5” AIR SANDER/DRILL

Model 35245

ASSEMBLY AND OPERATING INSTRUCTIONS

®

®

3491 Mission Oaks Blvd., Camarillo, CA 93011

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

Copyright 1997 by Harbor Freight Tools

®

. All rights reserved. No protion of this manual or any artwork contained therein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools.

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

SPECIFICATIONS

Free Speed

Air Pressure

Air Consumption

Weight

18,000 RPM

90 PSI

4 CFM

3-1/4 lbs.

SAVE THIS MANUAL

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

SAFETY WARNING & CAUTIONS

WARNING: When using pneumatic equipment, basic safety precautions should always be followed to reduce the risk of personal injury and hazards due to over pressurization.

READ ALL INSTRUCTIONS BEFORE USING THIS TOOL!

1.

KEEP WORK AREA CLEAN.

Cluttered areas invite injuries.

2.

OBSERVE WORK AREA CONDITIONS.

Do not use tools in damp, wet, or poorly lit locations. Don’t expose to rain. Keep work area well lit. Do not use electrically powered air compressors in the presence of flammable gases or liquids.

3.

KEEP CHILDREN AWAY.

Children must never be allowed in the work area. Do not let them handle machines, tools, or hoses.

4.

STORE IDLE EQUIPMENT. When not in use, tools must be locked up in a dry location to inhibit rust. Always lock up tools and keep out of reach of children.

5.

DO NOT FORCE THE TOOL.

It will do the job better and more safely at the rate for which it was intended. Do not use inappropriate attachments in an attempt to exceed the tool’s capacities.

6.

USE THE RIGHT TOOL FOR THE JOB.

Do not attempt to force a small tool or attachment to do the work of a larger industrial tool. Do not use a tool for a purpose for which it was not intended.

7.

DRESS PROPERLY. Do not wear loose clothing or jewelry as they can be caught in moving parts. Non-skid footwear is recommended. Wear restrictive hair covering to contain long hair.

8.

USE EYE AND EAR PROTECTION.

Always wear ANSI approved chemical splash goggles when working with chemicals. Always wear ANSI approved impact safety goggles at other times. Wear a full face shield if you are producing metal filings or wood chips. Wear an ANSI approved dust mask or respirator when working around metal, wood, and chemical dusts and mists.

9.

DO NOT ABUSE THE POWER CORD. Do not yank compressor’s cord to disconnect it from the receptacle. Do not carry tools by the cord.

10.

DO NOT OVERREACH. Keep proper footing and balance at all times. Do not reach over or across running machines.

11.

MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories. Inspect compressor’s cord periodically and, if damaged, have them repaired by an authorized technician. Inspect all hoses for leaks prior to use. The handles must be kept clean, dry, and free from oil and grease at all times.

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12.

REMOVE ADJUSTING KEYS AND WRENCHES.

Make it a habit to check that keys and adjusting wrenches are removed from the tool or machine work surface before plugging it in.

13.

AVOID UNINTENTIONAL STARTING. Do not carry any tool with your finger on the trigger, whether it is connected to the compressor or not.

14.

STAY ALERT.

Watch what you are doing; use common sense. Do not operate any tool when you are tired.

15.

CHECK DAMAGED PARTS. Before using any tool, any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts; any broken parts or mounting fixtures; and any other condition that may affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified technician. Do not use the tool if any switch does not turn on and off properly.

16.

REPLACEMENT PARTS AND ACCESSORIES.

When servicing, use only identical replacement parts. Use of any other parts will void the warranty. Only use accessories intended for use with this tool. Approved accessories are available from Harbor Freight Tools.

17.

DO NOT OPERATE TOOL IF UNDER THE INFLUENCE OF ALCOHOL OR DRUGS.

Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there is any doubt, do not operate the tool.

18.

DRAIN COMPRESSOR EVERY DAY.

Do not allow moisture to build up inside the compressor. Do not allow compressor to sit pressurized for longer than one hour.

19.

MAKE SURE ALL EQUIPMENT IS RATED TO THE APPROPRIATE CAPACITY. Make sure that regulator is set at least 10 PSI lower than the lowest rated piece of equipment you are using.

WARNING: This product contains or, when used, produces a chemical known to the State of

California to cause cancer and birth defects or other reproductive harm. (California Health &

Safety Code 25249.5, et seq.)

UNPACKING

When unpacking your 5" Sander/Drill, check the items against the list below. If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this manual.

Item# Description

N/A Drill Assembly

26 Holding Tool

N/A

30

29

28

27

Chuck Key

5-1/2" Backing Plate

4-1/2" Backing Plate

3" Backing Plate

Adapter Lock Down

Qty

1

1

1

1

1

1

1

ASSEMBLY

Your Sander/Drill comes assembled and ready for use as a Drill. To convert your Sander/Drill for use as a Sander, follow the Steps below.

Sander Assembly

Step 1: Open the CHUCK (#31) by turning the CHUCK counterclockwise. Insert the short end of a Hex Key Wrench into the CHUCK and tighten.

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REV 01/04

Step 2: Place the HOLDING TOOL (#26) into one of the two holes in the SANDING ADAPTER

(#25) as shown in Figure 1.

Figure 1 — Installing the Holding Tool

Step 3: Turn the Hex Key Wrench counterclockwise to loosen the CHUCK. You may gently tap

on the end of the Hex Key Wrench with a rubber mallet.

Step 4: Remove the CHUCK.

Step 5: You will need sandpaper discs the appropriate size for the Backing Plate you will be

using. These can be purchased at Harbor Freight Tools.

Step 6: Place the desired BACKING PLATE (#28, 29, or 30) over the threads of the ROTOR

(#19). Place the sandpaper disc over the BACKING PLATE.

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Step 7: Thread the ADAPTER LOCK DOWN (#27) onto the ROTOR as shown in Figure 2.

Tighten.

Figure 2 — Installing the Backing Plate

Drill Bit Installation

Step 1: Select the drill bit needed for the drilling you wish to perform.

Step 2: Open up the Jaws of the Drill by turning the CHUCK (#31) as shown in Figure 3.

Figure 3 — Opening the Drill Chuck

Step 3: When the Jaws are open wide enough to insert the drill bit, slide the bit into the CHUCK as far as possible.

Step 4: By hand, turn the CHUCK to tighten the Jaws.

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Step 5: Insert the Chuck Key into one of the three chuck holes in the DRILL CHUCK, mating the teeth of the Chuck Key with the teeth of the DRILL CHUCK.

Step 6: Turn the Chuck Key to tighten the Jaws. Make sure the Jaws are tight.

Step 7: Put the Chuck Key in a safe place. Do not lose the Chuck Key.

Air Connection

Step 1: Remove the plastic cap from the HOSE JOINT (#6).

Step 2: You will need a Union fitting (sold separately) before you can connect your Sander/Drill to an air compressor.

Step 3: Attach the Union fitting to the Sander/Drill and tighten.

Step 4: Attach an Air Coupler (sold separately) to the Union fitting if desired. This is a useful accessory as it allows quick-coupling action when using a variety of tools with the same air compressor.

Your Sander/Drill is ready for use.

OPERATION

Setup

Frequent, but not excessive, lubrication is required for best performance. Oil added through the airline connection will lubricate internal parts. An automatic airline oiler is recommended but oil may be added manually before every operation or after about 1 hour of continuous use. Only a few drops of oil at a time are necessary. Too much oil will collect inside the tool and be blown out during the exhaust cycle. ONLY USE PNEUMATIC TOOL OIL.

Do not use detergent oil or additives as these lubricants will cause accelerated wear to the seals in the tool.

Dirt and water in the air supply are major causes of pneumatic tool wear. Use a filter/oiler for better performance and longer life. The filter must have adequate flow capacity for the specific application. Consult the manufacturer’s instructions for proper maintenance of your filter.

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The connector on the tool must not hold pressure when the air supply is disconnected. If the wrong fitting is used, the tool can remain charged with air after being disconnected and still be able to drive a fastener. See Figure 4 for the recommended accessories and connection order.

Figure 4 -- Airline Oiler Assembly

Figure 4 — Airline Oiler Assembly

Use

Step 1: Set the compressor’s pressure regulator to 90 PSI. Do not set the compressor’s outlet regulator over 90 PSI.

Step 2: Connect the Sander/Drill to the air compressor’s hose. If leaking is detected, disconnect the air hose and repair before use.

Drilling

Step 1: Mark the material you wish to drill at the spot for the hole. Make sure your drill bit is the correct size for the hole you need to make.

Step 2: If possible, clamp the material in a vise to make sure the material does not move or begin to spin while drilling.

Step 3: Wear eye protection to guard against flying wood or metal.

Step 4: Set the compressor’s pressure regulator to 90 PSI. Do not set the compressor’s outlet regulator over 90 PSI.

Step 5: Connect the Sander/Drill to the air compressor’s hose. If leaking is detected, disconnect the air hose and repair before use.

Step 6: Grip the Sander/Drill firmly. Place the drill bit on the spot marked in Step 1.

CAUTION

Do not operate the Drill before placing the drill bit on the material.

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Step 7: To begin drilling, press the TRIGGER (#10) as shown in Figure 5.

Figure 5 — Drilling Operations

Step 8: Your Sander/Drill has a variable speed for drilling. To vary the speed of the drilling action, vary the pressure on the TRIGGER.

Step 9: Drill only as deep as necessary. Do not drill deeper than necessary into walls or other areas where you cannot identify any possible hazards behind the drilling surface.

Step 10: When you have drilled the hole, remove the drill bit from the hole while the Sander/Drill is still spinning. This is to prevent the drill getting caught in the hole and causing damage.

Sanding

Step 1: Identify the area you will be sanding. Make sure you are using the appropriate grit sandpaper for the material you will be working with.

Step 2: It is recommended that you start the Sander/Drill before placing the sandpaper disc onto the work surface. This will reduce deep scratching in the surface.

Step 3: To operate the Sander/Drill, grip the BODY (#1) with your palm and place pressure on the TRIGGER (#10) to begin sanding.

Step 4: You can vary the speed of the Sander/Drill to suit different sanding applications by varying the pressure placed on the TRIGGER.

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Step 5: It is recommended that you sand in a random pattern to avoid sanding a side to side into your work surface. Do not sand any one area too heavily, or for more than a few seconds at a time.

Step 6: Every few minutes during continuous sanding, check the condition and wear of the sandpaper. If necessary, peel and replace the sandpaper. Do not use torn or severely worn sandpaper, you may damage your work surface or suffer physical injury.

Step 7: When you are done sanding, remove the Sander/Drill from the work surface and release pressure on the TRIGGER to stop the Sander/Drill.

MAINTENANCE

Your Sander/Drill is best operated with an Airline Oiler. If you are using the Sander/Drill without an Airline Oiler, follow the steps below for maintenance.

CAUTION

Step 1: Disconnect the Sander/Drill from the air hose.

Do not use detergent oil or additives as these lubricants will cause accelerated wear to the seals in the tool.

Step 2: Apply a few drops of PNEUMATIC TOOL OIL through the air line before each use, or every hour if used continuously.

Step 3: Apply a few drops of oil to the TRIGGER (#10) as shown in Figure 6. Work the

TRIGGER a few times to lubricate.

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Figure 6 — Lubrication Points

12

13

14

15

8

9

10

11

6

7

4

5

2

3

Item# Description

1 Body

Control Pin

Rubber Gasket

Ball

Spring

Hose Joint

Rubber Gasket

O-Ring

Regulator

Trigger

Pin

Pin

Housing Lock Ring

Bearing

Spacer

PARTS LIST

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Qty Item# Description

1 16 Rear End Plate

17

18

Cylinder

Vanes

19

20

21

22

Rotor

Bushing

Front End Plate

Spacer

23

24

25

26

27

28

29

30

31

Bearing

Cylinder Housing

Sanding Adapter

Holding Tool

Adapter Lock Down

Backing 3" Plate

Backing 4-1/2" Plate

Backing 5-1/2" Plate

Chuck

1

1

1

1

1

1

1

1

1

Qty

1

1

4

1

1

1

1

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 THE

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 REPLACMENT PARTS THERETO.

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ASSEMBLY DIAGRAM