Makita BO6040 User manual

Random Orbit Sander
Pad size
150 mm 16”)
MODEL BO6040
Orbits per minute Overall length Net weight
1,600 - 5,800 316 mm (12-1/2”) 2.7 kg (5.9 Ibs)
INSTRUCTION MANUAL
DOUBLE
INSULATION

GENERAL SAFETY RULES USA0021
(For All Tools)
WARNING! Read and understand all instructions. Failure
tofollow all instructions listed below, may result
in electric
shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
Work Area
1. Keep your work area clean and well lit. Cluttered benchesand dark areas invite
accidents.
2. Donot operate power tools in explosive atmospheres, such as in the presence
of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.
3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control.
Electrical Safety
4. DoubleInsulatedtools are equipped witha polarized plug (oneblade iswider
than 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 a polarized outlet. Do not change
the
plug in any way. Double insulation eliminates the need for the three
wire grounded power cord and grounded power supply system.
5. 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.
6. Do notexpose power tools torainor wet conditions. Water entering a power
tool will increase the risk
of electric shock.
7. Do not abuse the cord. Never use the cordtocarry the tools or pullthe plug
from anoutlet. Keepcord away from heat, oil, sharp edges or movingparts.
Replace damaged cords immediately. Damaged cords increase the risk of
electric shock.
8. When operating a power tooloutside, use an outdoor extension cordmarked
“W-A’ or “W.“ These cords are rated for outdoor use and reduce the risk
of electric shock.
Personal Safety
9.
10.
2
Stay alert, watch what you aredoingand use common sensewhen 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.
Dressproperly.
Do notwear loose clothing or jewelry. Contain long hair. Keep
your hair, clothing, and gloves away from moving parts. Looseclothes, jewelry
or long hair can be caught in moving parts.

11. Avoid accidental starting. Be sure switchis off before plugging in. Carrying
tools with your finger onthe switchor
plugging in tools that have the switch
on invites accidents.
12. Remove adjusting keys or wrenches before turning the tool on. A wrench
or a key that is left attached toa rotating part of the tool may result in personal
injury.
13.
Do notoverreach. Keepproper footing and balance at alltimes. Proper footing
and balance enables better control of the tool
in unexpected situations.
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.
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 handor against your body is unstable
and may lead to
loss of control.
16. Donotforce 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.
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.
18. Disconnectthe plugfrom 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.
20. Maintain tools with care. Keep cutting tools sharp and clean. Properly
maintained tools,
with sharp cutting edges are less likely to bindand are easier
to control.
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 serviced before using. Many accidents are caused by poorly
maintained tools.
22. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool, may become hazardous
when used on another tool.
SERVICE
23.
Tool service must be performed only by qualified repair personnel. Service
or maintenance performed by unqualified personnel could result in a risk of
injury.
24. When servicing a tool, use only identical replacement parts. Follow
instructions
in the Maintenance sectionof this manual. Use of unauthorized
parts or failure tofollow Maintenance Instructions maycreate a risk of electric
shock
or injury.
3

USBO40-2
Specific Safety Rules
1. Holdtool by insulated gripping surfaces when performingan 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. Hold the tool firmly.
3. Do not leave the tool running. Operate the tool only when hand-held.
4. This tool has not been waterproofed, so do not use water on the workpiece
5. Ventilate your work area adequately when you perform sanding operations.
surface.
SAVE THESE INSTRUCTIONS.
4

SYMBOLS
The followings show the symbols used for tool.
v ........................................................ volts
A ........................................................ amperes
Hz ........................................................ herts
?, ....................................................... alternating current
b ........................................................ no load speed
....................................................... Class II Construction
/min ....................................................... orbits per minute
5

FUNCTIONAL DESCRIPTION
Switch action
CAUTION:
Before plugging in the tool, always check to see that the switch actuates properly and
returns to the "OFF" position when the side of the switch lever
is depressed.
Orbits
1 1,600
2 2,100
3 3,600
Number
per min.
To start the tool, slide the switch lever
toward the
"I" position. For continuous
operation, press the front of the switch
lever to lock it. To stop the tool, press the
rear of the switch lever, then slide it
toward the
"0" position.
Oscillationrate Forcible pad rotating
per minute speed per min.
3,200 180
4,200 240
7,200 420
Speedadjustingdial
The rotating speed can bechanged by
turning the speed adjustingdial
to a given
number setting from 1to 5.
Higher speed is obtained when the dial is
turned inthe direction
of number 5.
And lower speed is obtained when it is
turned inthe direction of number
1.
5
Speedadjustingdial
5,800 1 1,600 670
I I
I
I 4 I 5,100 I 10,200 I 590 I
CAUTION:
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 adjustingfunction may no longer work.
6

Selectingaction mode
Use the change lever to change the rotation mode.
Forcible rotation mode is orbital action plus
rotationaction
of padfor rough sanding and
polishing.
I
Change lever
Forciblerotation mode
~~
Free rotation mode is orbital action of pad
I
for fine sanding
Change lever
Free rotation mode
Rotate the change lever counterclockwise for forcible rotation mode and clockwise for
free rotation mode.
7

Typicalapplications for sanding and polishing
Sanding
Use
/ Material
Paintwork:
Sanding
Repairs (scratches.rust stops)
Roughpaint stripping
Plastics:
Soft plastics(PVC/ABS)
HardDlastics (FRP)
Woods:
Softwood
Hardwood
Veneers
Metals:
Non-ferrousmetal (aluminum,copper)
Steel
Steel, rust removal
Hardmetal (stainlesssteel)
Polishing
Rotationmode
Forcible
/ Free
Free
Forcible / Free
Forcible
Forcible
/ Free
Forcible
Free
Forcible
/ Free
Free
Forcible
/ Free
Forcible
Forcible
Forcible
Speedcontrol
setting
1-3
2-3
4-5
1-3
1-3
1-3
3-5
1-2
1-3
3-5
4-5
4-5
Pad
Soft
Hard
Soft
Super soft
/ Soft
Soft
/ Hard
___
Super soft / Soft
Soft
Super soft
Soft
Soft
/ Hard
Super soft
Soft
Applyingwax
Removingwax
Polishing
Forcible
Forcible
Forcible
2-4
4-5
4-5
Spongepad
Felt pad
Wool pad
The above information is intended only as a guide. In each case, the most appropriate
sanding disc grain should bedetermined by preliminary trials.
The tool equipped with electronic function
is easy to operate because of the following
features.
Electronic speed controlfor obtaining constantspeed
Possible to get fine finish, becausethe rotating speed is kept constantly even under the
loadedcondition.
Soft start feature
Safety andsoft start becauseof suppressed starting shock.
8

ASSEMBLY
Installingside grip (optionalaccessory)
Remove one of the screws which secure
the head cover. Screw the side grip
on the
tool securely.The side grip can be installed
on either side of the tool.
Installingor removingabrasive
disc
CAUTION:
Always be sure that the tool is switched off and unpluggedbefore installing or removing
Always use hook-and-loopsystem abrasivediscs. Never use pressure-sensitiveabrasive
the abrasive disc.
discs.
To install the abrasive disc, first remove all
dirt or foreign matter from the pad. Then
attach the abrasive disc to the pad, using
the hook-and-loop system of the abrasive
disc and the pad. Be careful to align the
holes in the abrasive disc with those in the
pad.
To remove the disc from the pad, just pull
up from its edge.
D Q
i - Abrasive disc
9

Changing pad
Makita offers an extensive range of
optional super soft, soft and hard pads.
Remove the screw counterclockwise from
the center of the base with a hex wrench.
After changing the pad, tighten the screw
clockwise to secure the pad.
Dust collection (optional accessory)
If
a Makita hose is used, you can connect the cuff to the nozzledirectly. If other hose with
an inner diameter of
24 mm (15/16"), attach the joint betweenthe nozzle and the cuff.
Cuff 7 Hose 7
10

OPERATION
Sandingoperation
Turn the tool on and wait until it attains full
speed. Then gently place the tool on the
workpiece surface. Keep the pad flush with
the workpiece and apply slight pressure on
thetool.
CAUTION:
Never switch on the tool when it is in contact with the workpiece surface, causing an
Neverrun the tool without the abrasivedisc. You may seriously damage the pad.
Never force the tool. Excessive pressure may decrease the sanding efficiency, damage
injun/ tooperator.
the abrasivedisc or shorten tool life.
Polishing operation
CAUTION:
*Use only a Makita genuine sponge pad, felt pador wool pad (optionalaccessories).
*Always operate the tool at low speedto prevent work surfaces from heating abnormally.
*Never force the tool. Excessive pressure may decrease the polishing efficiency and cause
motor overload, resulting intool malfunction.
Applying
wax
Use an optional sponge pad. Apply wax to
the sponge pad or work surface. Run the
toolat low speed to smooth out wax.
NOTE:
*First, wax
a not conspicuous portion of the work surface to make sure that the tool will
not scratch the surface or result in unevenwaxing.
11

Removing wax
Use an optional felt pad. Run the tool at
low speed to removewax.
Polishing
Use an optional wool pad. Run the tool at
low speed and apply the wool padgently to
the work surface.
MAINTENANCE
CAUTl ON :
Always be sure that the tool is switched off and unplugged before attempting to perform
inspection or maintenance.
To maintainproducts SAFETY and RELIABILITY,repairs, any other maintenance or adjust-
ment shouldbe performed
by Makita Authorizedor Factory Service Centers, always using
Makita replacement parts.
12

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.
The accessories or attachments should be usedonly inthe proper and intendedmanner.
Hook-and-loopsystem abrasivedisc Hook-and-loopsystem sponge pad
(Hook & loopbacking and pre-punchedholes)
Grit
Qty. per Pkg. Grit Qty per Pkg.
# 180
# 400
5 1 50
Sanding cloth 150
(Forfine sanding)
Grit # 100, # 200, # 800
Pad 150
(Super soft, Soft, Hard)
*Joint
- Hook-and-loopsystem wool pad
Hook-and-loopsystem felt pad
Side grip
Hex wrench
13

31
76
32
14

Random Orbit Sander Part Description
Item No. Descriotion
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
HEAD COVER
t FLAT HEAD SCREW M8Xll
INDICATIONLABEL
TAPPING SCREW 4x30
GEAR HOUSINGCOMPLETE
0 RING 62
HEX. NUT M10
FLAT WASHER 10
UPPER BALANCEWEIGHT
SPIRAL BEVEL GEAR 42
BALL BEARING 6201LLB
PAN HEAD SCREW M4X16
CAP
PAN HEAD SCREW M4X12
KNOBCOMPLETE
SPRINGHOLDER
COMPRESSIONSPRING 4
HOLDER
SKIRTCOMPLETE
STOP RING (EXT) WR 55
BALL BEARING 681lLLB
INTERNALGEAR 29
SPINDLE
LOWER BALANCE WEIGHT
SLEEVE
BALL BEARING 6001DDW
BALL BEARING 6001DDW
SPUR GEAR
26 COMPLETE
HEX SOCKET HEAD BOLT M8X14
BEARING RtlAlNER
80 COMPLETE
RUBBER GUARD
PAD 150
RETAINING RING
S-6
SPtRAL BEVEL GEAR 9
BALL BEARING 6001LLB
FLAT WASHER 12
GEAR HOUSING COVER
FAN57
ARMATUREASS'Y (withitem 39.41-43)
1
2
4
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
70
71
72
73
74
75
76
77
Qty
Use Item No Descriotion
1
..
INSUL~~I~N WASHER
FLAT WASHER 7
BALL BEARING 627DDW
LABYRINTH RUBBER RING 22
MAGNET SLEEVE
STOP RING E 4
BAFFLEPLATE
TAPPING SCREW 4x55
RETAINER
INSULATIONCOVER
FIELD
NAME
PCATE
TAPPING SCREW 4x18
STRAIN RELIEF
TAPPING SCREW PT3X10
SWITCH BLOCK
BRUSH HOLDER
A.C. CARBON BRUSHCB-318
POWER SUPPLY CORD
CORD GUARD
8
SWITCH ST115A-40
COVER
INDICATION LABEL
REAR COVER
TAPPING SCREW 4x18
SWITCH KNOB
MAKITA LABEL
MOTOR HOUSING
BRUSHHOLDER
COMPRESSION SPRING4
SWITCH LEVER
CONTROLLER
RETAINING RING 5-12
PAN HEAD SCREW M4X12
PAN HEAD SCREW M4X12
WAVE WASHER
6
ow. Used
1
1
1
1
1
1
2
2
2
1
1
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
1
15

WARNING
Some dust created by power sanding, sawing, grinding, drilling, and other
constructionactivitiescontainschemicals known
[to the State of Califomia] to
cause cancer, birth defects or other reproductive harm. Some examples of
these chemicalsare:
@ Leadfrom lead-based paints,
0 Crystalline silica from bricks and cement and other masonry products, and
@ Arsenic and chromiumfrom chemically-treatedlumber.
Your risk from these exposures vanes, 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 masksthat are speciallydesigned
to filterout microscopic particles.
i
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 ServiceCenters. If inspection shows
the trouble is caused by defective workmanship or material, Makita will repair (or at our option,
replace) without charge.
ThisWarranty does not apply where:
repqrs
repurs have been madeorattempted by others:
are required because of normal wear and tear:
The tool has been abused, misused orimproperly maintained;
alterations have been madetothe tool.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES FROM THE SALE OR USE OFTHE PRODUCT. THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THE TERM OFTHIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,”
AFTER THE ONE-YEAR TERM OFTHISWARRANTY.
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 onhow 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
884338-061
PRINTED IN JAPAN
2001 -2-N