Chicago Electric 90045 User manual

BELT SANDER
3” x 21”
Model 90045
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit ourWeb site at: http://www.harborfreight.com
Copyright®2003 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, please call 1-800-444-3353.
®

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PRODUCT SPECIFICATIONS
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, parts list and as-
sembly diagram. Keep your invoice with this manual. Write the invoice number
on the inside of the front cover. Keep this manual and invoice in a safe and dry
place for future reference.
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, fire, and/or serious injury.
SAVETHESE INSTRUCTIONS
1. Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases, or dust. Power tools create sparks
which may ignite the dust or fumes.
WORK AREA
Item Descri
p
tion
Electrical Requirements 120 V / 60 Hz / 7.5 Input Amps / 900 Watts.
Double Insulated Motor / 1,250 Belt FPM.
Belt Size 3” x 21”.
Power Switch Type Trigger w/Lock “ON” Button.
Base Plate Dimensions 6” L x 3-5/8” W.
Overall Dimensions 13-1/8” L x 5-3/8” W x 5-7/8” H.
Accessories Dust Bag (Qty. 1) / 120 Grit Belt (Qty. 1).
Weight 7.90 Pounds.

SKU 90045 For technical questions, please call 1-800-444-3353. Page 3
3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.
ELECTRICAL SAFETY
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 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.
5. 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.
6. 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.
7. Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
8. 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 immedi-
ately. Damaged Power Cords increase the risk of electric shock.
9. 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 oper-
ating a power tool. Do not use a power tool while tired or under the influ-
ence of drugs, alcohol, or medication. A moment of inattention while operat-
ing power tools may result in serious personal injury.

SKU 90045 For technical questions, please call 1-800-444-3353. Page 4
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, nonskid
safety shoes, hard hat, 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.

SKU 90045 For technical questions, please call 1-800-444-3353. Page 5
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 main-
tained 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. 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.
2. 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 the Belt Sander in
areas near flammable chemicals, dusts, and vapors.
3. Maintain labels and nameplates on the Belt Sander. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replace-
ment.
4. Keep this product and all other tools away from children and animals. Do
not allow spectators around the work area.
5. To avoid damage to the Belt Sander, do not use this tool on material that
may have nails, staples, tacks, or any other metal objects imbedded within.
6. Always wear safety impact eye goggles and hearing protection when using
this product. Safety impact eye goggles and hearing protection are available
from Harbor Freight Tools.
7. Keep all guards in place and working properly.
8. Whenever possible, secure the workpiece in a vise or using clamps.

SKU 90045 For technical questions, please call 1-800-444-3353. Page 6
14. Check for damaged parts. Before using this product, carefully check that it will
operate properly and perform its intended function. Check for damaged parts
and any other conditions that may affect the safe operation of this product.
Replace or repair damaged or worn parts immediately.
15. Replacement parts and accessories. When servicing, use only identical re-
placement parts. Only use accessories intended for use with this product.
16. Use the right product for the right job. There are certain applications for
which this product was designed. Do not use small equipment, tools, or attach-
ments to do the work of larger industrial equipment, tools, or attachments. Do
not use this product for a purpose for which it was not intended.
17. Stay alert. Watch what you are doing at all times. Use common sense. Do
not use this product when you are tired or distracted from the job at hand.
18. Do not operate this product when fatigued or under the influence of alcohol
or drugs.
11. Always remove all adjusting keys and wrenches from the Belt Sander be-
fore starting.
12. Do not pull or carry the Belt Sander by its Power Cord (14), or pull the Cord
around sharp corners or edges. Do not unplug the Belt Sander by pulling on
the Cord. Keep the Cord away from heated surfaces.
13. Do not force the tool. This Belt Sander will do the work better and safer at
the speed and capacity for which it is designed.
9. When using the Belt Sander, always maintain a firm grip on the tool with
both hands and keep hands and fingers away from the sanding area and
Sanding Belt (46).
10. Keep your body positioned to either side of the Sanding Belt (46), but
not in line with the Sanding Belt.
19. Always turn off the Belt Sander and unplug it from its electrical
outlet before changing accessories or performing any inspection, mainte-
nance, or cleaning procedures.
20. WARNING! The warnings and cautions discussed in this manual cannot
cover all possible conditions and situations that may occur. It must be under
stood by the operator that common sense and caution are factors which cannot
be built into this product, but must be supplied the operator.

SKU 90045 For technical questions, please call 1-800-444-3353. Page 7
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.
GROUNDEDTOOLS:TOOLS WITHTHREE 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.)
21. WARNING! Some dust created by power sanding, sawing, grinding, drill-
ing, and other construction activities contain chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm. Some ex-
amples of these chemicals are: lead from lead-based paints, crystalline silica
from bricks and cement and 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.)
22. 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 or failure of the pacemaker.
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.)

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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 that in the following illustration. (See Figure A.)
DOUBLE INSULATEDTOOLS:TOOLS WITHTWO PRONG PLUGS
4. Tools marked “Double Insulated” do not require grounding. They have a
special double insulation system which satisfies OSHA requirements and com
plies 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

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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, 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. 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.)
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
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. Protect your extension cords from sharp objects,
excessive heat, and damp or wet areas.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS
*
(120 VOLT)
NAMEPLATE
AMPERES
(
At Full Load
)
EXTENSION CORD LENGTH
25
Feet 50 Feet 75 Feet 100 Feet 150 Feet
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
* Based on limiting the line voltage drop
to five volts at 150% of the rated amperes.
FIGURE C

SKU 90045 For technical questions, please call 1-800-444-3353. Page 10
SYMBOLOGY
Double Insulated
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
Amperes
No Load Revolutions
per Minute (RPM)
noxxxx/min.
A
V ~
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts List on page 14
are included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.
ASSEMBLY INSTRUCTIONS
NOTE: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagram on page 15.
WARNING! Always make sure the Power Cord (14) of the Belt Sander is
unplugged from its electrical outlet prior to assembly, adding any accessories, or
making any adjustments to the tool.
To Remove/Install A Sanding Belt:
1. Pull out on the Tension Lever of the Front Wheel Frame (53), and slide the Sand-
ing Belt (46) out. (See Figure D, next page.)
2. Slide a new Sanding Belt (46) on. Then, push in on theTension Lever of the
Front Wheel Frame (53). (See Figure D.)

SKU 90045 For technical questions, please call 1-800-444-3353. Page 11
3. Plug the Power Cord (14) into the nearest 120 volt, grounded, electrical outlet.
CAUTION: The machined parts near theTension Adjuster (29) may be
sharp. Wear work gloves when adjusting the tension.
4. Grip the Belt Sander firmly with both hands. Lift the tool and squeeze the Power
Switch (66). As the Sanding Belt (46) turns, observe the Sanding Belt to see if it
is turning on-center and not moving to the right or left. If the Sanding Belt moves
to the right or left, while wearing heavy work gloves, turn the Tension Adjuster
(29) right or left until the Sanding Belt turns on-center. Then, turn off the Belt
Sander. (See Figures D, and E.)
To AttachThe Dust Bag:
To attach the Dust Bag (69), simply clip the opening of the Dust Bag onto the Dust Port
located on the Left Housing (18). (See Figures E, and F.)
DUST BAG (69)
FIGURE F
FIGURE E
TENSION ADJUSTER
(29)
POWER SWITCH
(66)
SWITCH LOCK
LEFT HOUSING (18)
FIGURE D TENSION LEVER
OF FRONTWHEEL FRAME (53)
SANDING BELT
(46)
POWER SWITCH
(66)
REV 10/04

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1. To start the Belt Sander, depress the Power Switch (66). To stop the tool, release
pressure on the Power Switch. (See Figure E.)
2. To lock the Power Switch (66) in the “ON” position for continuous operation,
depress the Power Switch and push in on the Switch Lock. The tool will continue
to run. To turn off the tool, squeeze and release the Power Switch once.
(See Figure E.)
3. WARNING! Prior to using the Belt Sander (each time), make sure the Switch
Lock mechanism is working properly. Always release the Switch Lock mecha-
nism before disconnecting the Belt Sander from its electrical outlet. Failure to do
so will cause the tool to start immediately the next time it is plugged into an
electrical outlet, resulting in possible injury or property damage. (See Figure E.)
The Power Switch:
OPERATING INSTRUCTIONS
Proper Operation DuringThe Sanding Process:
1. WARNING! When sanding a workpiece, always push and pull the Belt
Sander over the workpiece with both hands firmly gripping the tool. Never pass
hands or fingers directly in front of, to the rear, or below the Sanding Belt (46).
2. Make sure the workpiece is free from nails and any other foreign objects which
could damage the Sanding Belt (46).
3. Make sure the workpiece is supported at all times. Whenever possible, secure
the workpiece in a vise or with clamps (not included). If necessary, use a roller
stand (not included) with larger workpieces.
4. Plug the Power Cord (14) into the nearest 120 volt, grounded, electrical outlet.
5. Firmly grip the Belt Sander with both hands. Then, squeeze the Power Switch
(66) to turn on the tool. If desired, use the Switch Lock to run the Belt Sander in
its continuous mode.
6. Allow the Sanding Belt (46) to turn up to full speed before feeding the Sanding
Belt into the workpiece.
7. To avoid damaging the workpiece, always sand parallel to the grain of the wood.

SKU 90045 For technical questions, please call 1-800-444-3353. Page 13
INSPECTION, MAINTENANCE, AND CLEANING
1. WARNING! Make sure the Power Switch (66) of the Belt Sander is in its
“OFF” position and that the tool is unplugged from its electrical outlet before
performing any inspection, maintenance, or cleaning procedures.
2. BEFORE EACH USE, inspect the general condition of the Belt Sander. Check
for loose screws, misalignment or binding of moving parts, damaged electrical
wiring, dull or damaged Sanding Belt (46), 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.
3. CARBON BRUSH: To maintain peak efficiency of the Belt Sander’s Motor it is
recommended that every two to six months the Carbon Brush (27) be examined.
The Carbon Brush should be free of dust and dirt. The Carbon Brush should be
replaced when it has worn down to 3/16” in length. The Carbon Brush should
slide freely in and out of the Brush Holder (25) without sticking. To check the
Carbon Brush, remove the Brush Holder Cover (28) located at the front of the
Belt Sander. Lift out the Carbon Brush to inspect. If cleaning is necessary, rub
the Carbon Brush thoroughly with a pencil eraser. Next, clean the Brush Holder
opening with compressed air or a clean cloth. Then, replace the Carbon Brush
and Brush Holder Cover.
(See Figure G.)
4. TO CLEAN: The ventilation openings should be kept clean and free of sawdust
and debris. The most effective way to clean the ventilation openings is with com-
pressed air. The outer body may be cleaned with a clean cloth and a mild deter-
gent. Do not use solvents. Do not immerse the Belt Sander in liquid.
FIGURE G
FRONTVIEW BRUSH HOLDER COVER (28)
CARBON BRUSH (27)
BRUSH HOLDER (25)
8. Do not force the Belt Sander to remove material faster than it is designed to cut.
Push and pull the Sanding Belt (46) gradually along the surface of the workpiece.
9. Once the sanding job is completed, turn off the Belt Sander and wait until the
Sanding Belt (46) stops turning. Then, unplug the Power Cord (14) from its
electrical outlet.

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PARTS LIST
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
Part # Description Part # Description Part # Description
1 Close Cover (18) 25 Carbon Brush Holder 49 Belt
2 Bearing (626) 26 Nut (M5) 50 ----------------------------
3 Shaft Gear 27 Carbon Brush 51 ----------------------------
4 Bearing (608) 28 Brush Holder Cover 52 Front Wheel
Drive Axis
5 Dust Suction Cover 29 Tension Adjuster 53 Front Wheel Frame
6 Fan 30 Adjust Spring 54 Front Wheel
7 Screw (ST3.8 x 16) 31 Plain Washer (16) 55 Small Belt Wheel
8 Plain Washer (8) 32 Orientation Pin 56 Stator
9 Cover Board 33 Screw (ST4.8 x 20) 57 ----------------------------
10 Large Belt Wheel 34 Oil Bearing 58 Rotor
11 Belt Cover 35 Ring Washer 59 ----------------------------
12 Inductor 36 Rear Wheel 60 Right Housing
13 Capacitor 37 Needle Bearing 61 ----------------------------
14 Power Cord 38 Screw (M5 x 10) 62 Nameplate
15 Cable Plug 39 ---------------------------- 63 Screw (ST4.8 x 40)
16 -------------------------- 40 Baffle 64 Screw (ST4.8 x 25)
17 Pressure Cable 41 Spring 65 Screw (M5 x 40)
18 Left Housing 42 Screw (M4 x 10) 66 Power Switch
19 Bearing (6000) 43 Bearing Seat 67 Soft Grip
20 Plain Washer (10) 44 Front Cover 68 Adjust Nut
21 Large Gear 45 Screw (ST4.8 x 18) 69 Dust Bag (not shown)
22 Column Pin (3) 46 Sanding Belt 70 Roller Bearing
23 Retainer (10) 47 Cushion --------- ----------------------------
24 Nameplate 48 Bottom Plate --------- ----------------------------
PLEASE READTHE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST
AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEI-
THER THE MANUFACTURER OR 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 THAT ALL REPAIRS AND PARTS REPLACE-
MENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS,
AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARIS-
ING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACE-
MENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF
REPLACEMENT PARTS THERETO.
REV 12/04

SKU 90045 For technical questions, please call 1-800-444-3353. Page 15
ASSEMBLY DIAGRAM
NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts.
65
64
63
62
33
67
4
58
456
48
47
54
37
70
23
52
53
41
32
68 29
30
31
24
28
27
26
25
20 38
49
55
23
22
21
20
19
66
18
40
34
35
36
37
42
43
44
45
46
33 7
17
15
14
13
12
11
10
9
8
7
65
4
3
2
1
69: DUST BAG NOT SHOWN.
REV 12/04