ElEctric bElt sandEr
4”x24”
Model 97593
sEt up and OpErating instructiOns
read this material before using this product.
Failure to do so can result in serious injury.
saVE this Manual.
©
®
Copyright 2008 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 improve-
ments, 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.
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Unmodified plugs and matching out-
lets will reduce risk of electric shock.
non-skid safety shoes, hard hat, or
hearing protection used for appropri-
ate conditions will reduce personal
injuries.
b.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.
c.prevent unintentional starting.
Ensure the switch is in the off‑po‑
sition before connecting to power
source and/or battery pack, pick‑
ing up or carrying the tool. Carry-
ing power tools with your finger on
the switch or energizing power tools
that have the switch on invites acci-
dents.
c.do not expose power tools to rain
or wet conditions. Water entering
a power tool will increase the risk of
electric shock.
d.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.
d.remove any adjusting key or
wrench before turning the power
tool on. A wrench or a key left at-
tached to a rotating part of the power
tool may result in personal injury.
e.do not overreach. Keep proper
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
e.When operating a power tool out‑
doors, use an extension cord suit‑
able for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock.
f. 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.
f. if operating a power tool in a damp
location is unavoidable, use a
ground Fault circuit interrupter
(gFci) protected supply. Use of
a GFCI reduces the risk of electric
shock.
g.if devices are provided for the con‑
nection of dust extraction and col‑
lection facilities, ensure these are
connected and properly used. Use
of these devices can reduce dust-
related hazards.
3. personal safety
a.stay alert, watch what you are do‑
ing 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.
h.Only use safety equipment that
has been approved by an appropri‑
ate standards agency. Unapproved
safety equipment may not provide
adequate protection. Eye protection
must be ANSI-approved and breath-
ing protection must be NIOSH-ap-
proved for the specific hazards in the
work area.
b.use personal protective equip‑
ment. always wear eye protection.
Safety equipment such as dust mask,
SKU 97593
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4. power tool use and care
account the working conditions
and the work to be performed. Use
of the power tool for operations differ-
ent from those intended could result
in a hazardous situation.
a.do not force the power tool. use
the correct power tool for your ap‑
plication. The correct power tool will
do the job better and safer at the rate
for which it was designed.
5. service
b.do not use the power tool if the
switch does not turn it on and off.
Any power tool that cannot be con-
trolled with the switch is dangerous
and must be repaired.
a.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.
c.disconnect the plug from the
power source and/or the battery
pack from the power tool before
making any adjustments, chang‑
ing accessories, or storing power
tools. Such preventive safety mea-
sures reduce the risk of starting the
power tool accidentally.
belt sander safety Warnings
1. hold power tools by insulated grip‑
ping 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.
d.store idle power tools out of the
reach of children and do not allow
persons unfamiliar with the power
tool or these instructions to oper‑
ate the power tool. Power tools are
dangerous in the hands of untrained
users.
2. Maintain labels and nameplates on
the tool. These carry important safety
information. If unreadable or miss-
ing, contact Harbor Freight Tools for a
replacement.
e.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 dam‑
aged, have the power tool repaired
before use. Many accidents are
caused by poorly maintained power
tools.
3. Avoid unintentional starting. Prepare
to begin work before turning on the
tool.
4. Do not lay the tool down until it has
come to a complete stop. Moving
parts can grab the surface and pull
the tool out of your control.
5. When using a handheld power tool,
maintain a firm grip on the tool with
both hands to resist starting torque.
f. Keep cutting tools sharp and
clean. Properly maintained cutting
tools with sharp cutting edges are
less likely to bind and are easier to
control.
6. Do not leave the tool unattended
when it is plugged into an electrical
outlet. Turn off the tool, and unplug it
from its electrical outlet before leav-
ing.
g.use the power tool, accessories
and tool bits etc. in accordance
with these instructions, taking into
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7. This product is not a toy. Keep it out
of reach of children.
a chemical known to the State of
California to cause cancer, and birth
defects or other reproductive harm.
Wash hands after handling. (Califor-
nia Health & Safety Code § 25249.5,
et seq.)
8. People with pacemakers should
consult their physician(s) before use.
Electromagnetic fields in close prox-
imity to heart pacemaker could cause
pacemaker interference or pacemak- 11. The warnings, precautions, and in-
er failure. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with power switch locked
on.
• Properly maintain and inspect to
avoid electrical shock.
• Any power cord must be properly
grounded. Ground Fault Circuit Inter-
rupter (GFCI) should also be imple-
mented – it prevents sustained elec-
trical shock.
structions discussed in this instruction
manual cannot cover all possible con-
ditions 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.
Vibration safety
This tool vibrates during use. Re-
peated or long-term exposure to
vibration may cause temporary or
permanent physical injury, particularly
to the hands, arms and shoulders. To
reduce the risk of vibration-related
injury:
9. Some dust created by power sand-
ing, sawing, grinding, drilling, and
other construction activities, contains
chemicals known [to the State of Cali-
fornia] to cause cancer, birth defects
or other reproductive harm. Some
examples of these chemicals are:
• Lead from lead-based paints
1. Anyone using vibrating tools regu-
larly or for an extended period should
first be examined by a doctor and
then have regular medical check-
ups to ensure medical problems are
not being caused or worsened from
use. Pregnant women or people
who have impaired blood circulation
to the hand, past hand injuries, ner-
vous system disorders, diabetes, or
Raynaud’s Disease should not use
this tool. If you feel any medical or
physical symptoms related to vibra-
tion (such as tingling, numbness, and
white or blue fingers), seek medical
advice as soon as possible.
• Crystalline silica from bricks and ce-
ment or other masonry products
• Arsenic and chromium from chemi-
cally treated lumber
Your risk from these exposures var-
ies, 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.)
2. Do not smoke during use. Nico-
tine reduces the blood supply to the
10. WARNING: Handling the cord on
this product will expose you to lead,
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hands and fingers, increasing the risk
of vibration-related injury.
grOunding
tO prEVEnt
ElEctric shOcK
and dEath FrOM
3. Wear suitable gloves to reduce the
vibration effects on the user.
incOrrEct grOunding
WirE cOnnEctiOn:
Check with a qualified
4. Use tools with the lowest vibration
when there is a choice between dif-
ferent processes.
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.
5. Include vibration-free periods each
day of work.
6. Grip tool as lightly as possible (while
still keeping safe control of it). Let
the tool do the work.
7. To reduce vibration, maintain the tool
as explained in this manual. If any
abnormal vibration occurs, stop use
immediately.
saVE thEsE
instructiOns.
grounded tools: tools with three
prong plugs
1. Tools marked with “Grounding Re-
quired” 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
SKU 97593
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of electric shock. (see 3‑prong plug 2. Double insulated tools may be used
and Outlet.)
in either of the 120 volt outlets shown
in the preceding illustration. (see
Outlets for 2‑prong plug.)
2. The grounding prong in the plug is
connected through the green wire in-
side 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 3‑prong plug
and Outlet.)
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 exten-
sion cords with inadequately sized
wire causes a serious drop in voltage,
resulting in loss of power and pos-
sible tool damage.
3. The 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
preceding illustration. (see 3‑prong
plug and Outlet.)
(see table a.)
3. The smaller the gauge number of the
wire, the greater the capacity of the
cord. For example, a 14 gauge cord
can carry a higher current than a 16
gauge cord. (see table a.)
double insulated tools: tools
with two prong plugs
4. When using more than one exten-
sion cord to make up the total length,
make sure each cord contains at
least the minimum wire size required.
(see table a.)
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 table a.)
1. Tools marked “Double Insulated” do
not require grounding. They have
a special double insulation system
which satisfies OSHA requirements
and complies with the applicable
standards of Underwriters Labora-
tories, Inc., the Canadian Standard
Association, and the National Electri-
cal Code. (see Outlets for 2‑prong
plug.)
6. 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.
7. Make sure the extension cord is prop-
erly wired and in good electrical con-
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dition. Always replace a damaged
extension cord or have it repaired by
a qualified electrician before using it.
8. Protect the extension cords from
sharp objects, excessive heat, and
damp or wet areas.
rEcOMMEndEd MiniMuM WirE
gaugE FOr EXtEnsiOn cOrds*
(120/240 VOlt)
EXtEnsiOn cOrd
naMEplatE
lEngth
aMpErEs
(at full load)
0 – 2.0
2.1 – 3.4
18
18
18
18
18
14
12
18
18
18
16
14
12
10
18
18
16
14
12
10
-
18
16
14
12
10
-
16
14
12
12
-
3.5 – 5.0
5.1 – 7.0
7.1 – 12.0
12.1 – 16.0
16.1 – 20.0
-
-
-
* based on limiting the line
voltage drop to five volts at
150% of the rated amperes.
tablE a
symbology
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
Volts Alternating Current
Amperes
V~
a
No Load Revolutions per Minute
(RPM)
n xxxx/min.
0
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spEciFicatiOns
OpErating instructiOns
read the EntirE iMpOrtant
saFEtY inFOrMatiOn
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
Electrical Requirements
120V~ / 60Hz / 10A
Motor No Load Speed
Belt Speed
2,750 RPM
1,640 FPM
4” W x 24” L
Belt Size
unpacKing
tool set up
When unpacking, check to make sure
that the item is intact and undamaged. 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.
tO prEVEnt
sEriOus injurY
FrOM accidEntal
OpEratiOn:
turn the power switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
instructiOns FOr
putting intO usE
read the EntirE iMpOrtant
saFEtY inFOrMatiOn
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
Work piece and Work area set up
1. Designate a work area that is clean
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
tO prEVEnt
sEriOus injurY
2. Route the power cord along a safe
route to reach the work area without
creating a tripping hazard or exposing
the power cord to possible damage.
The power cord must reach the work
area with enough extra length to al-
low free movement while working.
FrOM accidEntal
OpEratiOn:
turn the power switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
assembling or making any
adjustments to the tool.
3. Secure loose work pieces using a
vise or clamps (not included) to pre-
vent movement while working.
note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
4. There must not be hazardous ob-
jects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
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belt release
lever
general Operating instructions
1. Secure the Dust Bag (83) to the Dust
Tube (27).
2. Make sure the Belt Sander’s Trig-
ger (3) is not engaged and plug the
Sander into a standard, grounded
120V electrical outlet.
dust tube (27) ‑ dust
bag (83) connects
here
trigger
lock
5. When sanding, use both hands to
hold the tool and sand along the grain
for best results.
6. The Trigger Lock can be pushed to
lock the Belt Sander on.
7. Hold the tool lightly on the workpiece
and allow the tool to do the work. Do
not push down on the Belt Sander or
move it along the surface too fast.
8. To turn the tool off with Trigger Lock
engaged; squeeze the Trigger once
and then release.
adjusting Knob
(56)
trigger (3)
9. To prevent accidents, turn off the tool
and disconnect its power supply after
use. Remove and empty the Dust
Bag. Clean, then store the tool in-
doors out of children’s reach.
3. Before beginning a job, make sure
that the Belt is on-center. If the Belt
is not centered on the Sander turn
the Adjusting Knob (56) until it is on-
center.
4. When a sanding belt tears or be-
comes worn, it will have to be re-
placed. Always turn the tool off and
unplug it before changing the Belt.
Pull out the Belt Release Lever. Re-
move the old Belt and replace with a
new 4”x24” belt. Make sure the ar-
rows on the inside of the new sanding
belt are consistent with the rotation
arrow on the rear wheel (39). Push
the Belt Release Lever back in to se-
cure the Belt in place, and make sure
it’s on-center before starting a job.
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mance of the tool decreases or stops
working completely. To maintain the
brushes:
MaintEnancE and
sErVicing
Procedures not specifically
explained in this manual
must be performed only by a
qualified technician.
a. Remove the brush cap (14) on each
side of the motor housing.
b. Remove the carbon brushes (12)
from the housing. Keep track of
which orientation the old carbon
brushes were in to prevent need‑
less wear if they will be rein‑
stalled.
tO prEVEnt
sEriOus injurY
FrOM accidEntal
OpEratiOn:
turn the power switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
c. If either carbon brush is worn down
by more than 1/2, replace both car-
bon brushes.
d. To clean old carbon brushes before
reusing them, rub the contact areas
with a pencil eraser.
e. Reinsert the old carbon brushes in
the same orientation to reduce wear.
tO prEVEnt sEriOus
injurY FrOM tOOl
FailurE:
do not use damaged
equipment. if abnormal noise
or vibration occurs, have the
problem corrected before
further use.
f. When installing the carbon brushes,
make sure the carbon portions of the
carbon brushes contact the motor
armature, and that the springs face
away from the motor. Also, make
sure the springs operate freely.
g. Replace the brush caps. Do not
overtighten.
cleaning, Maintenance, and
lubrication
note: New carbon brushes tend to spark
when first used until they wear and
conform to the motor’s armature.
1. bEFOrE Each usE, inspect the
general condition of the tool. Check
for loose screws, misalignment or
binding of moving parts, cracked or
broken parts, damaged electrical wir-
ing, and any other condition that may
affect its safe operation.
4.
Warning! if the supply cord of
this power tool is damaged, it must
be replaced only by a qualified
service technician.
2. aFtEr usE, clean external surfaces
of the tool with clean cloth.
3. carbOn brush MaintEnancE.
The carbon brushes may require
maintenance when the motor perfor-
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troubleshooting
problem
Tool will not start
possible causes
1. No power at outlet.
likely solutions
1. Check power at outlet.
2. Cord not connected.
2. Check that cord is plugged in.
3. Replace Carbon Brushes.
3. Carbon Brushes are worn.
Poor sanding
quality
1. Sanding belt worn or clogged. 1. Replace sanding belt.
2. Sanding against wood grain.
2. Sand along the wood grain.
3. Sanding belt not held flat
3. Keep surface of sanding belt flat on wood.
against the wood grain.
Follow all safety precautions whenever diagnosing or servicing the
tool. disconnect power supply before service.
plEasE rEad thE FOllOWing carEFullY
THE MANUfACTURER AND/OR DISTRIBUTOR HAS PROvIDED THE PARTS LIST AND ASSEMBLy
DIAgRAM IN THIS MANUAL AS A REfERENCE TOOL ONLy. NEITHER 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 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.
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parts list
part
description
Qty.
4
1
1
1
1
2
1
1
1
1
1
2
2
2
1
2
1
1
1
1
1
1
2
1
2
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
part
description
Qty.
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
4
1
1
1
4
1
2
1
2
2
1
1
2
3
4
5
6
7
8
9
Screw 2.4x16
43 Needle Bearing
Hand Stem Cover
Trigger
44 Rear Wheel Axis
45 Gear
46 Gear Box Cover
47 Screw M4x12
48 Belt Wheel
49 Nut M8
Cable
Cable Cover
Screw 4.2x16
Cable Pressure Board
Housing
50 Belt
51 Bearing
Small Belt Wheel
10 Belt Cover
52 Shaft Gear
53 Needle Bearing
54 Label
55 Screw M5x8
56 Adjusting Knob
57 Washer
58 Upper Handle Cover
59 Lower Handle Cover
60 Screw 4.2x16
61 Screw 4.2x55
62 Adjusting Spring
63 Screw M4x10
64 Bottom Plate
65 Cushion
11 Screw M4x12
12 Carbon Brush
13 Carbon Brush Holder
14 Brush Holder Cap
15 Stator
16 Screw 4.8x45
17 Bearing
18 Washer
19 Guide
20 Rotor
21 Bearing
22 Middle Cover
23 Screw 4.2x18
24 Dust Fan
25 Screw M5x12
26 Dust Cover
27 Dust Tube
28 Gasket
29 Cover
30 Screw 4.2x45
31 Label
32 Sanding Belt
33 Screw M4x12
34 Front Cover
35 Front Wheel Drive Axis
36 Pressure Spring
37 Front Wheel Frame
38 Nut M12
39 Rear Wheel
40 Bearing
41 Base
66 Pin
67 Screw 4.2x16
68 Baffle
69 Washer
70 Front Wheel
71 Needle Bearing
72 Washer
73 Half Circle Key
74 Washer
75 Washer
76 Washer
77 Washer
78 Screw
79 Screw
80 Pull Spring
81 Washer
82 Washer
83 Dust Bag
11
11
2
2
1
1
1
1
1
1
42 Screw 4.2x16
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 avail-
able individually as replacement parts.
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assEMblY diagraM (cOntinuEd On nEXt pagE)
SKU 97593
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assEMblY diagraM
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liMitEd 1 YEar 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 this product
is free from defects in materials and workmanship for the period of one year from the
date of purchase (90 days if used by a professional contractor or if used as rental equip-
ment). 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 ap-
ply 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 com-
plaint must accompany the merchandise. If our inspection verifies the defect, we will ei-
ther 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 re-
paired 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
SKU 97593
For technical questions, please call 1‑800‑444‑3353.
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