COMBINATION 4 X 6 INCH

BELT SANDER

38123

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?? 2005 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 REV 05/05

chemicals, dusts, and vapors. Do not use this product in a damp or wet location.

ELECTRICAL SAFETY

5.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.

6.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.

7.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.

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

9.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.

10.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

11.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.

12.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.

13.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.

14.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.

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, hardhat, or hearing protection must be used for appropriate conditions.

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.

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.

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.

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.

SPECIFIC SAFETY RULES

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

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

2.Never plug the Power Cord of the Sander into an electrical outlet while standing on a wet or damp surface.

3.Always turn off the Sander, remove the Switch Key (21), and unplug the unit from its electrical outlet before performing any inspection, maintenance, or cleaning procedures.

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

Make sure to unplug the Sander from its electrical outlet and remove the Switch Key

(21) before leaving the area.

5.Store idle equipment. When not in use, tools and equipment should be stored in a dry location to inhibit rust. Always lock up tools and equipment, and keep out of reach of children.

6.Industrial applications must follow OSHA requirements.

7.Reduce the risk of accidental starting. Make sure the Power Switch is in its ???OFF??? position before plugging the Power Cord into a 120 volt, grounded, electrical outlet.

8.Before sanding, turn on the Sander and check for excessively loose Sanding Belt or Disc. If necessary, turn off the Sander and correct the problem before using.

9.Always keep hands and fingers as far away as possible from the moving parts of the Sander.

10.Use the right tools for the job. Do not attempt to force a small tool or attachment to do the work of a larger industrial tool or attachment. There are certain applications for which this tool was designed. It will do the job better and more safely at the rate for which it was intended. Do not modify this tool, and do not use this tool for a purpose for which it was not intended.

11.Allow the Sanding Belt and Sanding Disc to spin up to full speed before feeding a workpiece into them. When turning off the Sander, allow the Sanding Belt and Sanding Disc to slow down and stop on their own. Do not press against the Belt or Disc to stop them.

12.Feed the workpiece into the Sanding Belt and Sanding Disc gradually and into the direction of rotation. Do not attempt to force the Sander to remove material faster than it was designed to cut.

13.When replacing the Sanding Belt, make sure the Belt has a minimum 2000 FPM rating. When replacing the Sanding Disc, make sure the Disc has a minimum 3500 RPM rating.

14.To avoid damage to the Sander and personal injury, allow 1/16??? clearance between the Sanding Belt and Backstop and 1/16??? clearance between the Sanding Disc and Worktable.

15.When sanding a large workpiece, make sure its entire length is properly supported.

16.Never attempt to remove material stuck in the moving parts of the Sander while it is plugged in or running.

17.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, 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.)

18.WARNING! People with pacemakers should consult their physician(s) before using this product. Operation of electrical equipment in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker.

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

SAVE THESE INSTRUCTIONS

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.

GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS

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

Figure A, next page.)

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 Figure A.)

3.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.)

THIS PRODUCT

USES A

3-PRONG PLUG

120 VOLT, GROUNDED,

ELECTRICAL OUTLET

FIGURE A

DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS

4.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.)

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

FIGURE B

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 Figure C.)

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 Figure C.)

4.If 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.)

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 Figure C.)

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 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.

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

RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*

(120 VOLT)

FIGURE C

SYMBOLOGY

UNPACKING

When unpacking, check to make sure all parts listed in the Parts List on page 19 are included. If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this manual as soon as possible.

ASSEMBLY INSTRUCTIONS

WARNING! Make sure the Power Switch of the Sander is in its ???OFF??? position, the Switch Key (21) is removed, and its Power Cord/Plug is un- plugged from the electrical outlet prior to performing any assembly.

To Secure The Sander Base Assembly To A Workbench:

1.The Sander must be secured before using. You may attach a large C-Clamp (not included) to each side of the Sander and the workbench. Or, you may permanently mount the Sander to a workbench following the instructions below.

2.Place the Sander in the desired location on the workbench.

3.Use the mounting holes located at the Sander Base (42) as a template to mark two drill holes in the workbench. Remove the Sander, and drill two 3/8??? holes through the workbench. (See Figure E.)

4.Align the Sander Base (42) over the two holes in the workbench, and secure the Sander to the workbench using two 3/8??? bolts and lock nuts (neither included). (See Figure E.)

DISC (30)

To Mount The Sandpaper Pad And Disc Guard:

1.Locate the 6??? Sandpaper Pad (27), and peel the backing off the Pad. (See Figure E.)

2.Align the perimeter of the Sandpaper Pad (27) over the Disc (30). When aligned, press the Sandpaper Pad firmly onto the Disc. (See Figure E.)

3.Attach the Disc Guard (32) over the lower portion of the Disc (30), using two Pan Head Screws (31). (See Figure E.)

To Mount The Table Assembly:

1.Locate the Table Support (36), mounting Hex Screws (6), Lock Washers (7), and Flat

Washers (8). (See Figure F.)

2.Set the Worktable (35) on its side, and align its mounting holes with the mounting holes in the Table Support (36). (See Figure F.)

3.Attach the Table Support (36) to the Worktable (35) using the Hex Screws (6), Lock Washers (7), and Flat Washers (8). (See Figure F.)

TABLE SUPPORT (36)

WORKTABLE (35)

FLAT WASHER (8)

LOCK WASHER (7)

HEX SCREW (6)

FIGURE F

4.Position the Table Support (36) in the corresponding mounting holes located on the side of the Base (42). (See Figure G, next page.)

5.Place a Flat Washer (8) on the shaft of the Knob (1). Then, screw the Knob into the threaded hole in the Base (42). (See Figure G.)

6.Loosen the three Hex Screws (6), and adjust the Worktable (35) so there is a maximum of 1/16??? space between the Sandpaper Pad (27) and the Worktable. Then, retighten the Hex Screws. (See Figures F and G.)

To Install The Backstop:

Place the Backstop (9) over the Bed (4), and use a Hex Screw (6), Lock Washer (7), and Flat Washer (8) to secure the Backstop to the Bed. The Backstop must not be in contact with the Sanding Belt (10). (See Figure H.)

HEX SCREW (6)

LOCK WASHER (7)

FLAT WASHER (8)

WRENCH

(NOT INCLUDED)

FIGURE H

OPERATING INSTRUCTIONS

To Adjust The Worktable For Vertical Sanding:

1.Remove the Hex Screw (6), Lock Washer (7), and Flat Washer (8). Then, remove the Backstop (9). (See Figure H.)

2.Unscrew and remove the Knob (1). (See Figure I, next page.)

3.Pull the Index Pins out of the mounting holes in the Table Support (36).

(See Figure G.)

4.Loosen the Hex Socket Screw (56), and raise the Bed (4) to the desired sanding position.

(See Figure I.)

5.Insert the Index Pins of the Table Support (36) into the Auxiliary (upper) Holes in the Bed (4). (See Figures G and I.)

6.Retighten the Hex Socket Screw (56). Check to make sure the Worktable (35) is not touching the Sanding Belt (10). (See Figure I.)

FIGURE I

AUXILIARY

MOUNTING HOLES

To Level The Worktable Assembly:

1.Place a combination square on the Worktable (35) so that the square also touches the Sanding Pad (27). (See Figure J.)

2.If the Worktable (35) is 90 degrees to the Sandpaper Pad (27), the combination square is flush on the Pad. (See Figure J.)

3.If the Worktable (35) is NOT 90 degrees to the Sandpaper Pad (27), loosen the Knob

(1) and tilt the Worktable until the combination square is flush with the Pad.

(See Figure J.)

4.Retighten the Knob (1) to secure the Worktable (35) in place. Then, attach the Scale

Label (37) to the ???0??? degree mark on the Dust Collector (34).(See Figure J.)

COMBINATION SQUARE

(NOT INCLUDED)

WORKTABLE (35) FIGURE J

To Install And Adjust The Sanding Belt:

1.Move the Tension Lever (66) to the right to release the Sanding Belt (10) tension.

(See Figure K.)

2.Place the Sanding Belt (10) over the Drive Drum (13) and Idler Drum (65), making sure the inside direction arrow points down towards the Drive Drum. (See Figure K.)

3.Center the Sanding Belt (10) on the Drive Drum (13) and Idler Drum (65).

(See Figure K.)

4.Slide the Tension Lever (66) to the left to tighten the belt tension. (See Figure K.)

5.Tighten the Hex Socket Screw (56) when the Bed (4) is in the desired working position.

(See Figure K.)

6.Plug the Power Cord (38) into the nearest 120 volt, grounded, electrical outlet. Turn the power Locking Switch (22) ON, then OFF, while viewing the movement of the Sanding Belt (10). If the Sanding Belt appears to be sliding off either the Drum Drive (13) or Idler Drive (65), the belt tracking needs to be adjusted. (See Figure K.)

7.If the Sanding Belt (10) moved toward the Sanding Pad (27) when the machine was turned on, turn the tracking Knob (1) clockwise 1/4 turn and test again.

(See Figure K.)

8.If the Sanding Belt (10) moved away from the Sanding Pad (27) when the machine was turned on, turn the tracking Knob (1) counterclockwise 1/4 turn and test again.

(See Figure K.)

IDLER DRUM (65)

KNOB (1)

TENSION LEVER (66)

DRIVE DRUM (13)

HEX SOCKET SCREW (56)

FIGURE K

The ON/OFF Locking Switch:

1.The ON/OFF Locking Switch (22) must have the Switch Key (21) inserted before the

ON/OFF Locking Switch can be used. This feature helps prevent unauthorized use of the Sander. (See Figure L.)

2.Insert the Switch Key (21) into the ON/OFF Locking Switch (22). (See Figure L.)

3.To turn the Sander on, place your finger under the left side of the ON/OFF Locking Switch (22) and pull out. (See Figure L.)

4.To turn the Sander off, push in on the left side of the ON/OFF Locking Switch (22).

(See Figure K.)

5.To lock the ON/OFF Locking Switch (22) in its OFF position, push and hold the left side of the Switch while pulling out the Switch Key (21). Always lock the Switch in its OFF position when the Sander is not in use. (See Figure L.)

PULL OUT TO TURN

LOCKING SWITCH ON (22)

INSERT

SWITCH KEY (21)

Sanding Methods: Surface Sanding On The Sanding Belt:

BACKSTOP (9)

SURFACE SANDING

ON SANDING BELT (10)

FIGURE M WORKTABLE (35)

Sanding Methods: End Sanding On The Sanding Belt:

END SANDING ON THE

SANDING BELT (10)

WORKTABLE

(35)

FIGURE N

Sanding Methods: Sanding Curved Edges:

SANDING CURVED EDGES BACKSTOP

(9)

FIGURE O WORKTABLE (35)

NOTE: The Sanding Belt is designed to rotate down towards the table. The Sanding Disc rotates up from the table and down towards the table.

When Sanding, always hold the workpiece securely, with two hands if possible, and keep hands and fingers away from all moving parts on the tool. Whenever possible, use the

Backstop (9) and Worktable (35) on the machine; they will allow you to work more safely, more accurately, and with less fatigue.

Caution: Sanding against the direction indicated on the disc is hazardous and could result in personal injury.

INSPECTION, MAINTENANCE, AND CLEANING

1.WARNING! Always turn the Sander???s ON/OFF Locking Switch (22) to its ???OFF??? position, remove the Switch Key (21), and unplug the machine from its electrical outlet and before performing any inspection, maintenance, or cleaning.

2.Before each use: Inspect the general condition of the Sander. Check for misalignment or binding of moving parts, loose, cracked or broken parts, damaged Power Cord, and any other condition that may affect its safe operation. If a problem occurs with the

Sander, have the problem corrected before further use.

Do not use damaged equipment.

3.Before each use: Apply a light coat of paste wax (not included) to the Worktable (35) to make feeding stock easier.

4.After each use: Use compressed air to blow out dust and debris from Sander and its Motor.

5.After each 10 hours of use: Oil the Sleeve Bearings with 30 weight oil. To do so, release the belt tension by sliding the Tension Lever (66) to the right. Move the Sanding Belt (10) slightly to the right or left of the Idler Drum (65) to expose the oval-shaped oiling hole. Apply only two or three drops of oil in the left and right oiling holes. Then, readjust the belt tracking as previously discussed. (See Figure P.)

OIL HERE

SLEEVE BEARINGS

IDLER DRUM (65)

TENSION LEVER (66)

FIGURE P

6.To replace the timing Drive Belt:

A.Remove the Screw (44) from the Belt Cover (52). Then, remove the Belt Cover.

(See Figure Q, next page.)

B.Loosen the three Screws to allow the Drive Pulleys (46, 49) to shift enough to place the Drive Belt (43) around them. (See Figure Q.)

C.Place the Drive Belt (43) around the Drive Pulley (46), then around the other Drive Pulley (49). (See Figure Q.)

D.Tighten the three Screws slightly. (See Figure Q.)

E.Adjust the tension of the Drive Belt (43) by placing a Standard screwdriver in the adjusting hole and pushing up on the screwdriver to apply tension to the Drive Belt.

(See Figure Q.)

F.Tighten the three Screws firmly. (See Figure Q.)

G.Grasp the Drive Belt (43) with two fingers on the outside-center and squeeze. There should be about 1/4??? give to the Drive Belt for proper tension. (See Figure Q.)

H.Note: Too much tension on the Drive Belt (43) can load-down the Motor and cause possible damage. If the Drive Belt is too loose, it may fail prematurely.

(See Figure Q.)

I.Make sure to replace the Belt Cover (52). (See Figure Q.)

7.When storing: Store the Sander in a safe, clean, dry, location out of reach of children and other unauthorized people.

8.WARNING! All maintenance, service, or repairs not listed in this manual are only to be attempted by a qualified service technician.

DRIVE PULLEY (49)

FIGURE Q

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIA-

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

TOR 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 LIABIL-

ITY 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.