HAND FINISHING

ORBITAL SANDER

40070

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Copyright © 2002 by Harbor Freight Tools ® . All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools.

For technical questions and replacement parts, please call 1-800-444-3353.

Manual Revised 10/05

W e i g h t

P R O D U C T S P E C I F I C A T I O N S

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SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep this manual and invoice in a safe and dry place for future reference.

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 injury.

SAVE THESE INSTRUCTIONS

1.

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WORK AREA

Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. Make sure there is adequate surrounding workspace.

Do not operate power tools in explosive atmospheres, such as in the presence

of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.

Keep bystanders, children, and visitors away while operating a power tool.

Distractions can cause you to lose control. Protect others in the work area from debris such as chips and sparks. Provide barriers or shields as needed.

SKU 40070 For technical questions, please call 1-800-444-3353.

REV 03/07

Page 2

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ELECTRICAL SAFETY

Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly

grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user.

Double insulated tools are equipped with a polarized plug (one blade is wider than the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any

way. Double insulation eliminates the need for the three wire grounded power cord and grounded power supply system.

Avoid body contact with grounded surfaces such as pipes, radiators, ranges,

and refrigerators. There is an increased risk of electric shock if your body is grounded.

Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

Do not abuse the Power Cord. Never use the Power Cord to carry the tools or pull the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp

edges, or moving parts. Replace damaged Power Cords immediately. Damaged

Power Cords increase the risk of electric shock.

When operating a power tool outside, use an outdoor extension cord marked

“W-A” or “W”. These extension cords are rated for outdoor use, and reduce the risk of electric shock.

PERSONAL SAFETY

10.

Stay alert. Watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while tired or under the influence of

drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury.

11.

Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep

your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.

12.

Avoid accidental starting. Be sure the Power Switch is off before plugging in.

Carrying power tools with your finger on the Power Switch, or plugging in power tools with the Power Switch on, invites accidents.

13.

Remove adjusting keys or wrenches before turning the power tool on. A wrench or a key that is left attached to a rotating part of the power tool may result in personal injury.

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 3

14.

Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the power tool in unexpected situations.

15.

Use safety equipment. Always wear eye protection. Dust mask, nonskid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.

Always wear ANSI approved safety goggles and a dust mask/respirator when using or performing maintenance on this tool.

TOOL USE AND CARE

16.

Use clamps (not included) or other practical ways to secure and support the

workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.

17.

Do not force the tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. Do not force the tool and do not use the tool for a purpose for which it is not intended.

18.

Do not use the power tool if the Power Switch does not turn it on or off. Any tool that cannot be controlled with the Power Switch is dangerous and must be replaced.

19.

Disconnect the Power Cord Plug from the power source before making any

adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally. Always unplug the tool from its electrical outlet before performing any inspection, maintenance, or cleaning procedures.

20.

Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

21.

Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools with a sharp cutting edge are less likely to bind and are easier to control. Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.

22.

Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool’s operation. If damaged, have the

tool serviced before using. Many accidents are caused by poorly maintained tools.

23.

Use only accessories that are recommended by the manufacturer for your

model. Accessories that may be suitable for one tool may become hazardous when used on another tool.

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 4

SERVICE

24.

Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.

25.

When servicing a tool, use only identical replacement parts. Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury.

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SPECIFIC SAFETY RULES

Maintain labels and nameplates on the Sander. These carry important information.

If unreadable or missing, contact Harbor Freight Tools for a replacement.

When using a handheld power tool, always maintain a firm grip on the tool with both hands to resist starting torque.

Avoid unintentional starting. Make sure you are prepared to begin work before plugging in the Sander.

WARNING! People with pacemakers should consult their physician(s) before

using this product. Electromagnetic fields in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker.

In addition, people with pacemakers should adhere to the following:

• Avoid operating power tools alone.

• If powered via a power cord be certain that the tool is properly grounded. A ground fault interrupt (GFCI) system is also a good precaution. This inexpensive device is a good safety measure because it prevents a sustained electrical shock.

• Properly maintain and inspect all tools before use to avoid electrical shock.

Never lay the tool down until it has come to a complete stop. Moving parts can grab the surface and pull the tool out of your control.

Never leave the Sander unattended when it is plugged into an electrical outlet.

Turn off the tool, and unplug it from its electrical outlet before leaving.

WARNING! Some dust created by power sanding, sawing, grinding, drilling, and other construction activities, contain 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 and cement or 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,

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 5

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and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

(California Health & Safety Code § 25249.5, et seq.)

Take caution as some woods contain preservatives such as copper chromium

arsenate (CCA) which can be toxic. When cutting these materials extra care should be taken to avoid inhalation and minimize skin contact.

9.

WARNING! Exposure to aluminum oxide (a dust generated from material removing processes) can result in eye, skin, and respiratory irritation. Always use a NIOSH

(National Institute for Occupational Safety and Health) approved respirator and ANSI approved safety goggles. Avoid skin exposure. Proper ventilation in the work area is required.

10.

WARNING! The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

Note: Performance of this tool (if powered by line voltage) may vary depending on variations in local line voltage. Extension cord usage may also affect tool performance.

GROUNDING

WARNING!

Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the power cord plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician.

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GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS

Tools marked with “Grounding Required” have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet. If the tool should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user, reducing the risk of electric shock. (See Figure A.)

The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 6

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wire connected to the tool’s grounding system and must never be attached to an electrically “live” terminal. (See Figure A.)

Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in the following illustration. (See Figure A.)

FIGURE A

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DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS

Tools marked “Double Insulated” do not require grounding. They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard

Association, and the National Electrical Code. (See Figure B.)

Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration. (See Figure B.)

FIGURE B

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 7

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EXTENSION CORDS

Grounded tools require a three wire extension cord. Double Insulated tools can use either a two or three wire extension cord.

As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage.

(See Figure C, next page.)

The smaller the gauge number of the wire, the greater the capacity of the cord.

For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

(See Figure C.)

When using more than one extension cord to make up the total length, make sure each cord contains at least the minimum wire size required. (See Figure C.)

If you are using one extension cord for more than one tool, add the nameplate amperes and use the sum to determine the required minimum cord size.

(See

Figure C.)

If you are using an extension cord outdoors, make sure it is marked with the suffix

“W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.

Make sure your extension cord is properly wired and in good electrical condition.

Always replace a damaged extension cord or have it repaired by a qualified electrician before using it.

Protect your extension cords from sharp objects, excessive heat, and damp or wet areas.

R E C O M M E N D E D M I N I M U M W I R E G A U G E F O R E X T E N S I O N C O R D S *

N A M E P L A T E

A M P E R E S

( A t F u l l L o a d )

E X T E N S I O N C O R D L E N G T H

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SKU 40070 For technical questions, please call 1-800-444-3353.

Page 8

SYMBOLOGY

UNPACKING

When unpacking, check to make sure that the item is intact and undamaged. If any parts are missing or broken, please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible.

ASSEMBLY INSTRUCTIONS

NOTE: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram on page 12.

CAUTION: Always make sure the Power Cord (17) of the Sander is unplugged from its electrical outlet prior to making any adjustments or assembling to the tool.

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ATTACHING THE DUST COLLECTION CHUTE (0)

Turn the Chute (0) so that the tab on top of the rectangular end faces up. Snap it in place into the rectangular shaft at the back of the Sander.

Connect a 1-1/4” dust collection hose from the Chute to your dust collection system

(hose and system not included).

The Dust Collection Chute (0) will only work if the sandpaper has holes that line up with the 6 dust collection holes in the Backing Pad (28). (There are 4 other holes in the Backing Pad for the Screws (29).)

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 9

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ATTACHING SANDPAPER TO THE BACKING PAD (28)

Press the tab on the Clamps (6) inward on both sides of the unit and swing the clamps on both sides up, out, and down. See 1 & 2, right.

Cut the sandpaper to fit the 4” W x 4 1 /

2

”

L Pad (28), with a little extra to overlap and fit under the Clamps (6). Do not use torn or frayed sandpaper.

After wrapping the overlapped edges of sandpaper under the Clamps (6), snap the Clamps (6) back into place.

Sandpaper goes under here

OPERATING INSTRUCTIONS

NOTE: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram on page 12.

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CAUTION: Always make sure the Power Cord (17) of the Sander is unplugged from its electrical outlet prior to making any adjustments to the tool.

Clamp your workpiece down, or insert it in a vise. Make sure the wood you are sanding does not have any nails or metal of any kind in it, or you will ruin the sandpaper and damage the Pad (28).

After donning the appropriate safety gear covered on page 2 of this manual, plug in the Sander.

Turn on the Sander by turning on the Switch (3).

Always run the Sander for a few seconds before contacting the workpiece.

6.

Contact the workpiece with minimal pressure. If the Sander is not removing enough material, try a grittier piece of sandpaper. If you want to remove a lot of material fast, use a belt sander.

Note: All orbital sanders leave sanding marks on the workpiece. To minimize sanding marks, always try to sand with the grain of the wood.

7.

Occasionally check the sandpaper for tears, wear, or fraying. Replace if necessary.

8.

When you are finished, turn off the Switch (3).

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 10

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INSPECTION, MAINTENANCE, AND CLEANING

WARNING! Make sure the Power Switch (3) of the Sander is in its “OFF” position and that the tool is unplugged from its electrical outlet before performing any inspection, maintenance, or cleaning procedures.

BEFORE EACH USE, inspect the general condition of the Sander. Check for loose screws, misalignment or binding of moving parts, cracked or broken parts, damaged electrical wiring, and any other condition that may affect its safe operation. If abnormal noise or vibration occurs, have the problem corrected before further use.

Do not use damaged equipment.

Wipe the unit down after each use with a dry, lint free cloth.

Make sure the vents on the top are clear of dust and debris.

Periodically, have a qualified service technician clean or replace the Carbon

Brushes (14).

5

6

7

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PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS

MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES

ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED

TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY

PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY

STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED

AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND

LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT

PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS

THERETO.

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 11

ASSEMBLY DIAGRAM

Part 0 - Dust Collection Chute - not shown.

NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts.

SKU 40070 For technical questions, please call 1-800-444-3353.

Page 12