Craftsman 320.39592 User manual

Operator's ManuaJ
®
3.0 Amp RANDOM ORBIT SANDER
Model No. 320.39592
LISTED
_WARNING: To reduce the risk of injury,
the user must read and understand the
Operator's Manual before using this product.
* WARRANTY
* SAFETY
* DESCRiPTiON
* ASSEMBLY
* OPERATION
* MAINTENANCE
Sears Brands Management Corporation, Hoffman Estates,
IL 60179 U.S.A.
www, craftsman,com

Warranty Page 2
Safety Symbols Pages 4-5
Safety Instructions Pages 6-8
Description Pages 9-10
Assembly Page 11
Operation Pages 12-16
Maintenance Pages 16-17
Troubleshooting Page 17
Parts List Pages 18-20
CRAFTSMAN ONE YEAR LiMiTED WARRANTY
FOR ONE YEAR from the date of purchase, this product is warranted
against any defects in material or workmanship. With proof of purchase, a
defective product will be replaced free of charge.
For warranty coverage details to obtain free replacement, visit the web
page: www.craftsman.corn/warranty
This warranty does not cover the sandpaper, which is an expendable part that
can wear out from normal use within the warranty period.
This ONE YEAR warranty is void if this product is ever used while providing
commercial services or if rented to another person. For 90 DAY commercial
and rental use terms, see the Craftsman warranty web page.
This warranty gives you specific legal rights, and you may also have other
rights which vary from state to state.
Sears Brands Management Corporation, Hoffman Estates, IL 60179
SAVE THESE INSTRUCTIONS!
READ ALL INSTRUCTIONS!
This random orbit sander has many features for making its use more pleasant
and enjoyable. Safety, performance, and dependability have been given top
priority in the design of this product, making it easy to maintain and operate.
_, DANGER: People with electronic devices, such as 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 © Sears Brands, LLC

_,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
Crystalline silica from bricks and cement and other masonry products, and
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 chemical: 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.

Thepurposeofsafetysymbolsistoattractyouattentiontopossibledangers.
Thesafetysymbolsandtheexplanationswiththemdeserveyourcareful
attentionandunderstanding,symbolwarningsdonot,bythemselves,eliminate
anydanger.Theinstructionsandwarningstheygivearenosubstitutesfor
properaccidentpreventionmeasures.
WARNING:Besuretoreadandunderstandallsafetyinstructionsinthis
manual,includingallsafetyalertsymbolssuchas"DANGER,""WARNING,"
and"CAUTION"beforeusingthistool.Failuretofollowallinstructionslistedin
thismanualmayresultinelectricshock,fire,and/orseriouspersonalinjury.
SYMBOL SIGNAL MEANING
SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, or CAUTION; may
be used in conjunction with other symbols or pictographs.
DANGER: Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
,_, WARNING: Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
_, CAUTION: Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
Damage prevention and Information Messages
These inform the user of important information and/or instructions that could
lead to equipment or other property damage if they are not followed. Each
message is preceded by the word "NOTICE", as in the example below.
NOTICE" Equipment and/or property damage may result if these instructions are
not followed.
_WARNING: To ensure safety and reliability, all repairs should be performed
by a qualified service technician.
_, WARNING: The operation of any power tools can result in
foreign objects being thrown into your eyes, which can result
in severe eye damage. Before beginning power tool operation,
always wear safety goggles or safety glasses with side shield
and a full face shield when needed. We recommend a Wide
Vision Safety Mask for use over eyeglasses or standard safety
glasses with side shields. Always use eye protection which is
marked to comply with ANSI Z87.1.

SAVE THESE iNSTRUCTiONS
Some of these following symbols may be used on this tool. Please study them
and learn their meaning. Proper interpretation of these symbols will allow you to
operate the tool better and more safely.
SYMBOL NAME DESIGNATION/EXPLANATION
V Volts Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
min Minutes Time
Alternating Current Type of current
Direct Current Type or a characteristic of current
n O No-load Speed Rotational speed, at no load
[] Class II Construction Double=insulated construction
.../min Per Minute Revolutions, strokes, surface speed,
orbits, etc., per minute
Wet Conditions Alert Do not expose to rain or use in damp
locations.
To reduce the risk of injury, user must
Read The Operator's Manual read and understand operator's manual
before using this product.
O Always wear safety goggles or safety
Eye Protection glasses with side shields and a fulI face
shield when operating this product.
Alert Precautions that involve
Safety your safety.
No=Hands Symbol Failure to keep your hands away from theblade will result in serious personal injury.
No=Hands Failure to keep your hands away from the
Symbol blade will result in serious personal injury.
No=Hands Failure to keep your hands away from the
Symbol blade will result in serious personal injury.
No=Hands Symbol Failure to keep your hands away from the
blade will result in serious personal injury.
Hot Surface To reduce the risk of injury or damage,
avoid contact with any hot surface.
5

GENERAL POWER TOOL SAFETY WARNINGS
WARNING: Read all safety warnings and instructions. Failure to follow the
warnings and instructions may result in electric shock, fire and /or serious injury.
Save all warnings and instructions for future reference.
The term "power tool" in the warnings refers to your mains-operated (corded)
power tool or battery-operated (cordless) power tool.
WORK AREA SAFETY
= Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• 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.
= Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
ELECTRICAL SAFETY
•Power tool plugs must match the outlet. Never modify the plug in any
way. Do not use any adaptor plugs with earthed (grounded) power tools.
Unmodified plugs and matching outlets will reduce risk of electric shock.
• Avoid body contact with earthed or grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. Water entering a
power tool will increase the risk of electric shock.
• Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords increase the risk of electric shock.
• When operating a power tool outdoors, use an extension cord suitable
for outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
if operating a power tool in a damp location is unavoidable, use a
ground fault circuit interrupter (GFCl} protected supply. Use of a GFCI
reduces the risk of electric shock.

PERSONAL SAFETY
= Stay alert, watch what you are doing and use common sense when
operating a power tool. Do not use 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.
• Use personal protective equipment. Always wear eye protection. Protective
equipment such as dust mask, non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will reduce personal injuries.
•Prevent unintentional starting. Ensure the switch is in the off-position
before connecting to power source and/or battery pack, picking up or
carrying the tool. Carrying power tools with your finger on the switch or
energizing in power tools that have the switch on invites accidents.
• Remove any adjusting key or wrench before turning the power tool
on. A wrench or a key left attached to a rotating part of the power tool may
result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
= Dress properly. Do not wear loose clothing or jewelry. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelry or
long hair can be caught in moving parts.
=if devices are provided for the connection of dust extraction and
collection facilities, ensure these are connected and properly used. Use
of these devices can reduce dust-related hazards.
POWER TOOL USE AND CARE
• Do not force the power tool. Use the correct power tool for your
application. The correct power tool will do the job better and more safely at
the rate for which it was designed.
Do not use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and must
be repaired.
Disconnect the plug from the power source and/or the battery pack
from the power tool before making any adjustments, changing
accessories, or storing power tools. Such preventive safety measures
reduce the risk of starting the power tool accidentally.
Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate
the power tool. Power tools are dangerous in the hands of untrained users.
Maintain power tools. Check for misalignment or binding of moving
parts, breakage of parts and any other condition that may affect the
power tool's operation, if damaged, have the power tool repaired before
use. Many accidents are caused by poorly maintained power tools.

Keepcuttingtoolssharpandclean.Properlymaintainedcuttingtoolswith
sharpcuttingedgesarelesslikelytobindandareeasiertocontrol.
Usethepower tool, accessories and tool bits etc., in accordance with
these instructions, taking into account the working conditions and the
work to be performed. Use of the power tool for operations different
from those intended could result in a hazardous situation.
SERVICE
Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power
tool is maintained.
Follow instructions in the Maintenance section of this manual. Use of
unauthorized parts or failure to follow Maintenance instructions may create
a risk of shock or injury.
SPECIFIC SAFETY RULES FOR RANDOM ORBIT SANDER
Hold power tools by insulated gripping surfaces, because the
sandpaper may contact its own cord. Cutting a "live" wire may make
exposed metal parts of the power tool "live" and could give the operator an
electric shock.
* A suitable breathing respirator must be worn while sanding lead paint,
some woods and metal to avoid breathing the harmful/toxic dust or air.
*Always wear safety goggles and a dust mask when sanding, especially
sanding over-head.
*The machine is not suitable for wet sanding.
*Secure the workpiece. A workpiece clamped with clamping devices or in a
vice is held more secure than by hand.
*Do not leave the tool running. Operate the tool only when hand-held.

KNOW YOUR RANDOM ORBIT SANDER (Fig. 1)
Fig. 1 Live-Tool Indicator
On/Off Rocker
Switch
LED Worklight
Sandpapers
Speed Dial
Vent
Dust-Exhaust Port
Pressure-Control Indicator
Vent
Sanding Pad
Dust Box with Filter
PRODUCT SPECIFICATIONS
Input 120V, 60Hz, AC only, 3.0 Amps
No-load Speed 5,000-13,000 OPM
Sanding Pad 5 in. Hook-and-Loop fastening system
Motion Random orbital
Protection Class II
,_ WARNING: The safe use of this product requires an understanding of the
information on the tool and in this operator's manual as well as knowledge of the
project you are attempting. Before using this product, familiarize yourself with all
operating features and safety rules.

RANDOM ORBIT
The random orbit motion provides overlapping sanding movements by
combining orbital and spinning motion.
VARIABLE=SPEED DIAL
The variable-speed dial is located on the motor housing of your tool for selecting
the appropriate speed.
PRESSURE CONTROL
Your tool is equipped with pressure-control indicator lights. The indicator lights will
letyou know ifyou are applying the proper amount of pressureduring operation.
DUST BOX WITH FILTER
Use the box for removing dust from the sanding space to help keep the working
area clean.
DUST=EXHAUST PORT
Allows you to connect the dust box or a 1-1/4 in. diameter vacuum hose to help
keep the work area clean.
ON/OFF ROCKER SWITCH
The on/off rocker switch is conveniently located for easy control and is sealed to
keep out dust for long life.
HOOK=AND=LOOP SANDING PAD
The hook-and-loop sanding pad is for easy attachment of hook-and-loop type
sandpapers with pre-punched holes.
LED WORKLIGHT
The LEDworklight, located in the front of the tool, illuminates when the rocker
switch is in the ON position. This feature provides extra light for increased visibility.
LIVE-TOOL INDICATOR
The LED indicator shines green when the tool is plugged into a power source.
PAD BRAKE
The integrated pad brake will quickly stop the spinning pad when the sander is
turned off.
10

,_ WARNING: If any parts are broken or missing, do not attempt to connect the
sander to a power source or operate the sander until the broken or missing parts
are replaced. Failure to do so could result in possible serious injury.
_, WARNING: Do not attempt to modify this sander or create accessories not
recommended for use with this sander. Any such alteration or modification is misuse
and could result in a hazardous condition leading to possible serious injury.
,_, WARNING: To prevent accidental starting that could cause serious personal
injury, always disconnect the sander from the power source when assembling
parts, making adjustments, installing or removing sandpaper, cleaning, or when
it is not in use.
UNPACKING
* Carefully remove the tool and any accessories from the carton. Make sure
that all items listed in the packing list are included.
* Inspect the tool carefully to make sure no breakage or damage occurred
during shipping.
* Do not discard the packing material until you have carefully inspected and
satisfactorily operated the tool.
* If any parts are damaged or missing, please return the tool to the place
of purchase.
PACKING LiST
Random orbit sander, sandpapers (grit 60,120,220), dust box, bag and
operator's manual.
11

,& WARNING: To prevent accidental starting that could cause serious personal
injury, always disconnect the sander from the power source when assembling
parts, making adjustments, installing or removing sandpaper, cleaning, or when
it is not in use.
TURNING THE SANDER ON/
OFF (Fig. 2}
To turn on the sander, connect
the plug to an electrical outlet,
and then depress the side of the
rocker switch marked "1".
To turn it off, depress the side of
the rocker switch marked "O". The
integrated pad brake will quickly
stop the spinning pad when the
sander is turned off.
LED WORKLIGNT (Fig. 3}
The LED worklight, located in the
front of the tool, will turn on when
the rocker switch is in the ON (I)
position. The LED worklight will
turn off when the switch is in the
OFF (O) position. This provides
additional lighting on the surface
of the workpiece for operation in
lower-light areas.
Fig. 2
On/Off
rocker
switch
Fig. 3
LED
worklight
12

VARIABLE=SPEED
DiAL (Fig. 4}
The variable-speed dial allows
you to match the correct speed
to the sandpaper you are using
and the particular surfaces you
are sanding for either fast material
removal or a fine, smooth finish.
Rotate the dial from 1to 6, with 1
being the lowest speed and 6 the
highest speed.
Fig. 4 Live-tool
indicator
Variable-
speed dial
THE LIVE=TOOL INDICATOR (Fig. 4}
When the tool is plugged into an electrical supply, the live-tool indicator
will shine green to remind you that the tool is plugged in. When the tool is
unplugged, the live-tool indicator will turn off.
PRESSURE CONTROL (Fig. 5)
The pressure-control indicator F
lights to let you know if you are
applying the proper amount of
pressure during operation.
If only the green indicator light Pressure
illuminates, it indicates that you control
are applying the correct amount
of pressure, indicator
If the yellow and the green lights
both illuminate, they indicate that
you are applying a little more
pressure than needed.
Ifthe red, yellow and green indicator lights all illuminate, this indicates that you are
applying too much pressure and you need to lessen the pressure as soon as possible.
,_ CAUTION: To prevent possible personal injury or tool or workpiece damage,
always be sure that the pressure control illuminates only green during tool operation.
13

ATTACHING THE
SANDPAPER (Fig. 6)
WARNING: Always inspect the
sandpaper before attaching. Do
not use if broken, torn or defective.
1. Disconnect the sander from
the power source.
2. Place the random orbit sander
upside down on a flat surface.
3. Remove any dust or debris
from the sanding pad.
4. Align the holes of the
sandpaper with the holes in
the sanding pad and firmly
press the sandpaper against
the sanding pad to ensure a
good attachment.
Fig. 6
Fig. 7
Sandpaper
Sanding pad
DUST BOX (Fig. 7)
,_ WARNING: Do not use the
dust box when sanding metal.
Using the dust box when sanding
metal creates a fire hazard, which
could damage the tool and lead to
serious personal injury.
Your random orbit sander is
supplied with a dust box to help
you keep the working area clean. The dust box is ideal for smaller jobs.
To install:
1. Disconnect the sander from the power source.
2. Align the rib on the dust-exhaust port with the groove on the dust-collecting
box outlet.
3. Slide the dust box onto the port as far as possible (Fig. 7).
NOTICE: From time to time, clean the vacuum adaptor with a dry brush.
To remove:
1. Disconnect the sander from the power source.
2. Grip the dust-collecting box firmly, and pull it out from the tool (Fig. 7).
14

NOTICE: For longer periods of use, or on large pieces of work, it is advisable to
use a suitable vacuum cleaner. Attach a 1-1/4 in. wet/dry-vacuum hose to the
dust-exhaust port. it is advisable to wear a suitable dust mask, as there may be
residual airborne dust particles in the area.
,_ WARNING: The dust that is produced while sanding can be detrimental
to health, flammable, or explosive. Suitable safety measures are required.
Examples: Some types of dust are known to cause cancer. Always wear a dust
mask, and use the proper dust collection method: dust box for small volume and
vacuum connection for large volume dust collection.
SELECTING THE RIGHT GRADE OF SANDPAPER
Different grades of sandpaper can be purchased from the store where you
purchased the tool. Available grades are: Coarse, Medium and Fine.
Use a coarse grit to sand rough finishes, medium grit to smooth the work and
fine grit for finish sanding.
It is best to make a trial run on a scrap piece of material to determine the
optimum grade of sandpaper for a particular job.
SANDING
This sander can be used for most sanding operations on materials such as wood,
plastic, metal and painted surfaces. Do not use the sander for wet sanding.
,_, WARNING: Do not touch the vents after prolonged use; the gear box could
be very hot.
_, WARNING: Wear safety goggles, dust mask, and hearing protection.
_1_ CAUTION: Clamp the workpiece to prevent it from moving during operating.
An unsecured workpiece could be thrown towards the operator, causing injury.
1. Plug the sander to the power source.
WARNING: Before connecting the sander to power source, always check to
be sure that the switch is in the OFF (O) position. Failure to do so could result in
accidental starting of the sander, causing possible serious injury.
2. Place the sander on the workpiece so that the sandpaper is fully in contact
with the workpiece.
3. Start the sander.
,_ WARNING: Keep your head away from the sander and the sanding area.
Your hair could be drawn into the sander causing serious injury.
4. For best sanding results, apply light pressure on the sander, but do not
force the tool. Check to make sure that the red pressure control indicator
light never illuminates.
15

NOTICE: Applying additional pressure only slows the motor, rapidly wears
sandpaper, and greatly reduces sander speed. Excessive pressure will overload
the motor, possibly causing damage from the motor overheating and can result
in inferior work.
5. Move the sander slowly over the workpiece, making successive passes in parallel
lines, circles, or crosswise movements. The removal rate and the sanding pattern
are determined by the choice of sandpaper and the work surface.
6. Do not allow sanding on one spot too long, as the sander's rapid action may
remove too much material and make the surface uneven.
7.
8.
Upon completion of the sanding operation, remove the sander from the
workpiece, turn the sander off and wait until it comes to a complete stop
before putting it down.
Extended periods of sanding may tend to overheat the motor. If this occurs,
remove the sander from the workpiece and turn it off. Wait until the sander
comes to a complete stop before putting the sander down. Remove the
sandpaper and, without obstructing the vent area with your hand, turn the
sander on and run it free without a load to cool the motor.
AWARNING: Before cleaning or performing any maintenance, make sure that
the random orbit sander has been disconnected from the power source.
,_ WARNING: Always wear safety goggles or safety glasses with side shields
when using compressed air to clean the tool. Ifthe operation is dusty, also wear a
dust mask.
CLEANING THE DUST
BOX (Fig. 8)
For most efficient operation,
empty the dust box when it is no
more than half full. This will permit
the air to flow through the box
better. Always empty and clean
the dust box thoroughly when you
have finished sanding and before
you store the sander.
To empty the dust box
Fig. 8
Upper cover Filter
_st box
1. Disconnect the sander from the power source.
2. Remove the dust box from the sander and shake out the dust.
3. For a more thorough cleaning of the dust box, open the upper cover and
remove it from the dust box.
16

4. Gently shake or tap the dust box and the cover to empty.
5. Use a soft brush to clean the filter.
NOTICE: The filter cannot be rinsed with water.
6. Reattach the upper cover to the box, and firmly reinstall the box on the sander.
WARNING: Collected sanding dust from sanding surface coatings such as
polyurethanes, linseed oil, etc. can self-ignite in the sander dust box or elsewhere
and cause fire. To reduce the risk of fire, always empty the dust box frequently
while sanding and never store or leave a sander without totally emptying its dust
box. Also follow the recommendations of the coating manufacturers.
GENERAL MAINTENANCE
Avoid using solvents when cleaning plastic parts. Most plastics are susceptible
to damage from various types of commercial solvents and may be damaged
by their use. Use clean clothes to remove dirt, dust, oil, grease, etc. Keep all
ventilation openings clean.
WARNING: Do not at any time let brake fluids, gasoline, petroleum-based
products, penetrating oils, etc. come in contact with plastic parts. Chemicals can
damage, weaken or destroy plastic which may result in serious personal injury.
WARNING: When servicing, use only identical replacement parts. Use of any
other parts may create a hazard or cause product damage. To ensure safety and
reliability, all repairs should be performed by a qualified service technician.
PROBLEM
The sander does not
work
Unsatisfactory
sanding result
CAUSE
Not connected to power
source
Sandpaper is worn
Sandpaper is not suitable
for the workpiece
SOLUTION
Plug the sander into a
power source
Install new sandpaper
Use correct sandpaper
17

C
o
E
0_
_=<
o o
o
E_
c_
4_
co
_o__g
_2z x
@,,

3.0 Amp RANDOM ORBIT SANDER MODEL NUMBER 320.39592
The Model Number will be found on the nameplate of the tool Always mention
the Model Number when ordering parts for this tool
To order parts, call 1=888=331 =4569.
1 3127400000 LED Cover 1
2 3321108000 Upper Housing 1
3 2740353000 Stator 1
201 2823858000 Motor Assembly 1
4 5700005000 Ball Bearing 1
5 5650050000 Plain Washer 1
6 3124643000 Insulated Pad 1
7 2751012000 Rotor 1
8 5650043000 Plain Washer 2
9 5700010000 Ball Bearing 1
10 3420858000 Dust Fan 1
11 3420066000 Bearing Support 1
12 5650041000 Plain Washer 1
13 5700018000 Ball Bearing 1
14 3700090000 Washer 1
15 5620069000 Screw 1
16 3121122000 Bearing Cover 1
17 3127394000 Fan Baffle 1
18 5690214000 Brake Ring 1
19 3400153000 Base Pad 1
20 5620419000 Screw With Washer 4
21 3810300000 Sanding Paper 1
22 3127321000 Switch Cover 1
23 3700577000 Fixing Board 1
24 4870051000 Switch 1
25 3321106000 Left Housing 1
26 3127402000 LED Cover 1
19

3127401000 LED Cover
28 2830025000 Electric Assembly 1
29 5610024000 Tapping Screw 2
30 4960285000 Carbon Brush 2
31 5610011000 Tapping Screw 4
32 4930384000 Receptacle 2
33 3120234000 Cord Anchorage 1
34 3121124000 Cord Guard 1
35 4970034000 Capacitor 1
36 4930004000 Connecter 1
37 4930061000 Shark Teeth Terminal 2
38 2800186000 Brush Holder 2
39 5690013000 O Ring 1
40 4810002000 Power Cord & Plug 1
41 2490136000 Nylon String 1
41 2490136000 Nylon String 1
42 5610013000 Tapping Screw 2
43 5610248000 Tapping Screw 8
44 3321095000 Right Housing 1
45 5660187000 C Ring 1
46 5690268000 O Ring 1
202 2823731000 Dust Box Assembly 1
47 3127366000 Dust Box Cover 1
48 3705602000 Dust Filter Paper 1
49 3127367000 Dust Box 1
2O