Craftsman 3 Inch Dustless Belt Sander

Warranty Information

Full One Year Warranty on Craftsman Belt Sander: If this Craftsman Belt Sander fails to give complete satisfaction within one year from the date of purchase, return it to the nearest Sears store in the United States for free repair. For commercial or rental purposes, the warranty is 90 days. This warranty grants specific legal rights, and other rights may vary by state. Contact: Sears, Roebuck and Co., DEPT. 817 WA, Hoffman Estates, IL 60179.

Introduction

Double Insulation: This safety feature in electric power tools eliminates the need for a three-wire grounded power cord and system. It provides two complete sets of insulation to protect the user. All exposed metal parts are isolated from internal motor components with protective insulation.

Important Note on Servicing: Servicing tools with double insulation requires extreme care and knowledge. It should only be performed by a qualified service technician. For service, return the tool to your nearest Sears Store. Always use original factory replacement parts.

General Use: The Craftsman Belt Sander is suitable for coarse, medium, and fine sanding of wood, metals, plastics, and other materials. It is ideal for smoothing rough boards, chamfering, rounding edges, and general sanding applications. It is also effective for removing paint, varnishes, and stains. Its balanced design ensures ease of use.

Rules for Safe Operation

General Safety Precautions:

• 1. Know Your Power Tool: Read the owner's manual carefully to understand applications, limitations, and potential hazards.
• 2. Guard Against Electrical Shock: Prevent body contact with grounded surfaces like pipes, radiators, or refrigerator enclosures.
• 3. Keep Guards in Place: Ensure all guards are in place and in working order.
• 4. Keep Work Area Clean: Cluttered areas invite accidents.
• 5. Avoid Dangerous Environment: Do not use the power tool in damp or wet locations or expose it to rain. Keep the work area well lit.
• 6. Keep Children and Visitors Away: Ensure visitors wear safety glasses and stay a safe distance from the work area. Do not let them contact the tool or extension cord.
• 7. Store Idle Tools: Store tools in a dry, high, or locked-up place out of reach of children when not in use.
• 8. Don't Force Tool: Use the tool at its designed rate for better and safer performance.
• 9. Use Right Tool: Do not force a small tool or attachment to do the job of a heavy-duty tool, nor use it for unintended purposes (e.g., using a circular saw for cutting tree limbs).
• 10. Wear Proper Apparel: Avoid loose clothing or jewelry that could get caught in moving parts. Rubber gloves and non-skid footwear are recommended for outdoor work. Wear protective hair covering to contain long hair.
• 11. Always Wear Safety Glasses: Everyday eyeglasses are not sufficient; use impact-resistant safety glasses.
• 12. Protect Your Lungs: Wear a face or dust mask if the operation is dusty.
• 13. Protect Your Hearing: Wear hearing protection during extended periods of operation.
• 14. Don't Abuse Cord: Never carry the tool by its cord or yank it to disconnect. Keep cords away from heat, oil, and sharp edges.
• 15. Secure Work: Use clamps or a vise to hold work. Both hands are needed to operate the tool.
• 16. Don't Overreach: Maintain proper footing and balance. Do not use on a ladder or unstable support.
• 17. Maintain Tools with Care: Keep tools sharp and clean for best performance. Follow instructions for lubricating and changing accessories.
• 18. Disconnect Tools: Disconnect tools from power supply before servicing or changing parts.
• 19. Remove Adjusting Keys and Wrenches: Always check that these are removed before turning the tool on.
• 20. Avoid Accidental Starting: Do not carry plugged-in tools with a finger on the switch. Ensure the switch is off when plugging in.
• 21. Ensure Extension Cord is in Good Condition: Use a heavy enough cord to carry the product's current. An undersized cord causes voltage drop and overheating. A 14 AWG cord is recommended for 100 feet or less. Use a heavier gauge if in doubt.
• 22. Outdoor Use Extension Cords: Use only extension cords suitable for outdoor use (marked W-A, e.g., SJTW-A or SJOW-A).
• 23. Never Use for Wet Sanding: Failure to comply can result in electrical shock and serious injury.
• 24. Keep Hands Away from Sanding Area.
• 25. Never Use in an Explosive Atmosphere: Motor sparking could ignite fumes.
• 26. Inspect Tool Cords Periodically: Have damaged cords repaired at a Sears Repair Center. Be aware of cord location.
• 27. Inspect Extension Cords Periodically: Replace if damaged.
• 28. Keep Handles Dry, Clean, and Free from Oil and Grease: Use a clean cloth for cleaning. Avoid solvents like brake fluid, gasoline, or petroleum-based products.
• 29. Stay Alert: Watch what you are doing, use common sense, and do not operate when tired or rushed.
• 30. Check Damaged Parts: Before further use, carefully check any damaged guard or part to ensure proper operation. If damaged, have it repaired or replaced by an authorized service center.
• 31. Do Not Use Tool if Switch Does Not Turn On/Off: Have defective switches replaced by an authorized service center.
• 32. Inspect for and Remove Nails: Remove all nails from lumber before sanding.
• 33. Drugs, Alcohol, Medication: Do not operate the tool under the influence.
• 34. Do Not Use for Overhead Sanding: This can lead to dropping the sander or loss of control, resulting in possible serious injury.
• 35. Use Only Identical Craftsman Replacement Parts: For servicing.
• 36. Polarized Plugs: This tool has a polarized plug (one blade wider than the other) for reduced shock risk. If it does not fit the outlet, reverse it. If it still doesn't fit, contact a qualified electrician. Do not alter the plug.
• 37. Save These Instructions: Refer to them frequently and use them to instruct others. Loan them with the tool.

Product Information and Accessories

Dust and Chemical Hazards: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects, or other reproductive harm. Examples include lead from lead-based paints, crystalline silica from bricks and cement, and arsenic and chromium from chemically-treated lumber. Reduce exposure by working in a well-ventilated area and using approved safety equipment like dust masks designed for microscopic particles.

Recommended Accessories (Current and available at time of printing):

• 3 in. x 21 in. Aluminum Oxide Plyweld Belts
• 3 in. x 21 in. "Sears Best" Zirconium Plyweld Belts

Warning: The use of attachments or accessories not listed above might be hazardous.

Eye Protection: The operation of any sander can result in foreign objects being thrown into your eyes, potentially causing severe eye damage. Always wear safety goggles or safety glasses with side shields, and a full face shield when needed. Wide Vision Safety Mask (available at Sears) is recommended for use over eyeglasses or standard safety glasses with side shields.

Operation

Power Supply: Ensure power supply is 110-120 volts, 60 Hz, AC only.

Familiarization: Before use, familiarize yourself with all operating features and safety requirements.

Switch: The switch features a "lock-on" function for extended sanding. To engage, depress the trigger, push the lock button on the side of the handle, and then release the trigger. To disengage, depress and release the trigger. If the sander disconnects from power while locked on, disengage the lock immediately. Warning: Always check that the switch is not in the "lock-on" position before connecting to power to prevent accidental starting and potential injury. Do not lock the trigger on jobs where the sander may need to be stopped suddenly.

Preparing for Operation:

• The sander has a front and rear handle for two-hand operation, aiding control, keeping the sanding area level, and keeping hands clear of the sanding belt.
• Always hold the front handle with your left hand and the rear handle with your right hand.
• Warning: Keep hands and fingers clear of the moving sanding belt, front idler pulley, and drive roller assembly to prevent serious injury.
• Warning: Do not let fingers rest over the front or right edge of the sander, as the belt could run off and cause injury.

Figure 2: Illustration showing the correct two-hand grip on the sander's front and rear handles.

Figure 3: Illustration highlighting areas to keep hands and fingers away from during operation.

Selecting and Installing Sanding Belts:

• Choose the correct size and type of sanding belt for the desired finish (coarse for material removal, fine for smooth finish).
• Warning: Always wear safety goggles or safety glasses with side shields. If dusty, wear a face or dust mask to prevent dust or particles from entering eyes.
• Installing Dust Bag: Fit the dust bag retainer over the dust exhaust hole on the blower cover and slide it into place. Ensure it fits snugly. Warning: Never attempt to use the sander without the dust bag properly installed, as sawdust thrown into the face and eyes could cause serious injury.
• Installing and Adjusting Sanding Belt:
• Disconnect the sander from power before assembly or adjustments.
• To release the belt, lift the tension release lever. This compresses the spring, allowing the pulley to lock in a rear position, freeing the belt.
• Install the new belt, ensuring the arrow inside the belt points in the direction of rotation (clockwise when viewed from the open side).
• Roughly align the belt, then release tension by lowering the tension release lever. The pulley will snap back.
• Warning: Keep hands and fingers clear of the front idler pulley and spring mechanism at all times to avoid pinching.

Figure 4: Illustration showing the dust bag retainer being fitted onto the blower cover.

Figure 5: Illustration showing the correct installation of a sanding belt onto the pulleys.

Figure 6: Illustration showing the tension release lever for removing and securing the sanding belt.

Adjusting Belt Tracking:

• Connect the sander to power. Place the sander upside down (for adjustment only).
• Pull and release the switch trigger. Observe the belt's tracking.
• If the belt runs inward, turn the tracking screw clockwise. If it runs outward, turn it counterclockwise. Adjust until the belt does not run off the sander or contact internal parts.
• After installing a new belt, adjustments may be needed several times until the belt becomes pliable.
• Warning: If the sanding belt wears excessively on the inner edge, the tracking screw is adjusted too far inward, causing the belt to rub against internal parts. Readjust immediately.
• Once the belt is correctly adjusted (outer edge even with the sander's base edge), fine-tune the tracking screw until the belt stabilizes. Proper tracking significantly increases belt life.
• Warning: Keep hands and fingers away from the moving sanding belt. Contact can cause serious injury. Do not wear loose clothing or jewelry.

Figure 7: Illustration showing the sander upside down for belt tracking adjustment, with the tracking screw indicated.

Figure 8: Illustration showing fine-tuning the tracking screw for belt stabilization.

To Operate:

• Secure the workpiece with clamps or a vise to prevent movement. Warning: Unsecured work could be thrown back, causing injury.
• Before placing the sander on the work surface, squeeze the trigger to reach maximum speed.
• Lower the sander to the work surface with a slight forward motion.
• Use the rear handle to control the sander and the front handle to guide it. Move slowly over the work.
• Allowing the sander to remain in one place will result in an uneven surface.
• Warning: Keep a firm grip on the sander with both hands at all times to prevent loss of control and potential serious injury.
• Do not apply excessive pressure; the tool's weight is designed for efficient pressure. Extra pressure can lead to uneven work, clogged belts, and motor burnout.
• The front roller is not designed for contour sanding; doing so can cause belt tracking irregularities.
• Use a coarser belt for heavy cutting, not increased pressure.

Figure 9: Illustration showing the correct method of operating the belt sander on a workpiece.

Maintenance

Warning: When servicing, use only identical Craftsman replacement parts. Using other parts may create a hazard or cause product damage.

Timing Belt Replacement:

• Disconnect the sander from power supply before servicing.
• Use replacement belt number 989368-000 only.
• Remove the sanding belt. Remove the two belt cover screws and then the belt cover.
• Force the old belt from the small pulley with a screwdriver and remove it from the large pulley. Cut the old belt if worn out.
• Install the new belt over the large pulley first.
• Hold the belt and press it onto the small pulley, turning the large pulley to simplify the process.
• Reassemble the belt cover and screws. Caution: Never attempt to operate the sander without the belt cover in place.

Figure 10: Illustration showing the small and large pulleys and belt cover for timing belt replacement.

Figure 11: Illustration demonstrating how to apply pressure and turn the large pulley to install the belt onto the small pulley.

Switch Replacement:

• Disconnect the sander from power supply while replacing parts or making adjustments.
• Remove the handle cover and screws. Note the wiring locations and connections to the switch. These must be identical for the new switch.
• Lift the switch away from the handle. Release leads by inserting a 1/32 inch diameter pin or nail into each switch lead receptacle.
• Connect leads to the new switch by pushing them into the receptacles. Pull leads to check connections.
• Arrange wiring in the handle so it won't be pinched. Position the switch.
• Place the cord and bend relief in their correct locations.
• Replace the handle cover and screws, tightening securely.

Figure 12: Illustration showing the handle cover, switch, and screws for switch replacement.

Figure 13: Illustration showing the use of a 1/32 inch diameter nail or pin to release switch leads.

Cord Replacement:

• Disconnect the sander from power supply.
• Remove the handle cover and screws. Note wiring locations and connections.
• Remove the switch from the handle and disconnect cord leads.
• Transfer the bend relief from the old cord to the new one.
• Push each lead of the new cord into the proper switch lead receptacles. Check connections.
• Arrange wiring to avoid pinching. Position the switch.
• Place the bend relief and cord correctly, then replace the handle cover and screws. Tighten all screws securely.

Figure 14: Illustration showing the handle cover, switch, and cord for cord replacement.

Figure 15: Illustration showing the use of a 1/32 inch diameter nail or pin to disconnect cord leads from the switch.

General Maintenance:

• Only parts shown on the parts list are intended for customer repair. Other parts are critical to the double insulation system and should be serviced only by a qualified technician.
• Avoid using solvents on plastic parts, as they can be damaged. Use clean cloths to remove dirt and carbon dust.
• Warning: Do not let brake fluids, gasoline, petroleum-based products, or penetrating oils contact plastic parts, as they can damage or weaken them.
• Fiberglass Use: Using electric tools on fiberglass materials can cause accelerated wear due to abrasive chips and grindings. It is not recommended for extended work on fiberglass. If used, clean the tool frequently by blowing with an air jet. Always wear safety goggles, safety glasses with side shields, or a dust mask during operation or when blowing dust.

Lubrication: All bearings are lubricated with high-grade lubricant for the life of the unit under normal conditions; no further lubrication is required.

Extension Cords:

• Using an extension cord causes some power loss. To minimize this and prevent overheating, use cords of the correct size.
• For outdoor use, use only marked outdoor extension cords.
• Recommended wire sizes (AWG): 16 for 25-50 ft, 14 for 50-100 ft.
• Warning: Check extension cords before each use. Replace if damaged. Never use a tool with a damaged cord, as it could cause electrical shock and serious injury.

Parts List

The Model Number is found on a plate attached to the Blower Cover of your Sander. Always mention the Model Number when corresponding or ordering parts.

Note A: The assembly shown represents an important part of the Double Insulated System. To avoid the possibility of alteration or damage to the system, service should be performed by your nearest Sears Repair Center. Contact your nearest Retail Store.

* Standard Hardware Item - May Be Purchased Locally

** Available From Div. 98 - Source 980.00

*** Sanding Belts in assorted grits for both sanding wood and metal may be obtained from your nearest Sears Retail Store.

Service and Support

Get it fixed, at your home or ours!

• For repair of major brand appliances, call 1-800-4-MY-HOME (1-800-469-4663) anytime. Visit www.sears.com.
• To bring in products like vacuums, lawn equipment, and electronics for repair, call to find your nearest Sears Parts & Repair Center at 1-800-488-1222 anytime. Visit www.sears.com.
• For replacement parts, accessories, and owner's manuals, call Sears Parts Direct at 1-800-366-PART (1-800-366-7278), 6 a.m. - 11 p.m. CST, 7 days a week. Visit www.sears.com/partsdirect.
• To purchase or inquire about a Sears Service Agreement, call 1-800-827-6655, 7 a.m. - 5 p.m. CST, Mon. - Sat.
• For service in Spanish, call 1-888-SU-HOGAR (1-888-784-6427).
• For service in French (Canada), call 1-877-LE-FOYER (1-877-533-6937).

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