Belt Sander
76 mm (3”)
MODEL 9902
76 mm (3”)
MODEL 9903
76 mm (3”)
MODEL 9920
100 mm (4”)
MODEL 9404
003359
DOUBLE
INSULATION
I N S T R U C T I O N M A N U A L
WARNING:
For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
w w w. m a k i t a t o o l s . c o m
5. Avoid body contact with grounded sur-
faces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of
electric shock if your body is grounded.
14. Use safety equipment. Always wear eye
protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must
be used for appropriate conditions. Ordinary
eye or sun glasses are NOT eye protection.
6. Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
Tool Use and Care
15. Use clamps or other practical way to
secure and support the workpiece to a
stable platform. Holding the work by hand or
against your body is unstable and may lead
to loss of control.
7. Do not abuse the cord. Never use the cord
to carry the tools or pull the plug from an
outlet. Keep cord away from heat, oil,
sharp edges or moving parts. Replace
damaged cords immediately. Damaged
cords increase the risk of electric shock.
16. Do not force tool. Use the correct tool for
your application. The correct tool will do the
job better and safer at the rate for which it is
designed.
8. When operating a power tool outside, use
an outdoor extension cord marked “W-A”
or “W”. These cords are rated for outdoor
use and reduce the risk of electric shock.
17. Do not use tool if switch does not turn it
on or off. Any tool that cannot be controlled
with the switch is dangerous and must be
repaired.
Personal Safety
9. 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.
18. Disconnect the plug from the power
source before making any adjustments,
changing accessories, or storing the tool.
Such preventive safety measures reduce the
risk of starting the tool accidentally.
19. Store idle tools out of reach of children
and other untrained persons. Tools are
dangerous in the hands of untrained users.
10. Dress properly. Do not wear loose cloth-
ing or jewelry. Contain long hair. Keep
your hair, clothing, and gloves away from
moving parts. Loose clothes, jewelry, or long
hair can be caught in moving parts.
20. Maintain tools with care. Keep cutting
tools sharp and clean. Properly maintained
tools with sharp cutting edges are less likely
to bind and are easier to control.
11. Avoid accidental starting. Be sure switch
is off before plugging in. Carrying tools with
your finger on the switch or plugging in tools
that have the switch on invites accidents.
21. Check for misalignment or binding of
moving parts, breakage of parts, and any
other condition that may affect the tools
operation. If damaged, have the tool ser-
viced before using. Many accidents are
caused by poorly maintained tools.
12. Remove adjusting keys or wrenches
before turning the tool on. A wrench or a
key that is left attached to a rotating part of
the tool may result in personal injury.
22. Use only accessories that are recom-
mended by the manufacturer for your
model. Accessories that may be suitable for
one tool, may become hazardous when used
on another tool.
13. Do not overreach. Keep proper footing
and balance at all times. Proper footing and
balance enables better control of the tool in
unexpected situations.
3
24. When servicing a tool, use only identical
replacement parts. Follow instructions in
the Maintenance section of this manual.
Use of unauthorized parts or failure to follow
Maintenance instructions may create a risk of
electric shock or injury.
SERVICE
23. Tool service must be performed only by
qualified repair personnel. Service or main-
tenance performed by unqualified personnel
could result in a risk of injury.
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 1 shows the correct size to use depending on cord length and
nameplate ampere rating. If in doubt, use the next heavier gage. The smaller the gage num-
ber, the heavier the cord.
Table 1: Minimum gage for cord
Volts
120 V
Total length of cord in feet
Ampere Rating
25 ft.
50 ft.
100 ft.
150 ft.
More Than
Not More Than
AWG
0
6
10
12
6
18
18
16
14
16
16
16
12
16
14
14
14
12
12
10
12
16
Not Recommended
4
SPECIFIC SAFETY RULES
USB007-3
DO NOT let comfort or familiarity with product (gained from
repeated use) replace strict adherence to sander safety rules. If
you use this tool unsafely or incorrectly, you can suffer serious
personal injury.
1. Hold tool by insulated gripping surfaces
when performing an operation where the
cutting tool may contact hidden wiring or
its own cord. Contact with a “live” wire will
make exposed metal parts of the tool “live”
and shock the operator.
5. Keep hands away from rotating parts.
6. Do not leave the tool running. Operate the
tool only when hand-held.
7. This tool has not been waterproofed, so
do not use water on the workpiece sur-
face.
2. Always use safety glasses or goggles.
Ordinary eye or sun glasses are NOT
safety glasses.
8. Ventilate your work area adequately when
you perform sanding operations.
3. Hold the tool firmly with both hands.
9. Use of this tool to sand some products,
paints and wood could expose user to
dust containing hazardous substances.
Use appropriate respiratory protection.
4. Make sure the belt is not contacting the
workpiece before the switch is turned on.
SAVE THESE INSTRUCTIONS
WARNING:
MISUSE or failure to follow the safety rules stated in this
instruction manual may cause serious personal injury.
5
SYMBOLS
USD204-1
The followings show the symbols used for tool.
V .......................volts
................alternating current
....................Class II Construction
m/min ...............meter per minute
A .......................amperes
Hz .....................hertz
6
FUNCTIONAL
DESCRIPTION
CAUTION:
•
Always be sure that the tool is switched off and
unplugged before adjusting or checking function on the
tool.
003364
Switch action
CAUTION:
1
•
Before plugging in the tool, always check to see that the
switch trigger actuates properly and returns to the “OFF”
position when released.
2
•
Switch can be locked in “ON” position for ease of
operator comfort during extended use. Apply caution
when locking tool in “ON” position and maintain firm
grasp on tool.
1. Lock button
2. Switch trigger
To start the tool, simply pull the switch trigger. Release the
switch trigger to stop.
For continuous operation, pull the switch trigger and then
push in the lock button.
To stop the tool from the locked position, pull the switch trig-
ger fully, then release it.
Speed adjusting dial
For 9903, 9920 and 9404
003368
The belt speed can be infinitely adjusted between 210 m
(690 ft.) and 440 m (1,440 ft.) per minute by turning the
speed adjusting dial to a given number setting from 1 to 5.
Higher speed is obtained when the dial is turned in the direc-
tion of number 5; lower speed is obtained when it is turned in
the direction of number 1.
1
Select the proper speed for the workpiece to be sanded.
1. Speed adjusting dial
CAUTION:
•
•
If the tool is operated continuously at low speeds for a
long time, the motor will get overloaded, resulting in tool
malfunction.
The speed adjusting dial can be turned only as far as 5
and back to 1. Do not force it past 5 or 1, or the speed
adjusting function may no longer work.
7
ASSEMBLY
CAUTION:
•
Always be sure that the tool is switched off and
unplugged before carrying out any work on the tool.
003501
Installing or removing abrasive belt
1
Pull the lever all the way out and install the belt over the roll-
ers, then return the lever to the original position.
1. Lever
003376
CAUTION:
•
When installing the belt, make sure that the direction of
the arrow on the back of the belt corresponds to the one
on the tool itself.
003380
Adjusting belt tracking
more than 6mm (1/4”)
1
Switch on the tool and make sure that the belt is aligned
properly. If the edge of the belt extends beyond the edge of
the base or the edge of the belt retracts more than 6 mm
(1/4”) away from the edge of the base, use the adjusting
knob to adjust the belt tracking.
2
1. Steel plate
2. Adjusting knob
003385
Dust bag
Attach the dust bag onto the dust spout. The dust spout is
tapered. When attaching the dust bag, push it onto the dust
spout firmly as far as it will go to prevent it from coming off
during operation.
1
2
1. Dust bag
2. Dust spout
8
003389
When the dust bag is about half full, remove the dust bag
from the tool and pull the fastener out. Empty the dust bag of
its contents, tapping it lightly so as to remove particles adher-
ing to the insides which might hamper further collection.
1
NOTE:
•
If you connect a Makita vacuum cleaner to this tool,
more efficient and cleaner operations can be performed.
2
1. Dust bag
2. Fastener
OPERATION
003391
Sanding operation
CAUTION:
•
The tool should not be in contact with the workpiece
surface when you turn the tool on or off. Otherwise a
poor sanding finish or damage of the belt may result.
Hold the tool firmly with both hands. Turn the tool on and wait
until it attains full speed. Then gently place the tool on the
workpiece surface. Keep the belt flush with the workpiece at
all times and move the tool back and forth.
Never force the tool. The weight of the tool applies adequate
pressure. Excessive pressure may cause stalling, overheat-
ing of the motor, burning of the workpiece and possible kick-
back.
003394
Sanding shoe (optional accessory)
The sanding shoe readily allows you to sand workpieces
more evenly.
1
1. Sanding shoe
9
MAINTENANCE
CAUTION:
•
Always be sure that the tool is switched off and
unplugged before attempting to perform inspection or
maintenance.
001145
Replacing carbon brushes
Remove and check the carbon brushes regularly. Replace
when they wear down to the limit mark. Keep the carbon
brushes clean and free to slip in the holders. Both carbon
brushes should be replaced at the same time. Use only iden-
tical carbon brushes.
1
1. Limit mark
003396
Use a screwdriver to remove the brush holder caps. Take out
the worn carbon brushes, insert the new ones and secure
the brush holder caps.
1
2
To maintain product SAFETY and RELIABILITY, repairs, any
other maintenance or adjustment should be performed by
Makita Authorized or Factory Service Centers, always using
Makita replacement parts.
1. Brush holder cap
2. Screwdriver
ACCESSORIES
CAUTION:
•
These accessories or attachments are recommended for
use with your Makita tool specified in this manual. The
use of any other accessories or attachments might
present a risk of injury to persons. Only use accessory
or attachment for its stated purpose.
If you need any assistance for more details regarding these
accessories, ask your local Makita service center.
•
•
•
Abrasive belts
Sanding shoe
Dust bag
10
Memo
11
Memo
12
First-Class
Postage
Required
Post Office will
not deliver
without proper
postage.
Makita U.S.A., Inc.
14930 Northam Street
La Mirada, CA 90638-5753
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MAIL THIS PORTION
Your answers to the following questions are appreciated.
1.This product was purchased from:
3. How did you learn about this product:
Home Center
Other (
)
Magazine
Radio
Hardware/Lumber Store
Tool Distributor
From Dealer
Newspaper
Store Display
Catalog
Exhibition
From Friend
Previous Usage
Other (
Industrial Supply
Construction Supply
)
2. Use of the product is intended for:
4. Most favored points are:
Construction Trade
Industrial Maintenance
Home Maintenance
Hobby
Design
Repair Service
Durability
Power
Features
Size
Price
Other (
)
Other (
)
Makita Brand
5. Any comments:
DATE PURCHASED
MONTH
MODEL NO.
DAY
YEAR
SERIAL NO.
STATUS
SEX
Married Single
M
F
INTL.
LAST NAME / COMPANY NAME
STREET ADRESS
CITY
AREA
CODE
STATE
ZIP CODE
PHONE
40-49
Under 19
20-29
30-39
50-60
Over 60
AGE:
BE SURE TO COMPLETE THE CUSTOMER’S PORTION OF THIS FORM AND RETAIN FOR YOUR RECORDS.
Please return this portion by facsimile or mail.
Facsimile No: (714) 522-8133
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FACTORY SERVICE CENTERS
1-800-4-MAKITA
RETAIN THIS PORTION FOR YOUR RECORDS
ALABAMA
COLORADO
LOUISIANA
NEWYORK
PUERTO RICO
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(205) 620-1791
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(410) 590-0160
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NORTH CAROLINA
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(704) 527-0611
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Westwood, MA 02090
(617) 461-9754
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240 South Shackleford Rd.,
Ste. C
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5501 W. Waters Ave., Ste. 406
Tampa, FL 33634
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Columbus, OH 43213
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(281) 565-8665
(813) 886-8292
MINNESOTA
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Richfield, MN 55423
(612) 869-5199
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Fremont, CA 94538-5107
(510) 657-9881
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Parma Heights, OH 44130
(440) 843-7555
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MISSOURI
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Fresno, CA 93727
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UTAH
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145 E. 1300 S., Ste. 101
Salt Lake City, UT 84115
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Suites. 22 - 24
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53227
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Pittsburgh, PA 15237
(412) 366-6363
CUSTOMER’S RECORD
Date Purchased
When you need service: Send
complete tool (prepaid) to one
of the Makita Factory Service
Centers listed, or to an Authorized
Makita Service Center. Be sure
to attach a letter to the outside of
the carton detailing the problem
with your tool.
Dealer’s Name & Address
Model No.
Serial No.
15
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 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.
MAKITA LIMITED ONE YEAR WARRANTY
Warranty Policy
Every Makita tool is thoroughly inspected and tested before leaving the factory. It is warranted to be free of
defects from workmanship and materials for the period of ONE YEAR from the date of original purchase.
Should any trouble develop during this one year period, return the COMPLETE tool, freight prepaid, to one of
Makita’s Factory or Authorized Service Centers. If inspection shows the trouble is caused by defective
workmanship or material, Makita will repair (or at our option, replace) without charge.
This Warranty does not apply where:
• repairs have been made or attempted by others:
• repairs are required because of normal wear and tear:
• the tool has been abused, misused or improperly maintained:
• alterations have been made to the tool.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CONSEQUENTIAL
DAMAGES FROM THE SALE OR USE OF THE PRODUCT. THIS DISCLAIMER APPLIES BOTH DURING
AND AFTER THE TERM OF THIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED WARRANTIES OF
“MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,” AFTER THE ONE YEAR TERM OF THIS
WARRANTY.
This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you. Some states do not allow limitation on how long an implied
warranty lasts, so the above limitation may not apply to you.
Makita Corporation
3-11-8, Sumiyoshi-cho,
Anjo, Aichi 446-8502 Japan
884285C066
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