FOUR INCH BELT AND
6 INCH DISC SANDER
93981
ASSEMBLY AND OPERATING INSTRUCTIONS
due to continuing improvements, actual product may
differ slightly from the product described herein.
3491 Mission oaks Blvd., CaMarillo, Ca 93011
VISIT OUR WEB SITE AT hTTP://WWW.hARBORfREIGhT.COM
©
Copyright 2006 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.
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3.
4.
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 quali-
fied 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.
5.
6.
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
1.
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.
2.
3.
4.
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.
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.
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.
5.
6.
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.
Use safety equipment. Always wear eye protection. dust mask, non-skid safety
shoes, hard hat, or hearing protection must be used for appropriate conditions.
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Tool Use and Care
1.
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.
2.
3.
4.
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 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.
Disconnect the Power Cord Plug from the power source before making any adjust-
ments, changing accessories, or storing the tool. such preventive safety measures
reduce the risk of starting the tool accidentally.
5.
6.
Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.
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.
7.
8.
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.
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
1.
2.
Tool service must be performed only by qualified repair personnel. service or
maintenance performed by unqualified personnel could result in a risk of injury.
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.
Maintain labels and nameplates on the Belt Sander. These carry important informa-
tion. if unreadable or missing, contact Harbor Freight Tools for a replacement.
Always wear ANSI approved safety impact eye goggles and heavy work gloves
when using the Belt Sander. Using personal safety devices reduce the risk for injury.
safety impact eye goggles and work gloves are available from Harbor Freight Tools.
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3.
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.
4.
5.
6.
7.
8.
Avoid unintentional starting. Make sure you are prepared to begin work before turn-
ing on the Belt sander.
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.
Always unplug the Belt Sander from its electrical outlet before performing any
inspection, maintenance, or cleaning procedures.
Never leave the Belt Sander unattended while running. Turn power off if you have
to leave the Belt sander.
Before each use, check all nuts, bolts, and screws for tightness. vibration during
mixing may cause these to loosen.
9.
Keep extension cord off the ground and away from water.
10.
Always connect the Line Cord to a Ground fault Circuit Interrupter (GfCI) pro-
tected electrical outlet.
11.
12.
Install this product on a proper surface. locate on a flat, level, and solid surface
that is capable of supporting the weight of the Belt sander.
Always maintain a maximum of 1/16 inch clearance between the table and the
sanding Disc.
13.
14.
Do not use the right side of the disc for sanding. The material could kick back.
hold material securely while sanding to avoid kickback.
15.
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.)
16.
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.
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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 facil-
ity 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.
2.
3.
Tools marked with“Grounding required”have 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.)
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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 Table A, 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 Table A.)
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 Table A.)
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.)
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.
Table A
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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
section, and the assembly drawing and Parts list at the end of this manual. 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
feet Placement
1.
2.
Carefully set the Belt sander on its side.
Find four rubber Feet (45) in the parts bag.
(45)
(45)
(45)
(45)
3.
4.
Press-fit each rubber Foot (45) over the lip of the Base (44) corner.
Using Wrench (70), check the tightness of all the nuts and Bolts under the Base
(44).
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Mounting Sanding Disc
1.
2.
3.
Place the Belt sander so that it is sitting on its feet.
on disc (22), loosen the set screw (17) with a Hex Wrench (not supplied).
slide the disc all the way onto the drive shaft (6) so that the set screw (17) faces the
flat surface on the drive shaft (6).
Disc (22)
Set Screw (17)
Drive Shaft (6)
4.
1.
securely tighten the set screw (17).
Table Installation
Find the Table Bar (49) and insert one end into the mounting holes under the Table
(59) as shown below, left.
hex Bolt (51), flat Washer
(53), and Lock Washer (52)
Table (59)
Table Bar (49)
Rod
(47)
flat Washer (54) and
Adjusting Knob (55)
Pivot Bracket (48)
Table Tilt
Trunion (56)
2.
insert the other end of the Table Bar (end with the angle Pointer #58) into the Pivot
Bracket (48).
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3.
4.
5.
Mount theTableTiltTrunion (56) to theTable (59) using Hex Bolt (51), Flat Washer (53),
and lock Washer (52). securely tighten. see photos at the bottom of page 9.
Mount the other end of the Table Tilt Trunion (56) to the Pivot Bracket (48) using Flat
Washer (54) and adjusting knob (55). securely tighten.
slide the Pivot Bracket (48) all the way onto the rod (47) and tighten set screw (50).
Mounting the Block Stop
1.
remove disc (22) by loosing set screw (17) and pulling the disc off.
Block Stop (7)
hex Bolt (20)
flat Washer (21)
Platen (8)
2.
For sanding using the Belt (4), mount the Block stop (7) to the Platen (8) using Hex
Bolt (20) with Flat Washer (21). securely tighten.
OPERATING INSTRUCTIONS
horizontal to Vertical
Pivot hex Nuts (13)
Belt Tracking Ad-
justing Knob (35)
Belt Tension
Lever (34)
Table (59)
Angle Pointer (58)
Table Angle Scale
Switch (16)
Switch Key
Table Angle
Adjusting Knob (55)
Controls and Adjustments
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On / Off Switch
The locking on/off switch (16) needs to have the switch key inserted before the switch
can be used. This feature prevents unauthorized use of the Belt sander. The locking switch
operates as follows.
1.
2.
3.
4.
insert plastic switch key into locking switch (16).
Press the switch to the on position to start.
Press the switch to the off position to stop.
To lock switch in off position, pull out the key and store in a secure place.
Caution: Never walk away from the Belt Sander when the machine is running. Always
lock the switch in the Off position when not in use.
Sanding Safety Tips
1.
2.
3.
always maintain a maximum of 1/16 inch clearance between the table and the sand-
ing disc.
CAUTION: Do not use the right side of the disc for sanding.The material could
kickback.
hold material securely while sanding to avoid kick back.
Leveling Table Assembly
during this and other procedures, refer to the photos on the previous page and the assem-
bly drawing on the last page.
1.
Place a combination square on the Table (59) so that it also touches the sanding disc
(23). if the Table is 90 degrees to the sanding Paper, the square is flush on the Pad.
2.
if the Table is not 90 degrees with the Pad, loosen the Table angle adjusting knob (55)
and tilt the Table until the square is flush with the Pad.
3.
4.
retighten the knob to secure the table.
loosen the angle Pointer (58) screw and adjust it so that it points to 90 degrees. re-
tighten screw.
Adjusting the Sanding Belt Tracking
1.
2.
Turn the Belt sander on.
if the belt looks like it is going to slide off either roller, the belt tracking needs to be
adjusted (described in the next step).
Turn the Belt Tracking adjusting knob (35) until the belt rides on the center of the idle
roller (41) and drive drum (5).
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Adjusting the Sanding Belt for Vertical Operation
Caution: Never make adjustments to the Belt Sander without first unplugging the line
cord from the electrical outlet.
1.
Using a Wrench (70), loosen Hex nuts (13) until the belt frame Platen (8) can be
moved.
2.
Push the Platen to the desired angle (0 to 90 degrees).
hex Nut (13)
hex Nut (13)
3.
retighten Hex nuts (13).
INSPECTION, MAINTENANCE, AND CLEANING
WARNING! Make sure the Power Switch of the Belt Sander is in its “Off” position
and that the tool is unplugged from its electrical outlet before performing any inspec-
tion, maintenance, or cleaning procedures.
1.
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.
2.
3.
4.
5.
6.
Periodically recheck all nuts, bolts, and screws for tightness.
Cover and store in a clean and dry location.
apply a light coat of paste wax to the worktable to make feeding stock easier.
Use compressed air to blow out dust and debris from sander and motor.
The bearings within are sealed and do not require lubrication.
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Mounting Sanding Disc
remove Table (59) surrounding sanding disc (23).
Peel off old sanding disc.
1.
2.
3.
align perimeter of new sanding disc (23) over aluminum disc (22). When aligned,
press disc firmly onto disc.
Most sanding discs have self-adhering properties. others may require application of
an appropriate glue (not supplied).
4.
replace Table (59).
Sanding Belt Replacement
1.
2.
3.
Push the Belt Tension lever (34) to the right to loosen the Belt (4).
slide the old sanding Belt (4) off the idler roller (41) and drive drum (5).
slide the new sanding Belt (4) onto the idler roller (41) and drive drum (5).
refer to the Parts list for correct Belt (4) replacement size.
4.
5.
Push the Belt Tension lever (34) to the left to tighten the Belt (4).
Turn on the Belt sander to test the new Belt. if the Belt tracks to one side, go to page
11 and follow the procedure for Belt Tracking adjustment.
TROUBLEShOOTING
SYMPTOM
Belt sander does not
turn on
PROBABLE CAUSE
REMEDY
Connect to outlet
not plugged in to electrical outlet
switch key not inserted into switch insert switch key, then push
switch to on position
GFCi or facility circuit breaker open reset circuit breakers
Power switch defective
replace switch
Motor or wiring problem
v-Belt too tight
repair with a qualified technician
a qualified technician needs to
loosen tension
Motor slows when
sanding
sanding with too much pressure on apply less pressure when sanding
stock
sanding Belt runs off
idler roller
not tracking properly
adjust sanding Belt Tracking
Wood burns while
sanding
sanding disc or Belt is loaded with Clean or replace disc or Belt.
debris
sander makes exces-
sive noise
v-Belt too tight
a qualified technician needs to
loosen
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PARTS LIST
Part
1
1a
1B
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Description
Bolt, Pan Head, 4x8mm
Washer, lock, 4mm
Washer, Flat, 4mm
Bearing Plate ll
Ball Bearing, 6201
Belt, sanding, 4”x36”
drive, drum
drive shaft
Block stop
Platen
screw with set square
Bearing Plate l
Plate, reinforcing
Table Bracket
nut, Hex, 8mm
Horizontal stop
strain relief
Qty.
6
6
6
1
2
1
1
1
1
1
2
1
1
1
8
1
2
1
3
1
1
3
1
1
2
4
1
1
2
2
1
1
1
1
1
1
1
1
1
Part
35
36
37
38
39
40
41
Description
adjusting knob
adjusting spring
Block Plate
Push Back spring
idler roller shaft
Ball Bearing, 6201
idler roller
Qty.
1
1
1
1
1
2
1
1
8
12
1
4
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
1
41a screw, round Head
42
43
44
45
Bolt, Hex, 8x16mm
Washer, Flat, 8mm
Base
Feet
45a Motor Pulley
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
nut, Hex, 10mm
rod
Pivot Bracket
Table Bar
switch
set screw, 8x8mm
Bolt, Hex, 8x10mm
Washer, lock, 8mm
Washer, Flat, 8mm
Washer, Flat, 8mm
adjusting knob
Table Tilt Trunion
Bolt, Pan Head, 5x10mm
Pointer
16a Bolt, Pan Head, 5x12mm
16B Washer, lock, 5mm
16C Washer, serrated, 5mm
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
set screw, 6x6mm
v-Belt
Pulley, drive
Bolt, Hex, 8x12mm
Washer, Flat, 8mm
disc, aluminum
disc, sanding
Bolt, Hex, 6x12mm
Washer, Flat, 6mm
Bolt, Pan Head, 5x15mm
Washer, Flat, 5mm
Pulley Cover
Pulley Cover Plate
Washer, Flat, 5mm
Washer, lock, 5mm
nut, Hex, 5mm
Motor
Table
Finger l
Washer, lock, 4mm
61a Washer, Flat, 4mm
62
63
64
65
66
67
68
69
70
Bolt, Pan Head, 4x5mm
screw, lock
Miter Gage
Miter Bar
line Cord
Washer, lock, 4mm
Washer, Flat, 4mm
nut, Hex, 4mm
Wrench
Tension lever
NOTE: some parts are listed and shown for illustration purposes only and are not available
individually as replacement parts.
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.
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ASSEMBLY DRAWING
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.
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WARRANTY CARD
LIMIteD 90 DAy/1yeAr wArrAnty
Harbor FreightTools Co.makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser for a period of ninety days from date of purchase that the motor, the belts
(if so equipped), and the blades (if so equipped) are free of defects in materials and workmanship.Harbor Freight
Tools also warrants to the original purchaser, for a period of one year from date of purchase, that all other parts
and components of the product are free from defects in materials and workmanship.This warranty does not apply
to damage due directly or indirectly to misuse, abuse, negligence or accidents; repairs or alterations outside our
facilities; 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
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