Harbor Freight Tools 8 Amp 3 in. x 21 in. Professional Belt Sander Product manual

Safety ......................................................... 2

Specifications ............................................. 8

Setup .......................................................... 9

Operation ................................................... 10

Table of Contents

Maintenance .............................................. 11

Parts List and Diagram .............................. 13

Warranty .................................................... 16

WARNING SYMBOLS AND DEFINITIONS

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

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

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

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Addresses practices not related to personal injury.

IMPORTANT SAFETY INFORMATION

General Power Tool Safety Warnings

Read all safety warnings and instructions.

Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

The term ″power tool″ in the warnings refers to your mains-operated (corded) power tool.

Work area safety

1. Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

2. 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.

3. Keep children and bystanders

away while operating a power tool.

Distractions can cause you to lose control.

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Item 69860

Electrical safety

1. Power tool plugs must match the outlet.

Never modify the plug in any way.

Do not use any adapter plugs with grounded

power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.

2. 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.

3. Do not expose power tools to rain or wet

conditions. Water entering a power tool will increase the risk of electric shock.

Power tool use and care

1. Do not force the power tool. Use the

correct power tool for your application.

The correct power tool will do the job better and safer at the rate for which it was designed.

2. Do not use the power tool if the switch/trigger

does not turn it on and off.

Any power tool that cannot be controlled with the switch/trigger is dangerous and must be repaired.

3. Disconnect the plug from the power source before making any adjustments, changing

accessories, or storing power tools.

Such preventive safety measures reduce the risk of starting the power tool accidentally.

4. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool.

Keep cord away from heat, oil, sharp edges

or moving parts. Damaged or entangled cords increase the risk of electric shock.

5. When operating a power tool outdoors, use an extension cord suitable for

outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

6. If operating a power tool in a damp location is unavoidable, use a Ground Fault Circuit

Interrupter (GFCI) protected supply.

Use of a GFCI reduces the risk of electric shock.

Personal safety

1. Stay alert, watch what you are doing and use common sense when operating a power tool.

Do not use a power tool while you are tired or under the influence of drugs, alcohol or

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

2. Use personal protective equipment. Always wear

eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

3. Prevent unintentional starting. Ensure the switch is in the off-position before connecting to

power source, picking up or carrying the tool.

Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.

4. Do not overreach. Keep proper footing and

balance at all times. This enables better control of the power tool in unexpected situations.

5. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves

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

6. If devices are provided for the connection of dust extraction and collection facilities, ensure

these are connected and properly used. Use of these devices can reduce dust-related hazards.

7. Only use safety equipment that has been

approved by an appropriate standards agency.

Unapproved safety equipment may not provide adequate protection. Eye protection must be

ANSI-approved and breathing protection must be NIOSH-approved for the specific hazards in the work area.

4. Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions

to operate the power tool. Power tools are dangerous in the hands of untrained users.

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

power tool repaired before use. Many accidents are caused by poorly maintained power tools.

6. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

Item 69860 For technical questions, please call 1-800-444-3353.

Page 3

7. Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions

and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

Service

Have your power tool serviced by a qualified repair person using only identical replacement parts.

This will ensure that the safety of the power tool is maintained.

Belt and Non-disc Sander Safety Warnings

1. Hold power tools by insulated gripping surfaces when performing an operation where the cutting

tool may contact hidden wiring or its own cord.

Contact with a ″live″ wire will make exposed metal parts of the tool ″live″ and shock the operator.

2. Maintain labels and nameplates on the tool.

These carry important safety information.

If unreadable or missing, contact

Harbor Freight Tools for a replacement.

3. Avoid unintentional starting.

Prepare to begin work before turning on the tool.

4. Do not 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.

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

6. Do not leave the tool unattended when it is plugged into an electrical outlet. Turn off the tool, and unplug it from its electrical outlet before leaving.

7. This product is not a toy.

Keep it out of reach of children.

8. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.

In addition, people with pacemakers should:

• Avoid operating alone.

• Do not use with power switch/trigger locked on.

• Properly maintain and inspect to avoid electrical shock.

• Properly ground power cord. Ground Fault Circuit

Interrupter (GFCI) should also be implemented

– it prevents sustained electrical shock.

9. WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities, contains chemicals known [to the State of California] to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints

• Crystalline silica from bricks 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, 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.)

10. WARNING: Handling the cord on this product will expose you to lead, a chemical known to the State of

California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling.

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

11. The warnings, precautions, 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.

Page 4 For technical questions, please call 1-800-444-3353.

Item 69860

Vibration Safety

This tool vibrates during use.

Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders.

To reduce the risk of vibration-related injury:

1. Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical check-ups to ensure medical problems are not being caused or worsened from use. Pregnant women or people who have impaired blood circulation to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud’s Disease should not use this tool.

If you feel any symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible.

2. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury.

3. Wear suitable gloves to reduce the vibration effects on the user.

4. Use tools with the lowest vibration when there is a choice.

5. Include vibration-free periods each day of work.

6. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work.

7. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately.

SAVE THESE INSTRUCTIONS.

Item 69860 For technical questions, please call 1-800-444-3353.

Page 5

Grounding

TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING

WIRE CONNECTION:

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.

Grounded Tools: Tools with Three Prong Plugs

3-Prong Plug and Outlet

1. 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 3-Prong Plug and Outlet.)

2. 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 wire connected to the tool’s grounding system and must never be attached to an electrically

“live” terminal. (See 3-Prong Plug and Outlet.)

3. The 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 preceding illustration.

(See 3-Prong Plug and Outlet.)

Double Insulated Tools: Tools with Two Prong Plugs

Outlets for 2-Prong Plug

1. 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.

2. Double insulated tools may be used in either of the

120 volt outlets shown in the preceding illustration.

(See Outlets for 2-Prong Plug.)

Extension Cords

1. Grounded tools require a three wire extension cord.

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

2. 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 Table A.)

3. 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 Table A.)

4. 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 Table A.)

Page 6 For technical questions, please call 1-800-444-3353.

Item 69860

5. 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 Table A.)

6. 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.

7. Make sure the 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.

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

TABLE A: RECOMMENDED MINIMUM WIRE

GAUGE FOR EXTENSION CORDS* (120/240 VOLT)

NAMEPLATE

AMPERES

(at full load)

0 – 2.0

EXTENSION CORD

LENGTH

25´ 50´ 75´ 100´ 150´

18 18 18 18 16

2.1 – 3.4

3.5 – 5.0

5.1 – 7.0

7.1 – 12.0

12.1 – 16.0

18

18

18

18

14

18

18

16

14

12

18

16

14

12

10

16

14

12

10

-

16.1 – 20.0

12 10 -

* Based on limiting the line voltage drop to five volts at

150% of the rated amperes.

14

12

12

-

-

Symbology

Double Insulated

Canadian Standards Association

Underwriters Laboratories, Inc.

V~

Volts Alternating Current

A

Amperes

n0 xxxx/min.

No Load Revolutions per Minute (RPM)

WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields.

Read the manual before set-up and/or use.

WARNING marking concerning Risk of Fire.

Do not cover ventilation ducts.

Keep flammable objects away.

WARNING marking concerning

Risk of Electric Shock.

Properly connect power cord to appropriate outlet.

Item 69860 For technical questions, please call 1-800-444-3353.

Page 7

Specifications

Electrical Rating

No Load Speed

Belt Size

120V~ / 60Hz / 8.4A

390 –1180 FPM

3″ W x 21″ L

4001636

Page 8 For technical questions, please call 1-800-444-3353.

Item 69860

Setup - Before Use:

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product.

Note: For additional information regarding the parts listed in the following pages, refer to Parts List and Diagram on page 13.

Functions

Rear Handle

Power Cord

Trigger

Belt Tension

Release Lever

Dust Bag

Speed Control Knob

Front Handle

Front Handle

Locking Lever

Tracking Knob

Trigger

Trigger Lock

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Page 9

Operating Instructions

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product.

Tool Set Up

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:

Make sure that the Power Switch/Trigger is in the off-position and unplug the tool from its electrical outlet before performing any procedure in this section.

1. Secure the Dust Bag to the tool.

2. To position the adjustable Front Handle, pull the Front Handle Locking Lever out and move the handle to one of three available positions.

Lock the Front Handle by returning the Front

Handle Locking Lever to its original position.

3. Before use, make sure that the Sanding Belt is on-center. To check this, plug in the sander and hold the Belt clear while carefully turning it on. If the Belt moves to one side or the other during use, turn the Tracking Knob until it stays on-center.

Workpiece and Work Area Set Up

1. Designate a work area that is clean and well-lit.

The work area must not allow access by children or pets to prevent distraction and injury.

2. Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing the power cord to possible damage. The power cord must reach the work area with enough extra length to allow free movement while working.

General Operating Instructions

3. Secure loose workpieces using a vise or clamps

(not included) to prevent movement while working.

4. There must not be objects, such as utility lines, nearby that will present a hazard while working.

1. Make sure that the Trigger is not engaged, then plug in the tool.

2. To start the tool, squeeze the Trigger; release the Trigger to stop. For continuous operation squeeze the Trigger and push the Trigger Lock to lock the tool on.

3. To turn the tool off with Trigger Lock engaged, squeeze the Trigger once and then release.

4. Adjust the sander speed to suit different working material. Turn the Speed Control Knob to a higher number for a faster speed or to a lower number for a slower speed. Determine the optimum speed by testing on a scrap piece of material.

Note: Using the correct speed for the job increases the life of the tool.

5. When sanding, use both hands to hold the tool and sand along the grain for best results.

6. Hold the tool lightly on the workpiece and allow the tool to do the work. Do not push down on the

Belt Sander or move it along the surface too fast.

7. To prevent accidents, turn off the tool and unplug it after use. Clean, then store the tool indoors out of children’s reach.

Page 10 For technical questions, please call 1-800-444-3353.

Item 69860

Maintenance and Servicing

Procedures not specifically explained in this manual must be performed only by a qualified technician.

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:

Make sure that the Power Switch/Trigger is in the off-position and unplug the tool from its electrical outlet before performing any procedure in this section.

TO PREVENT SERIOUS INJURY FROM TOOL FAILURE:

Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use.

Cleaning, Maintenance, and Lubrication

1. BEFORE EACH USE, inspect the general condition of the tool. Check for:

• loose hardware,

• misalignment or binding of moving parts,

• damaged cord/electrical wiring,

• worn or torn sanding belt,

• cracked or broken parts, and

• any other condition that may affect its safe operation.

2. AFTER USE, wipe external surfaces of the tool with clean cloth.

3. Regularly check to see if any dust or foreign matter has entered the tool’s air vents near the motor and around the trigger. Keep the vents unclogged and clean at all times.

4. When a sanding belt tears or becomes worn, it must be replaced: a. Always turn the tool off and unplug it before changing the belt.

b. Pull out the Belt Tension Release Lever and push it forward until it locks into place.

c. Remove the old belt and replace with a new 3” x 21” belt. Make sure the arrows on the inside of the new sanding belt are pointing in the direction of rotation as indicated on the housing of the tool.

d. Push the Belt Tension Release Lever back in to secure the belt in place.

e. Make sure the new belt is on-center before use.

5. To replace a worn or broken Drive Belt: a. Make sure the tool is turned off and unplugged before changing the belt.

b. Peel back the label on the Drive Belt Cover to expose the cover mounting screws. Remove the screws and the Drive Belt Cover.

c. Take out the worn or broken belt and install a new belt by sliding it around the Small and Large Belt Pulleys.

d. Replace the Drive Belt Cover and secure it in place with the cover mounting screws.

e. Reaffix the label on the Drive Belt Cover.

6. WARNING! If the supply cord of this power tool is damaged, it must be replaced only by a qualified service technician.

Item 69860 For technical questions, please call 1-800-444-3353.

Page 11

Troubleshooting

Problem

Tool will not start.

Possible Causes

1. Cord not connected.

2. No power at outlet.

Likely Solutions

1. Check that cord is plugged in.

2. Check power at outlet. If outlet is unpowered, turn off tool and check circuit breaker.

If breaker is tripped, make sure circuit is right capacity for tool and circuit has no other loads.

3. Tool’s thermal reset breaker tripped (if equipped).

4. Internal damage or wear.

(Carbon brushes or switch, for example.)

Tool operates slowly. 1. Forcing tool to work too fast.

Performance decreases over time.

Motor runs but sanding belt does not rotate.

Excessive noise or rattling.

Overheating.

Broken drive belt.

Internal damage or wear. (Carbon brushes or bearings, for example.)

1. Forcing tool to work too fast.

3. Turn off tool and allow to cool.

Press reset button on tool.

4. Have technician service tool.

1. Allow tool to work at its own rate.

2. Extension cord too long or cord diameter too small.

2. Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See Extension Cords in Grounding section on page 6.

Carbon brushes worn or damaged. Have qualified technician replace brushes.

Replace drive belt, see page 11.

Have technician service tool.

1. Allow tool to work at its own rate.

2. Blocked motor housing vents.

3. Motor being strained by long or small diameter extension cord.

2. Wear ANSI-approved safety goggles and

NIOSH-approved dust mask/respirator while blowing dust out of motor using compressed air.

3. Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See Extension Cords in Grounding section on page 6.

Follow all safety precautions whenever diagnosing or servicing the tool.

Disconnect power supply before service.

Page 12 For technical questions, please call 1-800-444-3353.

Item 69860

Parts List and Diagram

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM

IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR 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.

Item 69860 For technical questions, please call 1-800-444-3353.

Page 13

Parts List

Part Description

1 Drive Belt Cover

2 Drive Belt

3 Middle Cover

4 Small Belt Pulley

5 Plate

6 Left Housing

7 Brush Cover

8 Brush Holder

9 Carbon Brush

10 Torsion Spring

11 Front Guard

12 Axle

13 Nut

14 Front Handle

15 M6 Pin

16 Screw

17 Front Handle Lever

18 Stator

19 Screw

20 Ball Bearing

21 Spacer

22 Rotor

23 Ball Bearing

24 Fan Housing

25 Right Housing

26 Decorative Cover

27 Screw

28 Nameplate

29 Screw

30 Screw

31 Dust Bag

32 Cord Sleeve

33 Power Cord

34 Cord Clamp

35 Screw

36 Trigger

Qty

1

1

2

7

3

1

1

1

1

1

12

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

2

1

2

2

1

1

1

1

1

1

Part Description

37 Speed Control Knob

38 Tracking Knob

39 Small Spring

40 Washer

41 Retaining Ring

42 Front Bushing Frame

43 Fixed Pin

44 Front Bushing

45 Needle Bearing

46 Front Bushing Axle

47 Washer

48 Belt Tension Release Lever

49 Rivet

50 Mounting Plate

51 Nut

52 Large Belt Pulley

53 Washer

54 Bearing

55 Small Gear Shaft

56 Spring

57 Large Gear

58 Washer

59 Bearing

60 Ball Bearing

61 Gearbox

62 Ceramic

63 Cylindrical Pin

64 Spring

65 Rear Bushing Axle

66 Copper Bushing

67 Bowl-Type Gasket

68 Rear Bushing

69 Ball Bearing

70 Spacer

71 Screw

72 Sanding Belt (80 Grit)

Record Product’s Serial Number Here:

Note: If product has no serial number, record month and year of purchase instead.

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

Qty

1

1

1

1

1

1

1

3

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

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Item 69860

Item 69860 For technical questions, please call 1-800-444-3353.

Page 15

Limited 90 Day Warranty

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.

If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product.

This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353