asseMbly and Operating instructiOns - Harbor Freight Tools

Oscillating spindle sander 

Model 38160 

Assembly and Operating Instructions 

Visit our website at: http://www.harborfreight.com 

Read this material before using this product. 

Failure to do so can result in serious injury. 

Save this manual. 

Copyright © 1998 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 improvements, actual product may 

differ slightly from the product described herein. Tools required for assembly and service may not be included. 

Revised Manual 10c 

For technical questions or replacement parts, please call 1-800-444-3353.

Save This Manual 

Keep this manual for the safety warnings 

and precautions, assembly, operating, 

inspection, maintenance and cleaning 

procedures. Write the product’s serial number 

in the back of the manual near the assembly 

diagram (or month and year of purchase if 

product has no number). Keep this manual 

and the receipt in a safe and dry place for 

future reference. 

Important SAFETY 

Information 

In this manual, on the labeling, and 

all other information provided with 

this product: 

This is the safety alert 

symbol. It is used to alert 

you to potential personal 

injury hazards. Obey all 

safety messages that follow 

this symbol to avoid possible 

injury or death. 

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, used with 

the safety alert 

symbol, indicates a hazardous 

situation which, if not avoided, 

could result in minor or moderate 

injury. 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

NOTICE is used to 

address practices not 

related to personal injury. 

CAUTION, without the 

safety alert symbol, is 

used to address practices not 

related to personal injury. 

General 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. 

KEEP GUARDS IN PLACE and in 

working order. 

REMOVE ADJUSTING KEYS AND 

WRENCHES. Form habit of checking to 

see that keys and adjusting wrenches 

are removed from tool before turning it 

on. 

KEEP WORK AREA CLEAN. Cluttered 

areas and benches invite accidents. 

DON’T USE IN DANGEROUS 

ENVIRONMENT. Don’t use power tools 

in damp or wet locations, or expose them 

to rain. Keep work area well lighted. 

KEEP CHILDREN AWAY. All visitors 

should be kept safe distance from work 

area. 

MAKE WORKSHOP KID PROOF 

with padlocks, master switches, or by 

removing starter keys. 

DON’T FORCE TOOL. It will do the job 

better and safer at the rate for which it 

was designed. 

REV 10e 

Page 2 For technical questions, please call 1-800-444-3353. SKU 38160

8. 

9. 

10. 

11. 

12. 

USE RIGHT TOOL. Don’t force tool or 

attachment to do a job for which it was 

not designed. 

RECOMMENDED MINIMUM WIRE 

GAUGE FOR EXTENSION CORDS 

(120 VOLT) 

NAMEPLATE 

AMPERES 

(at full load) 

SKU 38160 

EXTENSION CORD 

LENGTH 

25’ 50’ 100’ 150’ 

0 – 6 18 16 16 14 

6.1 – 10 18 16 14 12 

10.1 – 12 16 16 14 12 

12.1 – 16 14 12 Do not use. 

TABLE A 

USE PROPER EXTENSION CORD. 

Make sure your extension cord is in good 

condition. When using an extension 

cord, be sure to use one heavy enough 

to carry the current your product will 

draw. An undersized cord will cause a 

drop in line voltage resulting in loss of 

power and overheating. Table A shows 

the correct size to use depending on 

cord length and nameplate ampere 

rating. If in doubt, use the next heavier 

gauge. The smaller the gauge number, 

the heavier the cord. 

WEAR PROPER APPAREL. Do not wear 

loose clothing, gloves, neckties, rings, 

bracelets, or other jewelry which may get 

caught in moving parts. Nonslip footwear 

is recommended. Wear protective hair 

covering to contain long hair. 

ALWAYS USE SAFETY GLASSES. Also 

use face or dust mask if cutting operation 

is dusty. Everyday eyeglasses only have 

impact resistant lenses, they are NOT 

safety glasses. 

SECURE WORK. Use clamps or a vise 

to hold work when practical. It’s safer 

than using your hand and it frees both 

hands to operate tool. 

REV 10e 

13. 

14. 

15. 

16. 

17. 

18. 

19. 

20. 

21. 

DON’T OVERREACH. Keep proper 

footing and balance at all times. 

MAINTAIN TOOLS WITH CARE. Keep 

tools sharp and clean for best and safest 

performance. Follow instructions for 

lubricating and changing accessories. 

DISCONNECT TOOLS before servicing; 

when changing accessories, such as 

blades, bits, cutters, and the like. 

REDUCE THE RISK OF 

UNINTENTIONAL STARTING. Make 

sure switch is in off position before 

plugging in. 

USE RECOMMENDED ACCESSORIES. 

Consult the owner’s manual for 

recommended accessories. The use of 

improper accessories may cause risk of 

injury to persons. 

NEVER STAND ON TOOL. Serious 

injury could occur if the tool is tipped 

or if the cutting tool is unintentionally 

contacted. 

CHECK DAMAGED PARTS. Before 

further use of the tool, a guard or other 

part that is damaged should be carefully 

checked to determine that it will operate 

properly and perform its intended 

function – check for alignment of moving 

parts, binding of moving parts, breakage 

of parts, mounting, and any other 

conditions that may affect its operation. 

A guard or other part that is damaged 

should be properly repaired or replaced. 

DIRECTION OF FEED. Feed work into 

a blade or cutter against the direction of 

rotation of the blade or cutter only. 

NEVER LEAVE TOOL RUNNING 

UNATTENDED. TURN POWER OFF. 

Don’t leave tool until it comes to a 

complete stop. 

For technical questions, please call 1-800-444-3353. 

Page 3

Grounding Instructions 

To prevent 

electric shock 

and death from incorrect 

grounding wire 

connection 

Read and follow these 

instructions: 

110-120 V~ Grounded Tools: Tools 

with Three Prong Plugs 

6. 

3-pole receptacles that accept the tool’s 

plug. 

Repair or replace damaged or worn cord 

immediately. 

Grounding 

Pin 

1. 

2. 

3. 

In the event of a malfunction or 

breakdown, grounding provides a path 

of least resistance for electric current 

to reduce the risk of electric shock. 

This tool is equipped with an electric 

cord having an equipment-grounding 

conductor and a grounding plug. The 

plug must be plugged into a matching 

outlet that is properly installed and 

grounded in accordance with all local 

codes and ordinances. 

Do not modify the plug provided – if it will 

not fit the outlet, have the proper outlet 

installed by a qualified electrician. 

Improper connection of the equipmentgrounding 

conductor can result in a risk 

of electric shock. The conductor with 

insulation having an outer surface that 

is green with or without yellow stripes is 

the equipment-grounding conductor. If 

repair or replacement of the electric cord 

or plug is necessary, do not connect the 

equipment-grounding conductor to a live 

terminal. 

7. 

8. 

9. 

125 V~ 3-Prong Plug and Outlet 

(for up to 125 V~ and up to 15 A) 

This tool is intended for use on a circuit 

that has an outlet that looks like the one 

illustrated above in 125 V~ 3-Prong 

Plug and Outlet. The tool has a 

grounding plug that looks like the plug 

illustrated above in 125 V~ 3-Prong 

Plug and Outlet. 

The outlet must be properly installed and 

grounded in accordance with all codes 

and ordinances. 

Do not use an adapter to connect this 

tool to a different outlet. 

110-120 V~ Double Insulated Tools: 

Tools with Two Prong Plugs 

4. 

5. 

Check with a qualified electrician or 

service personnel if the grounding 

instructions are not completely 

understood, or if in doubt as to whether 

Outlets for 2-Prong Plug 

the tool is properly grounded. 

1. To reduce the risk of electric shock, 

Use only 3-wire extension cords that 

double insulated equipment has a 

have 3-prong grounding plugs and 

polarized plug (one blade is wider than 

REV 10e 


2. 

1. 

2. 

3. 

4. 

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 the proper outlet. Do 

not change the plug in any way. 

Double insulated tools may be used in 

either of the 120 volt outlets shown in the 

preceding illustration. (See Outlets for 

2-Prong Plug.) 

Sander Safety Warnings 

For Your Own Safety Read Instruction 

Manual Before Operating Sander 

Wear eye protection. 

Support workpiece with miter gauge, 

backstop, or worktable. 

The backstop is a fence near the surface 

that helps the operator maintain control 

of the workpiece and prevents the 

workpiece from being pulled into the 

machine. For safety, it must be adjusted 

very close to the sanding surface. 

The worktable is the surface mounted 

close to the sanding surface that the 

operator rests the workpiece against 

to prevent it from being pulled by the 

sanding surface. For safety, it must 

be adjusted very close to the sanding 

surface. 

8. 

9. 

10. 

11. 

12. 

13. 

Only use safety equipment that has been 

approved by an appropriate standards 

agency. Unapproved safety equipment 

may not provide adequate protection. 

Eye protection must be ANSI-approved 

and breathing protection must be 

NIOSH-approved for the specific hazards 

in the work area. 

Stay alert, watch what you are doing 

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. 

Industrial applications must follow OSHA 

guidelines. 

Maintain labels and nameplates on 

the tool. These carry important safety 

information. If unreadable or missing, 

contact Harbor Freight Tools for a 

replacement. 

Avoid unintentional starting. Prepare to 

begin work before turning on the tool. 

People with pacemakers should 

consult their physician(s) before use. 

Electromagnetic fields in close proximity 

to heart pacemaker could cause 

pacemaker interference or pacemaker 

failure. 

5. 

6. 

7. 

Do not operate with ANY 

guard disabled, damaged, or 

removed. Moving guards must 

move freely and close instantly. 

The use of accessories or attachments 

not recommended by the manufacturer 

may result in a risk of injury to persons. 

When servicing use only identical 

replacement parts. 

14. 

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 or other masonry products 

• Arsenic and chromium from chemically 

REV 10e 

SKU 38160 


Page 5

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.) 

Unpacking 

When unpacking, make sure that the 

item is intact and undamaged. If any parts 

are missing or broken, please call Harbor 

Freight Tools at 1-800-444-3353 as soon as 

possible. 

15. 

16. 

WARNING: Handling the cord on this 

product will expose you to lead, a 

chemical known to the State of California 

to cause cancer, and birth defects or 

other reproductive harm. Wash hands 

after handling. (California Health & 

Safety Code § 25249.5, et seq.) 

The warnings, precautions, and 

instructions discussed in this instruction 

manual cannot cover all possible 

conditions 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. 

Save these 

instructions. 

Electrical Input 

Specifications 

Motor No Load Speed 

Oscillations per 

Minute 

120 V~ / 60 Hz / 11 A 

1787 RPM 

58 OPM 

Oscillation Travel 7/8” 

Sanding Belt Capacity 3/4” - 2” 

Sanding Belt Height 4-1/2” 

Sanding Thickness 3/16 - 11/16” 

Dust Collection Port 2” 

Table Tilt Angle 0 - 45° 

Rev 00c; 10c 


To Change/Install Sand Belts 

(See Parts Diagram and Parts List on pages 8 and 9) 

Place switch in “OFF” position, and unplug the sander before performing any of the steps below. 

The Oscillating Sander has been shipped completely assembled with a 2” sand belt (#49) and regular core board 

installed. Change sand belts as follows: 

TO REMOVE SAND BELT 

1. Grasp and hold sand belt (#49) on rotating axle (#46). Loosen nut (#51). If nut is too tight and rotating axle 

spins inside sand belt, secure the rotating axle with a wrench and loosen nut. 

2. Remove nut, big washer (#50), and sand belt. Unscrew rotating axle clockwise and remove core board (#36) - 

also see instructions below describing how to remove core board. 

3. Remove big washer (#50) and clean sawdust accumulation. 

TO INSTALL SAND BELT 

1. Replace big washer (#50). Fin side of washer should always be installed down. The fins help push sawdust 

through the dust exhaust port opening, preventing buildup of sawdust. Sawdust buildup in this area may cause 

the oscillating motion to stop. The big washer must be used with all sanding sleeves. 

2. Select and install the desired rotating axle. 

3. Install appropriate sand belt on the rotating axle. (Note: If sanding sleeve becomes difficult to install or remove, 

apply talcum powder on the inside of the sand belt before installing on axle). 

4. Install big washer (#50) and nut. 

5. Grasp and hold sand belt and tighten nut. Do not overtighten. 

Replacing Core Boards 

The Oscillating Sander comes with two core boards. The core board with the circular opening is for sanding when the working 

table (#34) is level. The core board with the oblong opening is to be used when the working table is set at an angle. 

To Remove Core Boards 

Push firmly from underneath the working table until core board is removed. 

To Insert Core Boards 

1. Align the notch in the core board with the spring dowel (#35) located on the inner rim of the core board insert area. 

2. Push down firmly until the core board is fully inserted and flush with the surface of the working table. 

SKU 38160 


Page 7

Preparing For Operation 

Note: 

√ 

√ 

√ 

√ 

This sander is designed for use on plastic and wood surfaces only. Do not use this sander for sanding 

metals. Sanding metals will cause sparks that will ignite wood and dust particles on sander, in the dust 

collector, or in workshop. 

It is recommended that this tool not be used for extended work on any fiberglass or abrasive materials. 

It has been found that those materials are subject to accelerated wear and possible premature failure, 

as the fiberglass chips and grindings are highly abrasive to bearings, brushes, commutator, etc. During 

any sanding of these materials, it is important the tool be cleaned frequently by blowing with an air 

jet. 

Do not use sander without a sand belt. Doing so will damage the rotating axle. 

Make sure nut on the top of the rotating axle is tightened securely - but not overtightened. 

SAND BELT SELECTION 

Selecting the correct size diameter, type of grit and sanding sleeve is an extremely important step in achieving a 

high quality finish: 

√ 

√ 

Aluminum oxide, silicon carbide, and other synthetic abrasives are best for power sanding. 

Natural abrasives, such as flint and garnet are too soft for use in power sanding. 

Select and install the desired sand belt for the particular application. Sand belts from 3/4”- 2” can be used with this 

sander. Choose one that is close in size to the material you are sanding. 

GRIT SELECTION 

The condition of the surface to be sanded will determine which grit will do the proper job. In general, coarse grit will 

remove the most material. Finer grit will produce the best finish in all sanding operations. If the surface is rough, 

start with a coarse grit and sand until the surface is uniform. Medium grit may then be used to remove scratches 

left by the coarser grit and finer grit used for finishing of the surface. Always continue sanding with each grit until 

the surface is uniform. 

WARNING! Do not use water with this sander. It is for dry 

sanding only. Wet sanding will damage the machine, 

and may present a shock hazard. Use only in dry 

locations. 

REV 10c 


Operation 

Exercise caution! Never force the material into the sander. You will become familiar with the sander’s features from 

practice and use. If possible, practice sanding with a scrap piece of wood. 

ADJUSTING TABLE ANGLE 

1. If working table is to be used at an angle, make sure to install the angle core board (with the oblong-shaped 

opening) before sanding. 

2. Loosen dial knob (#32) and adjust working table to the desired angle using the numbers on the rotating plate 

(#31) as a guide. 

3. Tighten dial knob securely so that the working table will not move during operation. 

SANDING 

1. Turn sander on. 

2. Let the motor build to its full speed, then gradually feed material against sanding sleeve. Do not let the material 

contact sanding sleeve before turning on sander and allowing it to develop full speed. 

FEED DIRECTION 

When sanding, the sanding sleeve rotates counterclockwise. Therefore, feed the material against the sanding 

sleeve from right to left. When fed from right to left, the rotation of the sanding sleeve sands against the material. 

If fed in the opposite direction, the rotation forces of the spinning sanding sleeve will tend to throw or bounce the 

material away from the sanding sleeve. This could cause loss of control of the material. 

DUST COLLECTION CAPABILITY 

A standard 2-1/4” dust collect cover (#40) has been provided to make dustless sanding possible. The dust collection 

port is located under the working top on the rear side of the sander. The pickup adapter end of a vacuum hose (not 

included) will fit inside the dust collect cover. 

Even with a dust collection system, it is necessary to periodically clean sanding dust from the core board and big 

washer areas. Sanding dust buildup in this area may cause the core board surface to rise above the working table 

surface. 

Maintenance 

CLEANING: Regularly clean the work surface with dry brush or clean cloth. Clean sawdust accumulations from core 

board, big washers and rotating axle after each use. 

LUBRICATION: No lubrication is required. All of the bearings in this tool are lubricated with a sufficient amount of 

high grade lubricant for the life of the machine under normal operating conditions. 

POWER CORD: Inspect the power cord periodically, and if damaged, have it repaired by an authorized technician. 

REPLACEMENT PARTS: When servicing, use only identical replacement parts. Use of any other parts will void the 

warranty. 

SKU 38160 


Page 9

Parts List 

No. Name Quantity no. Name Quantity 

1 Stand 1 29 Hexagon-headed bolt M8x20 6 

2 Switch 1 30 Stand 1 of working table 1 

3 Vertical Motor 1 31 Rotating Plate 1 

4 Key of Motor 1 32 Parts of Dial Knob 2 

5 Clamp Nail 2 33 Crossed Disc Nail M5 x 8 7 

6 Worm 1 34 Working Table 1 

7 Spring Ring for Hole 55 1 35 Spring Dowel 3 x 8 1 

8 Bearing 80106 1 36 Core Board 2 

9 Spring Ring for Axle 32 1 37 Hexagonn Socket Head Cap 

10 Cross Head Disc Nail M5 x 55 2 screw M6 x 20 2 

11 Screw Washer 5 Holee 55 11 38 Dust Cover 1 

12 Rocker Arm 2 39 Hexagon-headed bolt M8 x 25 7 

13 Nut M5 4 40 Dust Collect Cover 1 

14 Hexagon Socket Head Cap 41 Pointer 1 

Screw M4 x 30 2 42 Stand II of Working Table 1 

15 Left Core Axle of Worm Wheel 1 43 Stand Board 1 

16 Worm Wheel 1 44 Dial 1 

17 Stand of Worm Wheel 1 45 Key 5 x 50 1 

18 Screw M8 x 65 1 46 Rotating Axle of Sand Belt 1 

19 Right Core Axle of Worm Wheel 1 47 Big Washer i 1 

20 Guide Pole 1 48 Rubber Cylinder 1 

21 Shuttle Axle Cover 1 49 Sand Belt 1 

22 Shuttle Axle 1 50 Big Washer ii 1 

23 Spring Dowel 4 x 30 1 51 Left Nut M8 1 

24 Bearing 61804 1 52 Board of Switch 1 

25 Hexagon Socket Head Cap 53 Nut M8 4 

Screw MG x 16 5 54 Washer Nut M8 4 

26 Spring Washer 8 7 55 Rubber Washer 4 

27 Frame to Fix Motor 1 

28 Screw Washer 14 


Assembly Diagram 

SKU 38160 


Page 11

Limited 1 year / 90 Day 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 for a period of ninety 

days from date of purchase that the engine/motor, the belts (if so equipped), and the blades 

(if so equipped) are free of defects in materials and workmanship. Harbor Freight Tools also 

warrants to the original purchaser, for a period of one year from date of purchase, that all other 

parts and components of the product are free from defects in materials and workmanship (90 

days if used by a professional contractor or if used as rental equipment). 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 apply 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 complaint 

must accompany the merchandise. If our inspection verifies the defect, we will either 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 repaired 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 

REV 10c

asseMbly and Operating instructiOns - Harbor Freight Tools

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