Milwaukee 5900-2 User manual

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READ and keep this for future reference
The Care and Operation of
»*
HEAVY-DUTY
Belt Sander
Cat. No. 5900
Cat. No. 5900-2 (240 V)
With 3" Belt
>
Shown with optional
VACUUM BAG KIT
Cat. Mo. 48-09-0100
IMPORTANT-Before placing tool in operation, record the following information from name plate.
Model Number Serial Number _Date of Purchase
MILWAUKEE ELECTRIC TOOL-CORPORATION
13135 West Lisbon Road •Brookfield. Wisconsin 53005

2
1.
That every tool manufactured by MILWAUKEE is produced in accordance with
applicable Standards for Safety of Underwriters' Laboratories and American
National Standards (ANSI).
2.
That compliance with applicable safety standards is assured by independent in-
spection and testing conducted 6y Underwriters' Laboratories (UL).
3. That every motorized tool manufactured by MILWAUKEE is fully inspected.
4. That every tool has with it adequate instructions and alist of safety rules for the
protection of the user.
SAFETY INSTRUCTIONS FOR ALL POWER TOOLS
1. KNOW YOUR POWER TOOL. Read owner's manual carefully. Learn its applica-
tions and limitations as well as the specific potential hazards peculiar to this tool
2. GROUND ALL TOOLS-UNLESS DOUBLE-INSULATED. If tool is equipped
with three-prong plug, it should be plugged into athree-hole electrical receptacle.
If adapter is used to accommodate two-pronged receptacle, the adapter wire.must
be attached to aknown ground. Never remove third prong.
3. KEEP GUARDS IN PLACE and in working order.
4. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents
5. AVOID DANGEROUS ENVI RONMENT. Don't expose power tools to rain or use
in damp, wet, or gaseous or explosive locations. Keep work area well lit.
6. KEEP CHILDREN AWAY. All visitors should be kept safe distance from work
area.
7. STORE IDLE TOOLS. When not in use, tools should be stored in dry, high or
locked-up place-out of reach of children.
8. DON'T FORCE TOOL. It will do the job better and safer at the rate for which it
was designed.
9. USE RIGHT TOOL. Don't force small tool or attachment to do the job of a
heavy-duty tool.
10. WEAR PROPER APPAREL. No loose clothing or jewelry to get caught in moving
parts. Rubber gloves and footwear are recommended when working outdoors.
11.USE SAFETY GLASSES with most tools. Also face or dust mask if cutting opera-
tion is dusty.
12. DON'T ABUSE CORD. Never carry tool by cord or yank it to disconnect from
receptacle. Keep cord from heat, oil and sharp edges.
13. SECURE WORK. Use clamps or avise to hold work. It's safer than using your
hand and it frees both hands to operate tool.
14. DON'T OVERREACH. Keep proper footing and balance at all times.
15. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean at all times for best
and safest performance. Follow instructions for lubricating and changing acces-
sories. CAUTION: Do not use carbon tetrachloride.
16. DISCONNECT TOOLS. When not in use, before servicing; when changing acces-
sories such as blades, bits, cutters, etc.

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17 .
18.
19.
20.
21 .
22 .
23.
REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see
that keys and adjusting wrenches are removed from tool before turning it on.
AVOID ACCIDENTAL STARTING. Don't carry plugged-in tool with finger on
switch. Be sure switch is off when plugged in.
WEAR EAR PROTECTORS when using for extended periods.
ACCESSORIES. The use of any accessories other than those listed or recom-
mended for this particular tool may be hazardous.
KEEP HANDS AWAY FROM CUTTING EDGES AND ALL MOVING PARTS
USE INSULATED SURFACES. Adouble insulated or grounded tool may be made
live if the blade or bit comes in contact with live wiring in awall, floor, ceiling,
etc. Always check the work area for live wires and hold the tool by the insulated
surfaces when making "blind" or plunge cuts.
GRINDING WHEELS. Use only grinding wheels with
high as "No Load RPM" marked on the name plate.
"Safe Speed" at least as
GROUNDING INSTRUCTIONS
This tool should be grounded while in use to protect the operator from electric
shock. The tool is equipped with an approved three-conductor cord and three-prong
grounding-type plug to fit the proper grounding-type receptacle. The green conductor
in the cord is the grounding wire. Never connect the green wire to alive termina It
your unit is for use on less than 150 volts, it has aplug that looks like Fig. "A .If it
is for use on 150 to 250 volts, it has aplug that looks like Fig. "C".
NOTE
The use of 3-prong adapters in Canada is prohibited by the Canadian Electrical Code.
An adapter Fig. "B" is available for connecting Fig. "A" plugs to two-prong recep-
tacles. The green grounding ear extending from the adapter must be connecte oa
permanent ground such as to properly grounded outlet box. No adapter is available
for Fig. "C" plugs.
COVER OF
OUTLET BOX
GROUNDING
BLADE
COVER OF COVER OF
©GROUNDED *
OUTLET BOX <5D GROUNDED^
OUTLET BOX ©
CD e
©Adapter ^©©
GREEN GROUNDING Fig. C
Fig. AGROUND- Fig. B
ING EAR BLADE
NOTE: RECEPTACLE MUST BE GROUNDED FOR
IF IN DOUBT CALL AQUALIFIED ELECTRICIAN
TACLE CHECKED FOR GROUND.
SAFE USE OF ADAPTER;
AND HAVE THE RECEP-
EXTENSION CORDS
Use only three-wire extension cords which have three-prong grounding-type plugs
and three-pole receptacles which accept the tool's plug. Replace or repair damaged
cords.

EXTENSION CORD CHART
When an extension cord is used, it should also be a3wire cord to permit proper
grounding of the tool. As the distance from the supply outlet increases, heavier gauge
extensions are required. The use of extension cords of inadequate size wire causes a
serious drop in voltage, loss of power and possible motor damage. This table is based
on limiting line voltage drop to 5volts at 150% of rated amperes.
Ampere rating 0- 2.10- 3.5- 5.10- 7.10- 12.1-
16.0
(on Nameplate) 2.00 3.4 5.00 7.0 12.0
Ext. Cable Length Wire Size
25 Ft. 18 18 18 18 16 14
50 Ft. 18 18 18 16 14 12 Not
75 Ft.
100 Ft.
150 Ft.
200 Ft.
300 Ft.
18
18
18 16 14 12 10 normally
1
6
14 12 r10 18available
16
16
14
14
12
12
12
10
8
8
8
6
as flexible
extension
14 12 .10 1864cord.
400 Ft. 12 10 8644
500 Ft. 12 10 8642
600 Ft. 10 86422
800 Ft. 10 86421
0
1000 Ft. 86421
IF USING EXTENSION CORD OUT OF DOORS
OUTDOOR USE. BE SURE IT IS RATED FOR
IDENTIFICATION OF PARTS
%
TRIGGER
FRONT
HANDLE
HEEL
REAR
DRUM FRONT
BELT LOCK BUTTON LEVER DRUM
(IN "ON" POSITION) BRUSH
CAP
BAFFLE
VACUUM BAG
/
REAR MOTOR
HOUSING COVER
REAR MOTOR HOUSING
TIMING
GEAR
COVER
BELT ALIGNMENT KNOB
(
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ABRASIVE BELTS AND SELECTION
The 5900 and 5900-2 3" MILWAUKEE Belt Sanders are furnished with a49-37-3120,
120 grit, Aluminum Oxide closed coat belt. The 5910 and 5910-2 4'Ml LWAUK EE
Belt Sanders are furnished with a49-37-41 20, 120 grit. Aluminum Oxide closed coat
belt. These belts are recommended for finishing work only. Refer to page 8for chart
on complete selection of MILWAUKEE Sanding Belts for your portable Belt Sander.
CHANGING THE ABRASIVE BELT
Pull the belt lock button lever located on the right side of the sander to "OFF",
toward the rear drum. Stand the sander on its front drum and push down on rear
handle firmly until the pulley locks into position. This releases tension on the
abrasive belt for easy removal.
Hold the new belt so the arrow which is printed on the inside of the belt is on top of
the drums and is facing to the front of the sander. Arrows are indicated on the belt
tension bracket plate to indicate the direction the belt travels. Be sure belt is pushed
completely on to the drums. Move the belt lock button lever to the "ON" position.
The front drum will snap into position with the proper tension on the abrasive belt.
Adjust the belt for proper alignment.
ADJUST THE ALIGNMENT OF THE BELT
Turn the sander over so the belt can run free. While holding it firmly with one hand,
start the motor by squeezing the trigger switch to its "ON" position. Adjust the belt
aligning knob located on your right, (the left side of the Belt Sander), by turning it
in either direction. Movement of this knob changes the angle of the front drum
assembly and alters the alignment of the belt. Move the nut until the edge of the belt
is running flush with the rear drum. The edge of the belt will extend beyond the edge
of the front drum. DO NOT LET THE BELT* RUB ON THE FRAME OF THE
SANDER.
OPERATION
Hold the Sander off the work with one hand holding the front handle and the other
holding the rear handle. Always start and stop the Sander off the work. Alocking
button is provided on the switch for extended use. To use the lock button, depress
the trigger switch, push the lock button in and release the trigger. To release the lock
button, depress the trigger and release. With the motor running full speed, apply the
Sander to the work with aforward motion. The Sander should be fed back and forth
parallel to the grain of the wood. DO NOT APPLY HEAVY PRESSURE. The weight
of the Sander is sufficient for horizontal sanding.
As the Sander is fed back and forth over the surface, guide the Sander sideways.
Overlap strokes keeping parallel to the grain and cover the entire surface to be sanded.
Work the entire surface down evenly and do not allow the Sander to stop moving or
stay too long in one small area. Short overlapping strokes produce the best results.
Avoid tilting the machine when feeding as belt will make agash in the work. To
obtain avery fine surface, change belts two or three times, using afiner grit for each
change and working the entire surface with each grit. Do not use an abrasive belt after
it has become worn or clogged.

USE ONLY IDENTICAL REPLACEMENT PARTS
Parts List Available On Request.
When ordering, include Catalog No. and Serial No. of Tool.
Write: MILWAUKEE ELECTRIC TOOL CORP. SERVICE DEPT.
13135 W. Lisbon Rd. Brookfield, Wl. 53005
OPERATION (Continued)
When rough boards or wide and uneven pieces have to be sanded, don't use extra
pressure as this will slow the sanding action. Use acoarse grit belt and hold the sander
at an angle to the grain of the wood. The movement of the sander remains parallel
with the grain as before, but the abrasive makes afast, coarse cut across or at an
angle to the wood grain. This will leave arough surface and must be finished with a
belt of finer grit with the sander held and fed parallel to the grain as described earlier.
SANDING HINTS
TO REMOVE OLD PAINT OR VARNISH
Use an open coat belt to prevent clogging. Make short backward strokes, lifting
quickly at the end of each stroke to prevent burning the finish. Start each new stroke
in anew area.
DOORS AND TRIM
When sanding doors, trim and other millwork, be careful not to sand cross grain at
the joints where the direction of the grain changes.
SANDING VERY SMALL AREAS
Make asmall felt pad about 1/8" thick in asize proportional to the area to be
sanded. Insert the pad under the base plate pad to reduce the sanding area. Use for
sanding glue joints, smoothing plaster patches or feathering taped joints on Sheetrock
walls.
METALS, PLASTICS AND STONE
Use asweeping rotary movement as grain is no problem with these materials. Overlap
every stroke to produce an even surface. Never use oil or other coolants as the belt
will throw the liquid.
MAINTENANCE
All servicing other than recommended in this instruction manual must be done by an
Authorized MILWAUKEE Service Station.
The MILWAUKEE Electric Tool Corporation assumes no responsibility
for any damage or accidents resulting. from the use, misapplication, or
nonadherence to safety precautionary measures.

BRUSHES AND COMMUTATOR
Failure of the motor to start or to operate efficiently
is usually caused by worn or damaged brushes, brushes
that stick in the holders and fail to make proper
contact with the commutator, or adirty or rough
commutator. Occasional inspection of brushes and
commutator is recommended
To inspect the brushes, remove plug from power source. Unscrew brush retainer caps
located on the motor housing. Pull out brush retainer springs and brushes.
Replace brushes when worn down to 3/16". Always replace both brushes at the same
time. When inspecting brushes, also check the commutator for wear. If badly worn,
send the complete tool to an Authorized MILWAUKEE Service Station for under-
cutting and dressing of the commutator.
LUBRICATION
The MILWAUKEE Belt Sander is equipped with greased, sealed bearings and requires
no further lubrication.
TIMING BELT
After approximately 200 hours of use the timing belt should be checked. Remove
the timing belt cover. Check the teeth on the belt. If excessively worn or missing,
replacement can be obtained through an Authorized MILWAUKEE Service Station.
Replace timing belt, cover and screw.
VACUUM BAG KIT (Optional) 3" Cat. No. 48-09-0100, 4" Cat. No. 48-09-0200
The Vacuum Bag Kit can be used on all models of MILWAUKEE Belt Sanders. The
kit consists of avacuum bag, arear motor housing cover, avacuum heel and agasket.
To assemble the Vacuum Bag Kit, remove the two screws holding the rear motor
housing cover. Replace the cover with the one furnished with the kit. Next, turn the
belt sander over and remove the black heel located near the rear drive pulley. Replace
the heel with the Vacuum Pick Up Heel supplied. Remove the timing gear cover. Re-
move gasket and replace it with gasket supplied with the kit so both openings in the
casting are exposed. Replace timing gear cover and attach the vacuum bag to the rear
motor housing cover.
TO EMPTY THE VACUUM BAG
For most efficient operation, empty the dust bag when it is half full. Open the
zipper and shake out the dust. Occasionally slip the bag off the wire frame and turn
the bag inside out. Brush the dust accumulation from the lining with asoft brush.
This will permit the bag to "breathe" better. Carefully slide the bag over the wire
again and replace on the Belt Sander.

8IF THE VACUUM SYSTEM FAILS
lt
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'susual|ybecause one of the two openings in the rear motor housing is clogged
with dust. Lay sander on its side, remove timing gear cover and clear out the open-
ings. Gently tap sander so that the dust falls out. Replace cover and continue Sanding.
CLEANING TH? BELT SANDER
Keep air vents, rear motor housing and drums clean and free of dust and other
debris. Remove the abrasive belt and use asmall paint brush to remove the dust
accumulations around the drum assemblies and rear motor housing. Care should be
thh |
that 0,1 °r9reaSe deposits are removedfrom the drums to prevent slippage of
BELT SPECIFICATIONS
BELTS
PER
CAT. NO. SIZE PACK GRIT USE
49-37-3036 3x 24 10 36 (2) Coarse -for fast sanding of wood
49-37-4036 4x 24 10 36 (2) and non-ferrous material.
49-37-3060 3x24 10 60(1/2) Medium -for general smoothness
49-37-4060 4x 24 10 60 (1/2) of wood or metal.
49-37-3120 3x 24 10 120 (3/0) Fine -for finish work on metal
49-37-4120 4x24 10 120 (3/0) and wood.
LIMITED WARRANTY
Every MILWAUKEE Tool is thoroughly inspected and tested before leaving the
factory. Should any trouble develop, return the complete tool prepaid to the
Factory, Branch of nearest Authorized MILWAUKEE Service Station. If inspec-
t'on shows the trouble is caused by defective workmanship or material, all repairs
wil be made without charge and the tool will be returned, transportation prepaid.
This warranty does not apply where: (1) repairs or attempted repairs have been
made by persons other than Factory, Branch or Authorized Service Station per-
sonnel; (2) repairs are required because of normal wear; (3) the tool has been
abused or involved in an accident; (4) misuse is evident such as caused by over-
loading the tool beyond its rated capacity; (5) the tooUias been used after partial
failure or (6) the tool has been used with an improper accessory. No other war-
wanty written or verbal, is authorized.
MILWAUKEE ELECTRIC TOOL CORPORATION
13135 W. LISBON ROAD BROOKFIELD, WISCONSIN 53005
Litho in U.S.A.
.58-12-1430 377