Chicago Electric 92158 Parts list manual

BANDFILE 1/2INCH
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 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 or replacement parts, please call 1-800-444-3353.

Page 2SKU 92158 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Motor 120 V~, 60 Hz, 600 watts, n010,000/min
Belt Speed 2300 FPM (feet per minute) (single speed);
Gear driven
Sanding Area 1/2 (W) x 5 (L) Inches
Pivot Head Adjustable 180°
Line Cord Two prong polarized, 8 feet, 9 inches long
Overall Dimensions 11 (L) x 4-1/2 (H) x 3 (W) Inches, 18-1/4 (L) with
sanding head
Weight 4.8 lb.
Accessories 5 – Sanding Belts
SAVE THIS MANUAL
You will need the manual for the safety warnings and precautions, assembly instructions,
operating and maintenance procedures, parts list and diagram. Keep your invoice with this
manual. Write the invoice number on the inside of the front cover. Keep the 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.
SAVE THESE INSTRUCTIONS
Work Area
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.
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. 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.
5. Do not expose power tools to rain or wet conditions. Water entering a power tool
will increase the risk of electric shock.
REV 09/06
230677

Page 3SKU 92158 For technical questions, please call 1-800-444-3353.
6. 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.
7. 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.
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 immediately. 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 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.
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.

Page 4SKU 92158 For technical questions, please call 1-800-444-3353.
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 FOR THIS PRODUCT
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.
1.
2.

Page 5SKU 92158 For technical questions, please call 1-800-444-3353.
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.
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.
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.
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.)
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.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
•
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•

Page 6SKU 92158 For technical questions, please call 1-800-444-3353.
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 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
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
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.)
1.
2.
3.
1.

Page 7SKU 92158 For technical questions, please call 1-800-444-3353.
Double insulated tools may be used in either of the 120 volt outlets shown in the pre-
ceding illustration. (See Figure B.)
EXTENSION CORDS
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.)
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.)
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.
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 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 - - -
FIGURE C * Based on limiting the line voltage drop to five volts at 150% of the rated amperes.
2.
1.
2.
3.
4.
5.
6.
7.
8.

Page 8SKU 92158 For technical questions, please call 1-800-444-3353.
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
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.
Place the Sanding Belt (66) over the Roller (65) and the Spindle (24).
1.
2.
3.
SYMBOLOGY
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
V~ Volts Alternating Current
AAmperes
n0xxxx/min. No Load Revolutions per Minute (RPM)

Page 9SKU 92158 For technical questions, please call 1-800-444-3353.
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)
Slide Lock (36)
Roller (65)
Sanding
Belt (66) Spindle (24)
OPERATING INSTRUCTIONS
Controls
Switch (48)
Brush Cover (41) Screw (49)
Angle Adjust
Bracket (22)
Slide Lock (36)
Loosen Sanding Belt
Adjusting Screw (59)
Sanding Belt Tracking
Operation
1. Secure the workpiece to be sanded.
2. Loosen Screw (49) and adjust Bracket (22) to the desired angle for sanding.
3. Plug the Line Cord (52) into a GFCI electrical outlet.
4. Always follow all safety instructions and warnings in this instruction manual.
4.
5.

Page 10SKU 92158 For technical questions, please call 1-800-444-3353.
5. Securely grasp the tool handle (with both hands) and press the On / Off Switch (48) to
the On (I) position.
6. Begin sanding with light movements and pressure until the sanding capability is
known on the material being sanded.
7. 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.
8. 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. Store in a clean and dry location.
3. 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. 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.
5. 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.

Page 11SKU 92158 For technical questions, please call 1-800-444-3353.
PARTS LIST
Part Description
1 Housing
2 Brush Holder
3 Stator
4 Brush Holder Ring
5 Screw, 4x65
6 Washer, Spring
7 Nut, M4
8 Nut Mount
9 Dust Seal
10 Armature
11 Bearing, 626
12 Cover, Inner
13 Bearing, 608
14 Bearing Cover A
15 Screw, M4x14
16 Washer, Spring
17 Woodruff Key
18 Washer, Flat
19 Washer, Spring
20 Nut, M6
21 Bear Box
22 Bracket
23 Cover
24 Spindle
25 Bearing, 608
26 Screw, M5x20
27 Gear
28 Pinion
29 Bearing, 6001
30 Gear Box Cover
31 Screw
32 Bearing Cover B
33 Screw, M4x14
Part Description
34 Washer, Spring
35 Screw, Tapping, M4x25
36 Slide Lock
37 Button
38 Lever
39 Screw
40 Carbon Brush
41 Brush Cover
42 Bushing, Rubber
43 Switch Base
44 Screw, Tapping, M4x18
45 Bracket, Fixed
46 Washer, Flat
47 Screw, Tapping, M4x18
48 Switch
49 Screw
50 Screw, Tapping, M4x10
51 Shaft
52 Line Cord
53 Line Cord Protector
54 Cord Clip
55 Spring
56 Bushing
57 Slide Block
58 Label
59 Screw, Adjusting
60 Bar, Adjusting
61 Screw, Hex, M4x20
62 Spring, Adjusting
63 Pin
64 Bearing, 693
65 Roller
66 Belt, Sanding
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE 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 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 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.

Page 12SKU 92158 For technical questions, please call 1-800-444-3353.
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.