Makita 9902 User manual

INSTRUCTION MANUAL
WARNING:
For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
ENGLISH
Belt Sander
MODEL 9902
MODEL 9903
MODEL 9920
MODEL 9404
003359
DOUBLE
INSULATION

2
SPECIFICATIONS
• Due to our continuing programme of research and development, the specifications herein are subject to change
without notice.
• Note: Specifications may differ from country to country.
SYMBOLS END201-2
The following show the symbols used for the equipment.
Be sure that you understand their meaning before use.
...................Read instruction manual.
...................DOUBLE INSULATION
..................Only for EU countries
Do not dispose of electric equipment
together with household waste
material!
In observance of European Directive
2002/96/EC on waste electric and
electronic equipment and its
implementation in accordance with
national law, electric equipment that
have reached the end of their life
must be collected separately and
returned to an environmentally
compatible recycling facility.
Intended use
The tool is intended for the sanding of large surface of
wood, plastic and metal materials as well as painted sur-
faces.
Power supply
The tool should be connected only to a power supply of
the same voltage as indicated on the nameplate, and
can only be operated on single-phase AC supply. They
are double-insulated in accordance with European
Standard and can, therefore, also be used from sockets
without earth wire.
For Model 9902/9903/9920/9404
For European countries only
Noise and Vibration
The typical A-weighted sound pressure level is 85 dB (A).
Uncertainty is 3 dB(A).
The noise level under working may exceed 85 dB (A).
– Wear ear protection. –
The typical weighted root mean square acceleration
value is not more than 2.5 m/s2.
These values have been obtained according to
EN60745.
EC-DECLARATION OF CONFORMITY
We declare under our sole responsibility that this product
is in compliance with the following standards of stand-
ardized documents, EN60745, EN55014, EN61000 in
accordance with Council Directives, 89/336/EEC, 98/37/
EC.
Yasuhiko Kanzaki CE 2005
Director
MAKITA INTERNATIONAL EUROPE LTD.
Michigan Drive, Tongwell, Milton Keynes, Bucks MK15
8JD, ENGLAND
Responsible manufacturer:
Makita Corporation Anjo Aichi Japan
Model 9902 9903 9920 9404
Belt size 76 mm x 533 mm 76 mm x 533 mm 76 mm x 610 mm 100 mm x 610 mm
Belt speed 440 m/min. 210 - 440 m/min.
Overall length 296 mm 334 mm
Net weight 4.3 kg 4.3 kg 4.5 kg 4.7 kg
Safety class /II

3
GENERAL SAFETY RULES GEA001-3
WARNING:
Read all instructions. Failure to follow all instructions listed below may result in
electric shock, fire and/or serious injury. The term “power tool” in all of the
warnings listed below refers to your mains-operated (corded) power tool or battery-
operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
Work area safety
1. Keep work area clean and well lit. Cluttered and
dark areas invite accidents.
2. Do not operate power tools in explosive atmos-
pheres, such as in the presence of flammable
liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
3. Keep children and bystanders away while oper-
ating a power tool. Distractions can cause you to
lose control.
Electrical safety
4. Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power
tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
5. 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.
6. Do not expose power tools to rain or wet condi-
tions. Water entering a power tool will increase the
risk of electric shock.
7. 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.
8. 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.
Personal safety
9. 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.
10. Use safety equipment. Always wear eye protec-
tion. Safety equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing protection used
for appropriate conditions will reduce personal inju-
ries.
11. Avoid accidental starting. Ensure the switch is
in the off-position before plugging in. Carrying
power tools with your finger on the switch or plug-
ging in power tools that have the switch on invites
accidents.
12. 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.
13. Do not overreach. Keep proper footing and bal-
ance at all times. This enables better control of the
power tool in unexpected situations.
14. Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing, and gloves
away from moving parts. Loose clothes, jewellery
or long hair can be caught in moving parts.
15. 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
16. Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the rate
for which it was designed.
17. 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.
18. 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.

4
19. Store idle power tools out of the reach of chil-
dren 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.
20. Maintain power tools. Check for misalignment or
binding of moving parts, breakage of parts and
any other condition that may affect the power
tools operation. If damaged, have the power tool
repaired before use. Many accidents are caused
by poorly maintained power tools.
21. Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
22. Use the power tool, accessories and tool bits
etc. in accordance with these instructions and in
the manner intended for the particular type of
power tool, taking into account the working con-
ditions and the work to be performed. Use of the
power tool for operations different from those
intended could result in a hazardous situation.
Service
23. 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.
24. Follow instruction for lubricating and changing
accessories.
25. Keep handles dry, clean and free from oil and
grease.
GEB015-1
Specific Safety Rules
DO NOT let comfort or familiarity with product
(gained from repeated use) replace strict adherence
to belt sander safety rules. If you use this tool
unsafely or incorrectly, you can suffer serious per-
sonal injury.
1. Hold power tools by insulated gripping sur-
faces 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.
2. Ventilate your work area adequately when you
perform sanding operations.
3. Some material contains chemicals which may
be toxic. Take caution to prevent dust inhala-
tion and skin contact. Follow material supplier
safety data.
4. Always use the correct dust mask/respirator for
the material and application you are working
with.
5. Always use safety glasses or goggles. Ordinary
eye or sun glasses are NOT safety glasses.
6. Hold the tool firmly with both hands.
7. Make sure the belt is not contacting the work-
piece before the switch is turned on.
8. Keep hands away from rotating parts.
9. Do not leave the tool running. Operate the tool
only when hand-held.
10. This tool has not been waterproofed, so do not
use water on the workpiece surface.
SAVE THESE INSTRUCTIONS.
WARNING:
MISUSE or failure to follow the
safety rules stated in this instruction
manual may cause serious personal
injury.

5
FUNCTIONAL
DESCRIPTION CAUTION:
• Always be sure that the tool is switched off and unplugged before
adjusting or checking function on the tool.
Switch action
CAUTION:
• Before plugging in the tool, always check to see that the switch trigger
actuates properly and returns to the “OFF” position when released.
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 but-
ton.
To stop the tool from the locked position, pull the switch trigger fully, and then
release it.
Speed adjusting dial
For 9903, 9920 and 9404
The belt speed can be infinitely adjusted between 210 m and 440 m 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 direction of number
5; lower speed is obtained when it is turned in the direction of number 1.
Select the proper speed for the workpiece to be sanded.
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.
ASSEMBLY CAUTION:
• Always be sure that the tool is switched off and unplugged before
carrying out any work on the tool.
Installing or removing abrasive belt
Pull the lever all the way out and install the belt over the rollers, and then return
the lever to the original position.
1. Lock button
2. Switch trigger
1
2
003364
1. Speed adjusting dial
1
003368
1. Lever
1
003501

6
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.
Adjusting belt tracking
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 away from the edge of the base, use the adjusting knob to
adjust the belt tracking.
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.
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 adhering to the insides which might hamper further collec-
tion.
NOTE:
•If you connect a Makita vacuum cleaner to this tool, more efficient and
cleaner operations can be performed.
003376
1. Steel plate
2. Adjusting knob
004230
more than 6mm 1
2
1. Dust bag
2. Dust spout
1
2
003385
1. Dust bag
2. Fastener
1
2
003389

7
Connecting to Makita vacuum cleaner
Cleaner sanding operations can be performed by connecting the belt sander to
Makita vacuum cleaner.
When connecting to Makita vacuum cleaner, an optional hose 28 mm in inner
diameter is necessary.
OPERATION
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. Exces-
sive pressure may cause stalling, overheating of the motor, burning of the
workpiece and possible kickback.
Sanding shoe (optional accessory)
The sanding shoe readily allows you to sand workpieces more evenly.
1. Optional hose 28 mm in inner
diameter
2. Hose of vacuum cleaner
3. Vacuum cleaner
004231
1
23
003391
1. Sanding shoe
1
003394

MAINTENANCE CAUTION:
•Always be sure that the tool is switched off and unplugged before
attempting to perform inspection or maintenance.
Replacing carbon brushes
Remove and check the carbon brushes regularly. Replace them when they are
worn 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 identical carbon brushes.
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.
To maintain product SAFETY and RELIABILITY, repairs, any other mainte-
nance or adjustment should be performed by Makita Authorized Service Cent-
ers, always using Makita replacement parts.
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.
1. Limit mark
1
001145
1. Brush holder cap
2. Screwdriver
1
2
003396
•Abrasive belts
•Sanding shoe
•Dust bag
•Hose 28 mm in inner diameter
•Belt sander stand
Makita Corporation Anjo, Aichi, Japan
884285D220