Harbor Freight Tools Cordless Sander 38160 User Manual

Oscillating spindle sander  
Model 38160  
asseMbly and Operating instructiOns  
Visit our website at: http://www.harborfreight.com  
read this material before using this product.  
Failure to do so can result in serious injury.  
saVe this Manual.  
Copyright© 1998 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.  
Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may  
differ slightly from the product described herein. Tools required for assembly and service may not be included.  
For technical questions or replacement parts, please call 1-800-444-3353.  
revised Manual 10c  
 
8. USE RIGHT TOOL. Don’t force tool or  
attachment to do a job for which it was  
not designed.  
13. DON’T OVERREACH. Keep proper  
footing and balance at all times.  
14. MAINTAIN TOOLS WITH CARE. Keep  
tools sharp and clean for best and safest  
performance. Follow instructions for  
recOMMended MiniMuM Wire  
gauge FOr eXtensiOn cOrds  
(120 VOlt)  
lubricating and changing accessories.  
eXtensiOn cOrd  
naMeplate  
aMperes  
(at full load)  
15. DISCONNECT TOOLS before servicing;  
when changing accessories, such as  
blades, bits, cutters, and the like.  
length  
25’  
50’ 100’ 150’  
0 – 6  
18  
18  
16  
14  
16  
16  
16  
12  
16  
14  
14  
14  
12  
12  
6.1 – 10  
16. REDUCE THE RISK OF  
UNINTENTIONAL STARTING. Make  
sure switch is in off position before  
plugging in.  
10.1 – 12  
12.1 – 16  
table a  
do not use.  
17. USE RECOMMENDED ACCESSORIES.  
Consult the owner’s manual for  
9. USE PROPER EXTENSION CORD.  
Make sure your extension cord is in good  
condition. When using an extension  
cord, be sure to use one heavy enough  
to carry the current your product will  
draw. An undersized cord will cause a  
drop in line voltage resulting in loss of  
power and overheating. Table A shows  
the correct size to use depending on  
cord length and nameplate ampere  
rating. If in doubt, use the next heavier  
gauge. The smaller the gauge number,  
the heavier the cord.  
recommended accessories. The use of  
improper accessories may cause risk of  
injury to persons.  
18. NEVER STAND ON TOOL. Serious  
injury could occur if the tool is tipped  
or if the cutting tool is unintentionally  
contacted.  
19. CHECK DAMAGED PARTS. Before  
further use of the tool, a guard or other  
part that is damaged should be carefully  
checked to determine that it will operate  
properly and perform its intended  
10. WEAR PROPER APPAREL. Do not wear  
loose clothing, gloves, neckties, rings,  
bracelets, or other jewelry which may get  
caught in moving parts. Nonslip footwear  
is recommended. Wear protective hair  
covering to contain long hair.  
function – check for alignment of moving  
parts, binding of moving parts, breakage  
of parts, mounting, and any other  
conditions that may affect its operation.  
A guard or other part that is damaged  
should be properly repaired or replaced.  
11. ALWAYS USE SAFETY GLASSES. Also  
use face or dust mask if cutting operation  
is dusty. Everyday eyeglasses only have  
impact resistant lenses, they are NOT  
safety glasses.  
20. DIRECTION OF FEED. Feed work into  
a blade or cutter against the direction of  
rotation of the blade or cutter only.  
21. NEVER LEAVE TOOL RUNNING  
UNATTENDED. TURN POWER OFF.  
Don’t leave tool until it comes to a  
complete stop.  
12. SECURE WORK. Use clamps or a vise  
to hold work when practical. It’s safer  
than using your hand and it frees both  
hands to operate tool.  
reV 10e  
SKU 38160  
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Page 3  
 
3-pole receptacles that accept the tool’s  
plug.  
grOunding instructiOns  
tO preVent  
electric shOck  
and death FrOM incOrrect  
grOunding Wire  
6. Repair or replace damaged or worn cord  
immediately.  
cOnnectiOn  
read and FOllOW these  
instructiOns:  
grounding  
pin  
110-120 V~ grounded tools: tools  
with three prong plugs  
1. In the event of a malfunction or  
breakdown, grounding provides a path  
of least resistance for electric current  
to reduce the risk of electric shock.  
This tool is equipped with an electric  
cord having an equipment-grounding  
conductor and a grounding plug. The  
plug must be plugged into a matching  
outlet that is properly installed and  
grounded in accordance with all local  
codes and ordinances.  
125 V~ 3-prong plug and Outlet  
(for up to 125 V~ and up to 15 a)  
7. This tool is intended for use on a circuit  
that has an outlet that looks like the one  
illustrated above in 125 V~ 3-prong  
plug and Outlet. The tool has a  
grounding plug that looks like the plug  
illustrated above in 125 V~ 3-prong  
plug and Outlet.  
8. The outlet must be properly installed and  
grounded in accordance with all codes  
and ordinances.  
2. Do not modify the plug provided – if it will  
not fit the outlet, have the proper outlet  
installed by a qualified electrician.  
9. Do not use an adapter to connect this  
tool to a different outlet.  
3. Improper connection of the equipment-  
grounding conductor can result in a risk  
of electric shock. The conductor with  
insulation having an outer surface that  
is green with or without yellow stripes is  
the equipment-grounding conductor. If  
repair or replacement of the electric cord  
or plug is necessary, do not connect the  
equipment-grounding conductor to a live  
terminal.  
110-120 V~ double insulated tools:  
tools with two prong plugs  
4. Check with a qualified electrician or  
service personnel if the grounding  
instructions are not completely  
Outlets for 2-prong plug  
understood, or if in doubt as to whether  
the tool is properly grounded.  
1. To reduce the risk of electric shock,  
double insulated equipment has a  
5. Use only 3-wire extension cords that  
have 3-prong grounding plugs and  
polarized plug (one blade is wider than  
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Page 4  
For technical questions, please call 1-800-444-3353.  
SKU 38160  
 
the other). This plug will fit in a polarized 8. Only use safety equipment that has been  
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 the proper outlet. Do  
not change the plug in any way.  
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.  
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.)  
9. 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.  
sander safety Warnings  
For your Own safety read instruction  
Manual before Operating sander  
1. Wear eye protection.  
10. Industrial applications must follow OSHA  
guidelines.  
2. Support workpiece with miter gauge,  
backstop, or worktable.  
11. Maintain labels and nameplates on  
the tool. These carry important safety  
information. If unreadable or missing,  
contact Harbor Freight Tools for a  
replacement.  
3. The backstop is a fence near the surface  
that helps the operator maintain control  
of the workpiece and prevents the  
workpiece from being pulled into the  
machine. For safety, it must be adjusted  
very close to the sanding surface.  
12. Avoid unintentional starting. Prepare to  
begin work before turning on the tool.  
4. The worktable is the surface mounted  
close to the sanding surface that the  
operator rests the workpiece against  
to prevent it from being pulled by the  
sanding surface. For safety, it must  
be adjusted very close to the sanding  
surface.  
13. 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.  
5. dO nOt Operate With any  
guard disabled, daMaged, Or  
reMOVed. Moving guards must  
move freely and close instantly.  
14. 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  
6. The use of accessories or attachments  
not recommended by the manufacturer  
may result in a risk of injury to persons.  
7. When servicing use only identical  
replacement parts.  
• Crystalline silica from bricks and  
cement or other masonry products  
• Arsenic and chromium from chemically  
reV 10e  
SKU 38160  
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Page 5  
 
treated lumber  
unpacking  
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.)  
When unpacking, make sure that the  
item is intact and undamaged. If any parts  
are missing or broken, please call Harbor  
Freight Tools at 1-800-444-3353 as soon as  
possible.  
15. 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.)  
16. 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.  
saVe these  
instructiOns.  
speciFicatiOns  
Electrical Input  
120 V~ / 60 Hz / 11 A  
Motor No Load Speed 1787 RPM  
Oscillations per  
Minute  
58 OPM  
7/8”  
Oscillation Travel  
Sanding Belt Capacity 3/4” - 2”  
Sanding Belt Height  
Sanding Thickness  
Dust Collection Port  
Table Tilt Angle  
4-1/2”  
3/16 - 11/16”  
2”  
0 - 45°  
rev 00c; 10c  
Page 6  
For technical questions, please call 1-800-444-3353.  
SKU 38160  
 
to change/install sand belts  
(see parts diagram and parts list on pages 8 and 9)  
place switch in “OFF” position, and unplug the sander before performing any of the steps below.  
The Oscillating Sander has been shipped completely assembled with a 2” sand belt (#49) and regular core board  
installed. Change sand belts as follows:  
tO reMOVe sand belt  
1. Grasp and hold sand belt (#49) on rotating axle (#46). Loosen nut (#51). If nut is too tight and rotating axle  
spins inside sand belt, secure the rotating axle with a wrench and loosen nut.  
2. Remove nut, big washer (#50), and sand belt. Unscrew rotating axle clockwise and remove core board (#36) -  
also see instructions below describing how to remove core board.  
3. Remove big washer (#50) and clean sawdust accumulation.  
tO install sand belt  
1. Replace big washer (#50). Fin side of washer should always be installed down. The fins help push sawdust  
through the dust exhaust port opening, preventing buildup of sawdust. Sawdust buildup in this area may cause  
the oscillating motion to stop. The big washer must be used with all sanding sleeves.  
2. Select and install the desired rotating axle.  
3. Install appropriate sand belt on the rotating axle. (Note: If sanding sleeve becomes difficult to install or remove,  
apply talcum powder on the inside of the sand belt before installing on axle).  
4. Install big washer (#50) and nut.  
5. Grasp and hold sand belt and tighten nut. Do not overtighten.  
replacing core boards  
The Oscillating Sander comes with two core boards. The core board with the circular opening is for sanding when the working  
table (#34) is level. The core board with the oblong opening is to be used when the working table is set at an angle.  
to remove core boards  
Push firmly from underneath the working table until core board is removed.  
to insert core boards  
1. Align the notch in the core board with the spring dowel (#35) located on the inner rim of the core board insert area.  
2. Push down firmly until the core board is fully inserted and flush with the surface of the working table.  
SKU 38160  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
preparing For Operation  
note:  
this sander is designed for use on plastic and wood surfaces only. do not use this sander for sanding  
metals. sanding metals will cause sparks that will ignite wood and dust particles on sander, in the dust  
collector, or in workshop.  
it is recommended that this tool not be used for extended work on any fiberglass or abrasive materials.  
it has been found that those materials are subject to accelerated wear and possible premature failure,  
as the fiberglass chips and grindings are highly abrasive to bearings, brushes, commutator, etc. During  
any sanding of these materials, it is important the tool be cleaned frequently by blowing with an air  
jet.  
do not use sander without a sand belt. doing so will damage the rotating axle.  
Make sure nut on the top of the rotating axle is tightened securely - but not overtightened.  
sand belt selectiOn  
Selecting the correct size diameter, type of grit and sanding sleeve is an extremely important step in achieving a  
high quality finish:  
Aluminum oxide, silicon carbide, and other synthetic abrasives are best for power sanding.  
Natural abrasives, such as flint and garnet are too soft for use in power sanding.  
Select and install the desired sand belt for the particular application. Sand belts from 3/4”- 2” can be used with this  
sander. Choose one that is close in size to the material you are sanding.  
grit selectiOn  
The condition of the surface to be sanded will determine which grit will do the proper job. In general, coarse grit will  
remove the most material. Finer grit will produce the best finish in all sanding operations. If the surface is rough,  
start with a coarse grit and sand until the surface is uniform. Medium grit may then be used to remove scratches  
left by the coarser grit and finer grit used for finishing of the surface. Always continue sanding with each grit until  
the surface is uniform.  
Warning! Do not use water with this sander. It is for dry  
sanding only. Wet sanding will damage the machine,  
and may present a shock hazard. Use only in dry  
locations.  
reV 10c  
Page 8  
For technical questions, please call 1-800-444-3353.  
SKU 38160  
 
Operation  
Exercise caution! Never force the material into the sander. You will become familiar with the sander’s features from  
practice and use. If possible, practice sanding with a scrap piece of wood.  
adJusting table angle  
1. If working table is to be used at an angle, make sure to install the angle core board (with the oblong-shaped  
opening) before sanding.  
2. Loosen dial knob (#32) and adjust working table to the desired angle using the numbers on the rotating plate  
(#31) as a guide.  
3. Tighten dial knob securely so that the working table will not move during operation.  
sanding  
1. Turn sander on.  
2. Let the motor build to its full speed, then gradually feed material against sanding sleeve. Do not let the material  
contact sanding sleeve before turning on sander and allowing it to develop full speed.  
Feed directiOn  
When sanding, the sanding sleeve rotates counterclockwise. Therefore, feed the material against the sanding  
sleeve from right to left. When fed from right to left, the rotation of the sanding sleeve sands against the material.  
If fed in the opposite direction, the rotation forces of the spinning sanding sleeve will tend to throw or bounce the  
material away from the sanding sleeve. This could cause loss of control of the material.  
dust cOllectiOn capability  
Astandard 2-1/4” dust collect cover (#40) has been provided to make dustless sanding possible. The dust collection  
port is located under the working top on the rear side of the sander. The pickup adapter end of a vacuum hose (not  
included) will fit inside the dust collect cover.  
Even with a dust collection system, it is necessary to periodically clean sanding dust from the core board and big  
washer areas. Sanding dust buildup in this area may cause the core board surface to rise above the working table  
surface.  
Maintenance  
cleaning: Regularly clean the work surface with dry brush or clean cloth. Clean sawdust accumulations from core  
board, big washers and rotating axle after each use.  
lubricatiOn: No lubrication is required. All of the bearings in this tool are lubricated with a sufficient amount of  
high grade lubricant for the life of the machine under normal operating conditions.  
pOWer cOrd: Inspect the power cord periodically, and if damaged, have it repaired by an authorized technician.  
replaceMent parts: When servicing, use only identical replacement parts. Use of any other parts will void the  
warranty.  
SKU 38160  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
parts list  
no.  
name  
Quantity  
no.  
name  
Quan-  
tity  
1
2
3
4
5
6
7
8
stand  
switch  
Vertical Motor  
key of Motor  
clamp nail  
Worm  
1
1
1
1
2
1
1
1
1
2
11  
2
4
29  
30  
31  
32  
33  
34  
35  
36  
37  
hexagon-headed bolt M8x20  
stand 1 of working table  
rotating plate  
parts of dial knob  
crossed disc nail M5 x 8  
Working table  
spring dowel 3 x 8  
core board  
hexagonn socket head cap  
screw M6 x 20  
6
1
1
2
7
1
1
2
spring ring for hole 55  
bearing 80106  
spring ring for axle 32  
cross head disc nail M5 x 55  
screw Washer 5 holee 55  
rocker arm  
nut M5  
hexagon socket head cap  
screw M4 x 30  
left core axle of Worm Wheel  
Worm Wheel  
stand of Worm Wheel  
screw M8 x 65  
right core axle of Worm Wheel  
guide pole  
shuttle axle cover  
shuttle axle  
spring dowel 4 x 30  
bearing 61804  
hexagon socket head cap  
screw Mg x 16  
spring Washer 8  
Frame to Fix Motor  
screw Washer  
9
10  
11  
12  
13  
14  
2
1
7
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
dust cover  
hexagon-headed bolt M8 x 25  
dust collect cover  
pointer  
stand ii of Working table  
stand board  
dial  
key 5 x 50  
rotating axle of sand belt  
big Washer i  
rubber cylinder  
sand belt  
big Washer ii  
left nut M8  
board of switch  
nut M8  
Washer nut M8  
rubber Washer  
2
1
1
1
1
1
1
1
1
1
1
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
5
7
1
14  
26  
27  
28  
Page 10  
For technical questions, please call 1-800-444-3353.  
SKU 38160  
 
assembly diagram  
SKU 38160  
For technical questions, please call 1-800-444-3353.  
Page 11  
 
liMited 1 year / 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 for a period of ninety  
days from date of purchase that the engine/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 (90  
days if used by a professional contractor or if used as rental equipment). This warranty does  
not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents,  
repairs or alterations outside our facilities, 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  
reV 10c  
Page 12  
For technical questions, please call 1-800-444-3353.  
SKU 38160  
 

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