Harbor Freight Tools Sander 92158 User Manual

1
BANDFILE / INCH  
2
BELT SANDER  
92158  
Assembly And OperAtiOn instructiOns  
Due to continuing improvements, actual product may differ slightly from the product described herein.  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Visit our website at: http://www.harborfreight.com  
tO preVent seriOus injury, reAd And understAnd  
All wArnings And instructiOns befOre use.  
©
®
Copyright 2004 by Harbor FreightTools . 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 or replacement parts, please call 1-800-444-3353.  
 
6.  
7.  
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 qualied 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 t in a polarized outlet only one way. if the plug  
does not t fully in the outlet, reverse the plug. if it still does not t, contact a  
qualied 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.  
8.  
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.  
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 inuence 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.  
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, non-skid safety  
shoes, hard hat, or hearing protection must be used for appropriate conditions.  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 3  
 
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 tools 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 qualied 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 fOr this prOduct  
1.  
2.  
hold tool 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.  
maintain labels and nameplates on the belt sander. These carry important informa-  
tion. If unreadable or missing, contact Harbor Freight Tools for a replacement.  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 4  
 
3.  
4.  
Always wear Ansi-approved safety impact eye goggles, heavy work gloves, and  
ear protection when using the belt sander. Using personal safety devices reduce  
the risk for injury.  
maintain a safe working environment. Keep the work area well lit. Make sure there  
is adequate surrounding workspace. Always keep the work area free of obstructions,  
grease, oil, trash, and other debris. Do not use a power tool in areas near flammable  
chemicals, dusts, and vapors. Do not use this product in a damp or wet location.  
5.  
Avoid unintentional starting. Make sure you are prepared to begin work before turn-  
ing on the Belt Sander.  
6.  
do not force the belt sander. This tool will do the work better and safer at the speed  
and capacity for which it was designed.  
7.  
Always unplug the belt sander from its electrical outlet before performing any  
inspection, maintenance, or cleaning procedures.  
8.  
never leave the belt sander unattended while running. Turn power off if you have  
to leave the Belt Sander.  
9.  
before each use, check all nuts, bolts, and screws for tightness. Vibration during  
mixing may cause these to loosen.  
10.  
use both hands when operating. Many tools such as chain saws, hand-held sand-  
ers, drills, routers, etc., require the use of both hands when operating. Also, hold stock  
with both hands when buffing or sanding. This helps maintain tool and stock stability  
and keeps hands away from the working area of the tool.  
11.  
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, 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.)  
12.  
wArning! People with pacemakers should consult their physician(s) before us-  
ing 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.  
• Don’t use a power tool with the power switch locked on.  
• 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.  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 5  
 
grOunding  
note: This tool comes with a two-prong, polarized plug and is double insulated for safety.  
wArning!  
improperly connecting the grounding wire can result in the risk of electric shock.  
check with a qualied 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 facil-  
ity before use. if the plug will not t the outlet, have a proper outlet installed by  
a qualied electrician.  
grOunded tOOls:tOOls with three prOng plugs  
1.  
2.  
3.  
Tools marked withGrounding Requiredhave a three wire cord and three prong ground-  
ing 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 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  
figure b  
dOuble insulAted tOOls:tOOls with twO prOng plugs  
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. (see figure b.)  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 6  
 
2.  
Double insulated tools may be used in either of the 120 volt outlets shown in the pre-  
ceding illustration. (see figure b.)  
extensiOn cOrds  
1.  
2.  
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 exten-  
sion 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.)  
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.  
5.  
6.  
7.  
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. Al-  
ways 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 Or 240 VOlt)  
nAmeplAte  
Amperes  
(at full load)  
extensiOn cOrd length  
25 feet  
50 feet  
75 feet 100 feet 150 feet  
0 – 2.0  
2.1 – 3.4  
18  
18  
18  
18  
18  
14  
12  
18  
18  
18  
16  
14  
12  
10  
18  
18  
16  
14  
12  
10  
-
18  
16  
14  
12  
10  
-
16  
14  
12  
12  
-
3.5 – 5.0  
5.1 – 7.0  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
-
-
-
* based on limiting the line voltage drop to five volts at 150% of the rated amperes.  
figure c  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 7  
 
symbOlOgy  
Double Insulated  
Canadian Standards Association  
Underwriters Laboratories, Inc.  
Volts Alternating Current  
V~  
A
Amperes  
No Load Revolutions per Minute (RPM)  
n xxxx/min.  
0
unpAcKing  
When unpacking, check to make sure that all the parts are included. Refer to the Assembly  
Drawing and Parts List at the end of this manual. Not shown are five accessory Sanding  
Belts.  
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 tool is in its Off (O) position and  
that the tool is unplugged from its electrical outlet before performing any assembly,  
inspection, maintenance, or cleaning procedures.  
installing the sanding belt  
1.  
2.  
Remove Screw (26) and Cover (23). Refer to the photos on the next page.  
Turn the Slide Lock (36) completely to one side.  
This reduces the tension on the Roller (65) so that the Sanding Belt (66) can be slipped  
over easily.  
3.  
Place the Sanding Belt (66) over the Roller (65) and the Spindle (24).  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 8  
 
4.  
5.  
Turn the Slide Bar (36) so it points to the Pulley (65) and tightens the tension on the  
Sanding Belt (66). Replace Cover (23) and Screw (26).  
If needed, adjust the tracking of the Sanding Belt by turning the Adjustment Screw (59).  
Screw (26)  
Cover (23)  
Sanding  
Belt (66)  
Spindle (24)  
Roller (65)  
Slide Lock (36)  
OperAting instructiOns  
controls  
Switch (48)  
Slide Lock (36)  
Loosen Sanding Belt  
Adjusting Screw (59)  
Sanding Belt Tracking  
Screw (49)  
Angle Adjust  
Brush Cover (41)  
Bracket (22)  
Operation  
1.  
2.  
3.  
4.  
Secure the workpiece to be sanded.  
Loosen Screw (49) and adjust Bracket (22) to the desired angle for sanding.  
Plug the Line Cord (52) into a GFCI electrical outlet.  
Always follow all safety instructions and warnings in this instruction manual.  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 9  
 
5.  
6.  
7.  
8.  
Securely grasp the tool handle (with both hands) and press the On / Off Switch (48) to  
the On (I) position.  
Begin sanding with light movements and pressure until the sanding capability is  
known on the material being sanded.  
When finished using the Belt Sander, press the On / Off Switch (48) to the Off (O)  
position. Wait until the motor stops before setting the tool down.  
Unplug the unit from the electrical outlet.  
inspectiOn, mAintenAnce, And cleAning  
wArning! make sure the power switch of the tool is in its Off (O) position and  
that the tool is unplugged from its electrical outlet before performing any inspection,  
maintenance, or cleaning procedures.  
1.  
Before each use, inspect the general condition of the Belt Sander. Check for loose  
screws, misalignment , binding, or tears of sanding belt, 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.  
2.  
3.  
Store in a clean and dry location.  
Inspect the Carbon Brushes every few months for excessive wear; Sooner if the tool  
is used daily. Over time, if the performance of the tool diminishes, or it stops working  
completely, it may be necessary to replace the motor’s Carbon Brushes. The brushes  
are accessed by removing the Carbon Brush Cover (41) on top and bottom of the unit.  
Pull out the Carbon Brushes (40) and clean or replace both. This procedure should be  
completed by a qualified technician.  
4.  
5.  
Before each use, inspect the general condition of the Belt 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.  
Clean the outside of the unit with a damp cloth. Never use solvents to clean any parts  
of this tool. Use compressed air to blow out debris from the motor vents.  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 10  
 
pArts list  
part  
1
2
3
4
5
6
7
8
description  
part  
description  
Housing  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
Washer, Spring  
Brush Holder  
Stator  
Brush Holder Ring  
Screw, 4x65  
Washer, Spring  
Nut, M4  
Screw, Tapping, M4x25  
Slide Lock  
Button  
Lever  
Screw  
Carbon Brush  
Brush Cover  
Bushing, Rubber  
Switch Base  
Screw, Tapping, M4x18  
Bracket, Fixed  
Washer, Flat  
Screw, Tapping, M4x18  
Switch  
Nut Mount  
Dust Seal  
Armature  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
Bearing, 626  
Cover, Inner  
Bearing, 608  
Bearing Cover A  
Screw, M4x14  
Washer, Spring  
Woodruff Key  
Washer, Flat  
Washer, Spring  
Nut, M6  
Screw  
Screw, Tapping, M4x10  
Shaft  
Line Cord  
Line Cord Protector  
Cord Clip  
Bear Box  
Bracket  
Cover  
Spindle  
Spring  
Bushing  
Slide Block  
Label  
Bearing, 608  
Screw, M5x20  
Gear  
Screw, Adjusting  
Bar, Adjusting  
Screw, Hex, M4x20  
Spring, Adjusting  
Pin  
Bearing, 693  
Roller  
Belt, Sanding  
Pinion  
Bearing, 6001  
Gear Box Cover  
Screw  
Bearing Cover B  
Screw, M4x14  
pleAse reAd the fOllOwing cArefully  
the mAnufActurer And/Or distributOr hAs prOVidedthe pArts list And Assembly  
diAgrAm inthis mAnuAl As A referencetOOl Only. neitherthe mAnufActurer Or  
distributOr mAKes Any representAtiOn OrwArrAnty Of Any KindtOthe buyerthAt  
he Or she is quAlified tO mAKe Any repAirs tO the prOduct, Or thAt he Or she is  
quAlifiedtO replAce Any pArts Ofthe prOduct. in fAct,the mAnufActurer And/Or  
distributOr expressly stAtesthAt All repAirs And pArts replAcements shOuld  
be undertAKen by certified And licensedtechniciAns, And nOt bythe 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 92158  
for technical questions, please call 1-800-444-3353.  
Page 11  
 
Assembly drAwing  
record products 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.  
SKU 92158  
for technical questions, please call 1-800-444-3353.  
Page 12  
 

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