see the work and that no obstructions will interfere with
safe operation BEFORE performing any work using your
tool.
ALWAYS TURN OFF THE SANDER before disconnecting
it to avoid accidental starting when reconnecting to power
supply. NEVER leave the tool unattended while connected
to a power source.
SUPPORT WORKPIECE with miter gauge, work rest, or
worktable.
MAINTAIN 1/16 in. clearance between worktable and
sanding belt or disc.
AVOID KICKBACK by sanding in accordance with
directional arrows.
IF THE POWER SUPPLY CORD IS DAMAGED, it must
be replaced only by the manufacturer or by an authorized
service center to avoid risk.
SAVE THESE INSTRUCTIONS. Refer to them frequently
and use them to instruct others who may use this tool. If you
loan someone this tool, loan them these instructions also.
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SYMBOLS
Some of the following symbols may be used on this tool. Please study them and learn their meaning. Proper interpretation
of these symbols will allow you to operate the tool better and safer.
SYMBOL NAME
V Volts Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
min Minutes Time
Alternating Current Type of current
Direct Current Type or a characteristic of current
DESIGNATION/EXPLANATION
n
o
.../min Per Minute Revolutions, strokes, surface speed, orbits etc., per minute
No Load Speed Rotational speed, at no load
Class II Construction Double-insulated construction
Wet Conditions Alert Do not expose to rain or use in damp locations.
Read The Operator’s Manual
Eye Protection
Safety Alert Precautions that involve your safety.
No Hands Symbol
No Hands Symbol
To reduce the risk of injury, user must read and understand
operator’s manual before using this product.
Always wear safety goggles or safety glasses with side shields and,
as necessary, a full face shield when operating this product.
Failure to keep your hands away from the blade will result in serious
personal injury.
Failure to keep your hands away from the blade will result in serious
personal injury.
No Hands Symbol
Hot Surface
Do not reach across the sanding disc to turn the belt/disc sander
ON or OFF. Contact with the sanding disc can result in serious
personal injury.
To reduce the risk of injury or damage, avoid contact with any hot
surface.
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SYMBOLS
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SYMBOL SIGNAL MEANING
DANGER:
WARNING:
CAUTION:
CAUTION:
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.
(Without Safety Alert Symbol) Indicates a situation that may result in property
damage.
SERVICE
Servicing requires extreme care and knowledge and should
be performed only by a qualified service technician. For
service we suggest you return the product to the nearest
AUTHORIZED SERVICE CENTER for repair. When servicing, use only identical replacement parts.
WARNING:
To avoid serious personal injury, do not attempt to use this
product until you read thoroughly and understand completely the operator’s manual. If you do not understand
the warnings and instructions in the operator’s manual,
do not use this product. Call Ryobi customer service for
assistance.
WARNING:
The operation of any power tool can result in foreign objects being thrown into your eyes, which can
result in severe eye damage. Before beginning power tool operation, always wear safety goggles or
safety glasses with side shields and, when needed, a full face shield. We recommend Wide Vision
Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always use eye
protection which is marked to comply with ANSI Z87.1.
SAVE THESE INSTRUCTIONS
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ELECTRICAL
EXTENSION CORDS
Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug.
When using a power tool at a considerable distance from the
power source, use an extension cord heavy enough to carry
the current that the tool will draw. An undersized extension
cord will cause a drop in line voltage, resulting in a loss of
power and causing the motor to overheat. Use the chart
provided below to determine the minimum wire size required
in an extension cord. Only round jacketed cords listed by
Underwriter’s Laboratories (UL) should be used.
**Ampere rating (on tool data plate)
0-2.0 2.1-3.4 3.5-5.0 5.1-7.0 7.1-12.0 12.1-16.0
Cord Length Wire Size (A.W.G.)
25' 16 16 16 16 14 14
50' 16 16 16 14 14 12
100' 16 16 14 12 10 —
**Used on 12 gauge - 20 amp circuit.
NOTE: AWG = American Wire Gauge
When working with the tool outdoors, use an extension cord
that is designed for outside use. This is indicated by the
letters “WA” on the cord’s jacket.
Before using an extension cord, inspect it for loose or
exposed wires and cut or worn insulation.
WARNING:
Keep the extension cord clear of the working area.
Position the cord so that it will not get caught on lumber,
tools or other obstructions while you are working with a
power tool. Failure to do so can result in serious personal
injury.
SPEED AND WIRING
The belt speed of this tool is approximately 1,900 SFM.
This speed is not constant and decreases under a load
or with lower voltage. For voltage, the wiring in a shop
is as important as the motor’s horsepower rating. A line
intended only for lights cannot properly carry a power
tool motor. Wire that is heavy enough for a short distance
will be too light for a greater distance. A line that can
support one power tool may not be able to support two
or three tools.
GROUNDING INSTRUCTIONS
In the event of a malfunction or breakdown, grounding
provides a path of least resistance for electric current to
reduce the risk of electric shock. This tool is equipped with
an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a
matching outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
Do not modify the plug provided. If it will not fit the outlet,
have the proper outlet installed by a qualified electrician.
Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with
insulation having an outer surface that is green with or without
yellow stripes is the equipment-grounding conductor. If repair
or replacement of the electric cord or plug is necessary, do
not connect the equipment-grounding conductor to a live
terminal.
Check with a qualified electrician or service personnel if the
grounding instructions are not completely understood, or if
in doubt as to whether the tool is properly grounded.
Repair or replace a damaged or worn cord immediately.
This tool is intended for use on a circuit that has an outlet
like the one shown in figure 1. It also has a grounding pin
like the one shown.
WARNING:
Check extension cords before each use. If damaged
replace immediately. Never use tool with a damaged cord
since touching the damaged area could cause electrical
shock resulting in serious injury.
ELECTRICAL CONNECTION
This tool is powered by a precision-built electric motor. It
should be connected to a power supply that is 120 volts,
60 Hz, AC only (normal household current). Do not operate
this tool on direct current (DC). A substantial voltage drop
will cause a loss of power and the motor will overheat. If the
tool does not operate when plugged into an outlet, double
check the power supply.
GROUNDING
PIN
7
120V GROUNDED OUTLET
Fig. 1
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GLOSSARY OF TERMS
Anti-Kickback Pawls (radial arm and table saws)
A device which, when properly installed and maintained,
is designed to stop the workpiece from being kicked back
toward the front of the saw during a ripping operation.
Arbor
The shaft on which a blade or cutting tool is mounted.
Bevel Cut
A cutting operation made with the blade at any angle other
than 90° to the table surface.
Chamfer
A cut removing a wedge from a block so the end (or part of
the end) is angled rather than at 90°.
Compound Cut
A cross cut made with both a miter and a bevel angle.
Cross cut
A cutting or shaping operation made across the grain or the
width of the workpiece.
Cutterhead (planers and jointer planers)
A rotating cutterhead with adjustable blades or knives. The
blades or knives remove material from the workpiece.
Dado Cut
A non-through cut which produces a square-sided notch or
trough in the workpiece (requires a special blade).
Featherboard
A device used to help control the workpiece by guiding
it securely against the table or fence during any ripping
operation.
FPM or SPM
Feet per minute (or strokes per minute), used in reference
to blade movement.
Freehand
Performing a cut without the workpiece being guided by a
fence, miter gauge, or other aids.
Gum
A sticky, sap-based residue from wood products.
Heel
Alignment of the blade to the fence.
Kerf
The material removed by the blade in a through cut or the
slot produced by the blade in a non-through or partial cut.
Kickback
A hazard that can occur when the blade binds or stalls,
throwing the workpiece back toward operator.
Leading End
The end of the workpiece pushed into the tool first.
Miter Cut
A cutting operation made with the workpiece at any angle
to the blade other than 90°.
Non-Through Cuts
Any cutting operation where the blade does not extend
completely through the thickness of the workpiece.
Push Blocks (for jointer planers)
Device used to feed the workpiece over the jointer planer
cutterhead during any operation. This aid helps keep the
operator's hands well away from the cutterhead.
Push Blocks and Push Sticks (for table saws)
Devices used to feed the workpiece through the saw blade
during cutting operations. A push stick (not a push block)
should be used for narrow ripping operations. These aids
help keep the operator's hands well away from the blade.
Pilot Hole (drill presses)
A small hole drilled in a workpiece that serves as a guide for
drilling large holes accurately.
Resaw
A cutting operation to reduce the thickness of the workpiece
to make thinner pieces.
Resin
A sticky, sap-based substance that has hardened.
Revolutions Per Minute (RPM)
The number of turns completed by a spinning object in one
minute.
Ripping or Rip Cut
A cutting operation along the length of the workpiece.
Riving Knife/Spreader/Splitter (table saws)
A metal piece, slightly thinner than the blade, which helps
keep the kerf open and also helps to prevent kickback.
Saw Blade Path
The area over, under, behind, or in front of the blade. As it
applies to the workpiece, that area which will be or has been
cut by the blade.
Set
The distance that the tip of the saw blade tooth is bent (or
set) outward from the face of the blade.
Snipe (planers)
Depression made at either end of a workpiece by cutter
blades when the workpiece is not properly supported.
Through Sawing
Any cutting operation where the blade extends completely
through the thickness of the workpiece.
Throw-Back
The throwing back of a workpiece usually caused by the
workpiece being dropped into the blade or being placed
inadvertently in contact with the blade.
Workpiece or Material
The item on which the operation is being done.
Worktable
Surface where the workpiece rests while performing a
cutting, drilling, planing, or sanding operation.
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FEATURES
4 x36
PRODUCT SPECIFICATIONS
Belt Size ...........................................................4 in. x 36 in.
Belt Speed ......................................................... 1,900 SFM
Belt Tilt .....................................................................0°- 90°
Disc Size ....................................................................... 6 in.
Disc Speed ............................................ 3,600 r/min. (RPM)
WORK
SUPPORT
TRACKING
KNOB
BELT
TENSION
LEVER
Table Size ............................................. 8-1/2 in. x 5-3/4 in.
Table Tilt .................................................................. 0°- 45°
Input ................................120 V, AC only, 60 Hz, 4.3 Amps
Motor ........................................................1/2 HP Induction
Net Weight ................................................................ 53 lbs.
SANDING
BELT
WORKTABLE
SANDING
DISC
MITER GAUGE
BEVEL
GAUGE
KNOW YOUR BELT/DISC SANDER
See Figure 2.
The safe use of this product requires an understanding of
the information on the tool and in this operator’s manual as
well as a knowledge of the project you are attempting. Before
use of this product, familiarize yourself with all operating
features and safety rules.
BELT TENSION LEVER
The belt tension lever releases the belt tension for easy belt
replacement.
BEVEL GAUGE
The worktable comes equipped with a bevel gauge that
indicates the degrees the worktable can be tilted up to 45°.
HORIZONTAL AN D VE RTICAL POSITIO N
HOLES
The horizontal and vertical position holes are used for
changing the position of the belt from horizontal to vertical.
MITER GAUGE
The miter gauge aligns the wood for positive stops at 90°
and 45°.
SWITCH
AND
SWITCH KEY
HORIZONTAL
AND VERTICAL
POSITION HOLES
SANDING BELT
The sanding belt can be adjusted from horizontal to vertical
providing different positions for sanding workpieces of
different shapes and sizes.
SANDING DISC
A round sanding disc is located on the side of the belt/disc
sander.
SWITCH AND SWITCH KEY
Your belt/disc sander has an easy access power switch.
TRACKING KNOB
A tracking knob aids in centering the sanding belt.
WORK SUPPORT
Supports the workpiece on the sanding belt.
WORKTABLE
Equipped with a sturdy worktable that provides a stable
surface when using either the disc sanding or the belt
sanding feature.
9
Fig. 2
Page 10
FEATURES
4 x36
WARNING:
Do not reach across the sanding disc to turn the belt/disc
sander ON or OFF. Contact with the sanding disc can
result in serious personal injury.
WARNING:
Before performing any adjustment, make sure the tool
is unplugged from the power supply and the switch is in
the OFF ( O ) position. Failure to heed this warning could
result in serious personal injury.
POWER SWITCH
See Figure 3.
The belt/disc sander is equipped with a power switch that
has a built-in locking feature. This feature is intended to
prevent unauthorized and possible hazardous use by children and others.
TO TURN THE BELT/DISC SANDER ON:
With the switch key inserted into the switch, lift the switch
button to turn ON.
TO TURN THE BELT/DISC SANDER OFF:
Press the switch button down to turn OFF.
SWITCH
ON
SWITCH
OFF
SWITCH
KEY
REMOVED
WARNING:
In the event of a power failure or when the tool is not in
use, turn the switch OFF and remove the switch key. This
action will prevent the tool from accidentally starting
when power returns.
WARNING:
ALWAYS make sure your workpiece is not in contact
with the belt before operating the switch to start the tool.
Failure to heed this warning may cause the workpiece to
be kicked back toward the operator and result in serious
personal injury.
WARNING:
To reduce the risk of accidental starting, ALWAYS make
sure the switch is in the OFF position before plugging
tool into the power source.
LOCKING THE SWITCH
See Figure 4.
Place the switch in the OFF position.
Wait until the belt/disc sander has come to a full and
complete stop.
Remove the switch key from the switch assembly. Store
key in safe place.
Fig. 3
SWITCH
KEY
Fig. 4
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The following items are included with the tool:
Sanding Disc
Disc Guard
Phillips Screws (2)
Socket Head Screws, M8 x 12 (2)
Washers (2)
SANDING DISC
MITER GAUGE
LOOSE PARTS
Miter Gauge
Hex Key
Worktable
Work Support
Operator’s Manual (not shown)
SOCKET HEAD
SCREWS
DISC GUARD
PHILLIPS
SCREWS
WORKTABLE
WORK
SUPPORT
ASSEMBLY
UNPACKING
This product requires assembly.
Carefully remove the tool and any accessories from the
box. Make sure that all items listed in the packing list are
included.
Inspect the tool carefully to make sure no breakage or
damage occurred during shipping.
Do not discard the packing material until you have care-
fully inspected and satisfactorily operated the tool.
If any parts are damaged or missing, please call
1-800-525-2579 for assistance.
WARNING:
HEX KEY
WASHERS
Fig. 5
WARNING:
Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such
alteration or modification is misuse and could result in a
hazardous condition leading to possible serious personal
injury.
WARNING:
Do not connect to power supply until assembly is
complete. Failure to comply could result in accidental
starting and possible serious personal injury.
If any parts are damaged or missing do not operate
this tool until the parts are replaced. Failure to heed this
warning could result in serious personal injury.
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4 x36
4 x36
4 x36
ASSEMBLY
INSTA LL I NG SA NDI NG DIS C AND DISC
GUARD
See Figure 6.
Unplug the belt/disc sander.
Remove the backing from the sanding disc.
Align perimeter of sanding disc with plate and press firmly
into position.
Position disc guard against the lower one-third of the
disc, aligning holes as shown in figure 6.
Using the two phillips head screws, securely tighten the
disc guard into place.
INSTALLING/REPLACING SANDING BELT
See Figure 7.
On the smooth side of the sanding belt, there is a directional
arrow. The sanding belt must run in the direction of the
arrow.
Unplug the belt/disc sander.
Pull the belt tension lever toward you to release belt
tension.
Place the sanding belt over the drive roller and idler roller
with the directional arrows running counterclockwise. Be
sure the sanding belt is centered on both drums.
Push the belt tension lever back into place to apply the
belt tension.
NOTE: The belt tension lever is spring loaded; use
extreme caution when pushing the tension lever back
into place to avoid personal injury.
MOUNTING THE WORKTABLE FOR USE WITH
THE DISC SANDER
See Figure 8.
Unplug the belt/disc sander.
Insert the index pin into the hole as shown in figure 8.
Position the worktable no farther than 1/16 in. from the
sanding surface.
Using a hex key, tighten the hex set screw securely.
MOUNTING THE WORKTABLE FOR USE WITH
THE BELT SANDER
See Figure 9.
Unplug the belt/disc sander.
Insert the index pin into the hole as shown in figure 9.
Position the worktable no farther than 1/16 in. from the
sanding surface.
Using a hex key, tighten the hex set screw securely.
DRIVE
ROLLER
HEX SET
SCREW
SANDING DISC
IDLE
ROLLER
BELT TENSION
LEVER
SANDING BELT
INDEX
PIN
DISC GUARD
PHILLIPS HEAD
SCREWS
Fig. 6
DIRECTIONAL
ARROW
Fig. 7
WORKTABLE
Fig. 8
WORKTABLE
CAUTION:
To avoid trapping the workpiece or your fingers between
the table and sanding surface, the table edge should
NEVER be further from the sanding surface than 1/16 in.
HEX SET
SCREW
Fig. 9
12
Page 13
4 x36
4 x36
ASSEMBLY
ASSEMBLING WORK SUPPORT
See Figure 10.
Place the work support over the holes in the side of the
tool housing.
Using a hex key, fasten in place with the washers and
socket head screws.
MOUNTING BELT/DISC SANDER TO WORKBENCH
See Figure 11.
If the belt/disc sander is to be used in a permanent location,
it is recommended you secure it to a workbench or other
stable surface. When mounting the belt/disc sander to a
workbench, holes should be drilled through the supporting
surface of the workbench.
Mark holes on workbench where belt/disc sander is to be
mounted using holes in the base as a template for hole
pattern.
Drill holes through workbench.
Place belt/disc sander on workbench aligning holes in
the base with holes drilled in the workbench.
Insert bolts (not included) and tighten securely with lock
washers and hex nuts (not included).
NOTE: All bolts should be inserted from the top. Install
the lock washers and hex nuts from the underside of the
workbench.
SUPPORT
SOCKET
HEAD
SCREWS
WASHERS
MOUNTING
BOLT
WORK
Fig. 10
MOUNTING
BOLT
CLAMPING BELT/DISC SANDER TO WORKBENCH
See Figure 12.
If the belt/disc sander is to be used as a portable tool, it
is recommended you fasten it permanently to a mounting
board that can easily be clamped to a workbench or other
stable surface. The mounting board should be of sufficient
size to avoid tipping while belt/disc sander is in use. Any
good grade plywood or chipboard with a 3/4 in. thickness
is recommended.
Mark holes on board where belt/disc sander is to be
mounted using holes in the base as a template for hole
pattern.
Follow the last three steps in section Mounting Belt/Disc
Sander to Workbench.
If lag bolts are used, make sure they are long enough to
go through holes in belt/disc sander base and material the
belt/disc sander is being mounted to. If machine bolts are
used, make sure bolts are long enough to go through holes
in belt/disc sander, the material being mounted to, and the
lock washers and hex nuts.
LOCK
WASHER
HEX NUT
LOCK
WASHER
HEX NUT
Fig. 11
MOUNTING
BOARD
13
C-CLAMPS
Fig. 12
Page 14
0
15
45
OPERATION
4 x36
4
x
3
6
WARNING:
Do not allow familiarity with tools to make you careless. Remember that a careless fraction of a second is
sufficient to inflict serious injury.
WARNING:
Always wear safety goggles or safety glasses with side
shields when operating power tools. Failure to do so
could result in objects being thrown into your eyes
resulting in possible serious injury.
WARNING:
Do not use any attachments or accessories not
recommended by the manufacturer of this tool. The use
of attachments or accessories not recommended can
result in serious personal injury.
APPLICATIONS
You may use this tool for the purpose listed below:
Sanding and finishing plastic, wood, and wood composi-
tion materials
Bevel sanding
Horizontal and vertical sanding
Sanding curved pieces
WARNING:
Applying the workpiece to the right side of the sanding
disc could cause the workpiece to kickback. Failure to
heed this warning could result in serious personal injury.
MITER GAUGE
VERTICAL
POSITION
HOLE
1/16 in. OR
LESS
TABLE
LOCK
KNOB
Fig. 13
Fig. 14
VERTICAL
SET SCREW
BEVEL SANDING
See Figure 13.
The worktable can be tilted from 0° to 45° for bevel sanding.
To tilt the worktable:
Loosen the table lock knob by turning it counterclockwise.
Set worktable to desired angle. Position the worktable
no farther than 1/16 in. from the sanding surface.
Tighten the table lock knob by turning it clockwise.
SANDING SMALL END SURFACES USING THE
MITER GAUGE
See Figure 14.
A miter gauge is included with the tool for increased
accuracy. Use of a miter gauge is recommended for sanding
small end surfaces on the sanding disc.
NOTE: Always move the workpiece across the sanding disc
from the left side toward the center.
HORIZONTAL
POSITION
HOLE
Fig. 15
14
Page 15
4 x36
4 x36
OPERATION
4
x
3
6
HORIZONTAL AND VERTICAL SANDING
See Figure 15.
The belt/disc sander can sand both vertically and horizontally.
Depending on the workpiece, the work support can be used
with either the horizontal or vertical sanding operation.
Insert the hex key provided into the holes in the pulley
cover. Loosen the screws by turning them counterclockwise.
Move the sanding belt into a vertical position as shown
in figure 15. Vertical position can be adjusted using the
vertical set screw.
Lock the sanding belt by retightening the screws.
NOTE: Sand long workpieces with the sanding belt in the
vertical position by moving the work evenly across the
sanding belt.
SURFACE SANDING ON THE SANDING BELT
See Figure 16.
Hold the workpiece firmly, keeping fingers away from the
sanding belt.
Keep the end pressed firmly against the work support
moving work evenly across the sanding belt.
NOTE: Use extra caution when sanding very thin pieces.
When sanding extra long pieces, remove the work
support. Apply only enough pressure to allow the sanding
belt to remove the material.
SANDING CURVED PIECES
See Figures 17 - 18.
WORK
SUPPORT
SURFACE SANDING
SANDING
INSIDE CURVES
WORKPIECE
Fig. 16
WORKPIECE
IDLER
ROLLER
WARNING:
Never attempt to sand the end pieces of a workpiece on
the idler drum. Applying the end of the workpiece on the
idler drum could cause the workpiece to fly up. Failure to
heed this warning could result in serious personal injury.
Sanding inside curves on the sanding belt:
Always sand inside curves on the idler drum as shown in
figure 17.
Hold the workpiece firmly, keeping fingers away from
the sanding belt.
Keep the curve pressed firmly against the idler drum
moving work evenly across the sanding belt.
NOTE: Use extra caution when sanding very thin pieces
and apply only enough pressure to allow the sanding belt
to remove the material.
Sanding outside curves on the sanding disc:
Always sand outside curves using the sanding disc and
moving the workpiece from the left side of center as
shown in figure 18.
Hold the workpiece firmly, keeping fingers away from
the sanding disc.
Keep the curve pressed firmly against the sanding disc
moving work evenly on the left side of the sanding disc.
Fig. 17
SANDING OUTSIDE CURVES
WORKPIECE
Fig. 18
15
Page 16
4 x36
ADJUSTMENTS
4 x36
WARNING:
Before performing any adjustment, make sure the tool
is unplugged from the power supply and the switch is in
the OFF ( O ) position. Failure to heed this warning could
result in serious personal injury.
ADJUSTING THE BELT TRACKING
See Figure 19.
Plug in belt/disc sander.
To check belt tracking:
Turn the switch ON and then immediately turn it OFF. If
the belt tends to slide off the idler drum or drive drum,
the belt is not tracking properly.
To adjust belt tracking:
If the sanding belt moves toward the disc, turn the
tracking knob clockwise 1/4 turn.
If the sanding belt moves away from the disc, turn the
tracking knob counterclockwise 1/4 turn.
Turn the switch ON and then immediately OFF again,
noting belt movement. Readjust track ing knob if
necessary.
SQUARING THE WORKTABLE TO THE SANDING
DISC
See Figure 20.
Unplug the belt/disc sander.
Using a combination square, check the angle of the
worktable with the sanding belt.
If the worktable is not 90° with the disc, loosen the table
lock knob and tilt the table.
Adjust worktable square to the sanding disc and retighten
the table lock knob.
NOTE: Use the adjustment screws beneath the worktable
to move the table further or closer to the sanding disc.
TRACKING
KNOB
SWITCH
Fig. 19
COMBINATION
SQUARE
ADJUSTMENT
SCREWS
TABLE
LOCK
KNOB
Fig. 20
16
Page 17
MAINTENANCE
WARNING:
When servicing, use only identical replacement parts.
Use of any other parts may create a hazard or cause
product damage.
WARNING:
Always wear safety goggles or safety glasses with side
shields during power tool operation or when blowing
dust. If operation is dusty, also wear a dust mask.
WARNING:
Do not at any time let brake fluids, gasoline, petroleumbased products, penetrating oils, etc., come in contact
with plastic parts. Chemicals can damage, weaken or
destroy plastic which may result in serious personal
injury.
GENERAL MAINTENANCE
Avoid using solvents when cleaning plastic parts. Most
plastics are susceptible to damage from various types of
commercial solvents and may be damaged by their use. Use
clean cloths to remove dirt, dust, oil, grease, etc.
Remove the old drive belt.
Fit the new drive belt on the drive pulley first and then
on the motor pulley.
Test belt tension by squeezing the belt with your
fingers.
Adjust the belt tension with the hex head set screw until
there is about 1/4 in. of give.
Tighten the belt tension nut securely.
Adjust the motor bracket so that it holds the motor against
the hex nut.
NOTE: Excessive tightness on the drive belt may cause
increased noise and overload the motor. Excessive
looseness on the drive belt (and improper adjustment
of the motor bracket) may cause the drive belt to fail
prematurely and make a severe chattering noise.
Using a phillips head screwdriver, reinstall the pulley cover
and the two phillips head screws. Tighten securely.
Replace the motor cover with the four screws, washers,
and rubber feet.
HEX HEAD
SET SCREW
SANDING
BELT
WARNING:
To prevent accidental starting that could cause possible
serious personal injury, turn off the tool, remove the
switch key, and unplug the belt sander before performing
any maintenance or adjustment.
Electric tools used on fiberglass material, wallboard, spackling
compounds, or plaster are subject to accelerated wear and
possible premature failure because the fiberglass chips and
grindings are highly abrasive to bearings, brushes, commutators, etc. Consequently, we do not recommended using this
tool for extended work on these types of materials. However,
if you do work with any of these materials, it is extremely
important to clean the tool using compressed air.
LUBRICATION
All of the bearings in this tool are lubricated with a sufficient
amount of high grade lubricant for the life of the unit under
normal operating conditions. Therefore, no further lubrication is required.
CHANGING DRIVE BELT
See Figure 21.
Unplug the belt/disc sander.
Using a phillips head screwdriver, remove the two screws in
the center of the pulley cover and the motor cover screws.
Remove the covers.
Loosen motor cover.
Raise sanding belt to the vertical sanding position
Next, loosen the hex head set screw. Raising the motor
pulley releases the belt tension.
MOTOR
BRACKET
SCREW
PHILLIPS
HEAD SCREWS
MOTOR
HEX NUT
DRIVE
BELT
MOTOR COVER
RUBBER FEET
DRIVE
PULLEY
MOTOR
PULLEY
Fig. 21
17
Page 18
OPERATOR’S MANUAL
BELT/DISC SANDER
BD4600
WARNING:
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known 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 masonry products, and
• 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.
• SERVICE
Now that you have purchased your tool, should a need ever exist for repair parts or service,
simply contact your nearest Authorized Service Center. Be sure to provide all pertinent
facts when you call or visit. Please call 1-800-525-2579 for your nearest Authorized
Service Center. You can also check our web site at www.ryobitools.com for a complete
list of Authorized Service Centers.
• MODEL NO. AND SERIAL NO.
The model number of this tool will be found on a plate attached to the motor housing.
Please record the model number and serial number in the space provided below.
• HOW TO ORDER REPAIR PARTS
When ordering repair parts, always give the following information:
• MODEL NUMBER
• SERIAL NUMBER
Ryobi® is a registered trademark of Ryobi Limited used under license.
BD4600
983000-017
5-2-08 (REV:04)
ONE WORLD TECHNOLOGIES, INC.
1428 Pearman Dairy Road, Anderson, SC 29625
Phone 1-800-525-2579
www.ryobitools.com
18
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