makita 9902 3-by-21-Inch Belt Sander Instruction Manual

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
INSTRUCTION MANUAL

WARNING:
For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
www.makitatools.com

SPECIFICATIONS

(4″ x 24″)
Belt speed| 440 m
(1,4 40 ft.) /min.| 210 – 440 m (690 – 1,440 ft.) /min.
Overall length| 296 mm (11-5/8″)| 334 mm (13-1/8″)
Net weight| 4.3 kg (9.5 Ibs)| 4.3 kg (9.5 Ibs)| 4.5 kg (9.9 Ibs)| 4.7 kg (10.3 Ibs)

• Manufacturer reserves the right to change specifications without notice.
• Specifications may differ from country to country.

GENERAL SAFETY RULES

USA002-2
(For All Tools)
WARNING:
Read and understand all instructions. Failure to follow 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 benches and dark areas invite accidents.

2. Do not 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. Double insulated tools are equipped with a polarized plug (one blade is wider 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 0insulation eliminates the need for the three wire 0grounded 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 not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

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.

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.
   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.

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.

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.

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.

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.

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. 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.

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.

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. 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.

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.

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 main- tenance 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 section of this manual. Use of unauthorized parts or failure to follow Maintenance instructions may create a risk of electric shock or 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 number, the heavier the cord.
Table 1: Minimum gage for cord

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.
2. Always use safety glasses or goggles. Ordinary eye or sun glasses are NOT safety glasses.
3. Hold the tool firmly with both hands.
4. Make sure the belt is not contacting the workpiece before the switch is turned on.
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 surface.
8. Ventilate your work area adequately when you perform sanding operations.
9. Use of this tool to sand some products, paints and wood could expose user to dust containing hazardous substances. Use appropriate respiratory protection.

SAVE THESE INSTRUCTIONS
WARNING:
MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury.

SYMBOLS

USD204-1
The followings show the symbols used for tool.
V ………………….. volts
A ………………….. amperes
Hz ………………… hertz
……………. alternating current
……………….. Class II Construction
m/min …………… meter per minute

FUNCTIONAL DESCRIPTION

CAUTION:

• Always be sure that the tool is switched off and unplugged before adjusting or checking function on the tool.

1. Lock button
2. Switch trigger

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.
• 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.
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 trigger fully, then release it.
Speed adjusting dial

1. Speed adjusting dial

For 9903, 9920 and 9404
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 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.

1. Lever

Installing or removing abrasive belt Pull the lever all the way out and install the belt over the rollers, then return the lever to the original position. 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.

1. Steel plate
2. Adjusting knob

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 (1/4”) away from the edge of the base, use the adjusting knob to adjust the belt tracking.

1. Dust bag
2. Dust spout

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. Dust bag
2. Fastener

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.
NOTE:

• If you connect a Makita vacuum cleaner to this tool, more efficient and cleaner operations can be performed.

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. Excessive pressure may cause stalling, overheating of the motor, burning of the workpiece and possible kickback.

1. Sanding shoe

Sanding shoe (optional accessory)
The sanding shoe readily allows you to sand workpieces more evenly.

MAINTENANCE

CAUTION:

• Always be sure that the tool is switched off and unplugged before attempting to perform inspection or maintenance.

1. Limit mark

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 identical carbon brushes.

1. Brush holder cap
2. Screwdriver

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 maintenance or adjustment should be performed by Makita Authorized or Factory Service Centers, 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.

• Abrasive belts
• Sanding shoe
• Dust bag

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

MAIL THIS PORTION
Your answers to the following questions are appreciated.

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

FACTORY SERVICE CENTERS

1-800-4-MAKITA
RETAIN THIS PORTION FOR YOUR RECORDS

ALABAMA
2365 Pelham Parkway
Pelham, AL 35124
(205) 620-1791
ARIZONA
3707 E. Broadway Rd., Ste. 6
Phoenix, AZ 85040
(602) 437-2850
ARKANSAS
Shackleford Shopping Center
240 South Shackleford Rd.,
Ste. C
Little Rock, AR 72211
(501) 224-5733
CALIFORNIA
41850 Christy St.
Fremont, CA 94538-5107
(510) 657-9881
1421 N. Clovis Ave., Ste. 112
Fresno, CA 93727
(559) 252-5166
14930 Northam St.
La Mirada, CA 90638-5753
(714) 522-8088
1970 Fulton Avenue
Sacramento, CA 95825
(916) 482-5197
1440 South “E” Street
San Bernardino, CA 92408
(909) 885-1289
7674 Clairemont Mesa Blvd.
San Diego, CA 92111
(858) 278-4471
1565 Winchester B.
Campbell, CA 95008-0501
(408) 379-0377
16735 Saticoy St., Ste. 105
Van Nuys, CA 91406
(818) 782-2440| COLORADO
11839 E. 51st Ave.
Denver, CO 80239-2709
(303) 371-2850
FLORIDA
620 Douglas Ave. Suite 1302
Altamonte Springs, FL 32714
(407) 774-6000
750 East Sample Road
Pompano Beach, FL 33064
(954) 781-6333
Thompson Center Waters
5501 W. Waters Ave., Ste. 406
Tampa, FL 33634
(813) 886-8292
GEORGIA
4680 River Green Parkway
Duluth, GA 30096-2566
(770) 476-8911
ILLINOIS
1450 Feehanville Dr.
Mt. Prospect, IL 60056-6011
(847) 297-3100
INDIANA
8403 Michigan Road, Unit 1
Indianapolis, IN 46268
(317) 334-9980
KANSAS
8819 W. 95th St.
Overland Park, KS 66212
(913) 642-1111
KENTUCKY
1215 S. Hurstbourne Parkway
Louisville, KY 40222
(502) 326-3740| LOUISIANA
5626 Jefferson Hwy.
Harahan, LA 70123
(504) 733-4138
MARYLAND
7541 – 45 Ritchie Highway
Glen Burnie, MD 21061
(410) 590-0160
MASSACHUSETTS
232 Providence Hwy.
Westwood, MA 02090
(617) 461-9754
MINNESOTA
6427 Penn Ave. South
Richfield, MN 55423
(612) 869-5199
MISSOURI
9876 Watson Road
St. Louis, MO 63126-2221
(314) 909-9889
NEBRASKA
4129 S. 84th St.
Omaha, NE 68127
(402) 597-2925
NEVADA
3375 S. Decatur Blvd.
Suites. 22 – 24
Las Vegas, NV 89102
(702) 368-4277
NEW JERSEY
251 Herrod Blvd.
Dayton, NJ 08810-1539
(609) 655-1212| NEW YORK
4917 Genessee Street
Cheektowaga, NY 14225
(716) 685-9503
131-35 31st Ave.
Flushing, NY 11354
(718) 886-0971
NORTH CAROLINA
3501-G S. Tryon St.
Charlotte, NC 28217
(704) 527-0611
OHIO
6253 E. Main St.
Columbus, OH 43213
(614) 860-0222
6379 Pearl Road
Parma Heights, OH 44130
(440) 843-7555
1617 E. Kemper Rd.
Sharonville, OH 45246
(513) 771-0788
OKLAHOMA
552 E. Memorial Road
Oklahoma City, OK 73114
(405) 752-2655
OREGON
828 19th Avenue., N.W.
Portland, OR 97209
(503) 222-1823
PENNSYLVANIA
Springwater Plaza
364 Wilmington W. Chester
Pike
Glen Mills, PA 19342
(610) 459-4122
6200 Babcock Blvd
Pittsburgh, PA 15237
(412) 366-6363| PUERTO RICO
200 Guayama St.
Hato Rey, PR 00917
(787) 250-8776
TENNESSEE
4655 Nolensville Rd.
Nashville, TN 37211
(615) 331-9922
TEXAS
12801 Stemmons Fwy Ste. 809
Farmers Branch, TX 75234
(972) 243-1150
12701 Directors Dr.
Stafford, TX 77477-3701
(281) 565-8665
3453 IH-35 North, Ste. 101
San Antonio, TX 78219
(210) 228-0676
UTAH
145 E. 1300 S., Ste. 101
Salt Lake City, UT 84115
(801) 359-3410
WASHINGTON
22220 84th Ave. So., Bldg. A
Kent, WA 98032
(253) 395-8055
WISCONSIN
Lincoln Plaza Shopping Ctr.
2245 S. 108th St. West Allis, WI
53227
(414) 541-4776
---|---|---|---|---

CUSTOMER’S RECORD

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.

Date Purchased…………………………
Dealer’s Name & Address……………….
Model No……………………………………….
Serial No……………………………………………….

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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