Milwaukee 5900-2 Care And Operation Instructions Manual
- Category
- Power tools
- Type
- Care And Operation Instructions Manual
*
READ
a
nd
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
a
list 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
a
three-hole
electrical
receptacle.
If
adapter
is
used
to
accommodate
two-pronged
receptacle,
the
adapter
wire.
must
be
attached
to
a
known
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.
1
1
. 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
a
vise
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.
3
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.
A
double
insulated
or
grounded
tool
may
be
made
live
if
the
blade
or
bit
comes
in
contact
with
live
wiring
in
a
wall,
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
a
live
termina
It
your
unit
is
for
use
on
less
than
150
volts,
it has
a plug
that
looks
like
Fig.
"A
.
If
it
is
for
use
on
150
to
250
volts,
it
has
a
plug
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
o
a
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.
A
GROUND-
Fig.
B
ING
EAR
BLADE
NOTE:
RECEPTACLE
MUST
BE
GROUNDED
FOR
IF
IN
DOUBT
CALL
A
QUALIFIED
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
a
3
wire
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
5 volts
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
r
10
1
8
available
16
16
14
14
12
12
12
10
8
8
8
6
as
flexible
extension
14
12
.10
1
8
6
4
cord.
400
Ft.
12
10
8
6
4
4
500
Ft.
12
10
8
6
4
2
600
Ft.
10
8
6
4
2
2
800
Ft.
10
8
6
4
2
1
0
1000
Ft.
8
6
4
2
1
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
(
«
ABRASIVE
BELTS
AND
SELECTION
The 5900
and
5900-2
3"
MILWAUKEE
Belt
Sanders
are
furnished
with
a
49-37-3120,
1
20
grit,
Aluminum
Oxide
closed
coat
belt.
The 5910
and
5910-2 4
'
Ml LW
AUK
EE
Belt
Sanders
are
furnished
with
a
49-37-41
20,
1
20
grit.
Aluminum
Oxide
closed
coat
belt.
These
belts
are
recommended
for
finishing
work
only.
Refer
to
page 8
for
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. A
locking
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 a
forward
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
a
gash in
the
work.
To
obtain a
very
fine
surface,
change
belts
two
or
three
times,
using
a
finer
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
a
coarse
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 a fast,
coarse
cut
across or
at
an
angle
to the
wood
grain.
This will
leave
a
rough
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
a new
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
a
small
felt
pad
about
1/8"
thick
in
a size
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 a
sweeping
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 a
dirty
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
a
vacuum
bag,
a
rear
motor
housing
cover, a
vacuum
heel
and a
gasket.
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
a
soft
brush.
This
will
permit
the
bag
to
"breathe"
better.
Carefully
slide
the
bag
over
the
wire
again
and
replace
on
the
Belt
Sander.
8
IF
THE
VACUUM
SYSTEM
FAILS
lt
.
'
s
usual|
y
because
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
a
small
paint
brush
to
remove
the
dust
accumulations
around
the
drum
assemblies
and
rear
motor
housing.
Care
should
be
thh |
that
0,1
°r
9reaSe
deposits
are
remove
d
from
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
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Milwaukee 5900-2 Care And Operation Instructions Manual
- Category
- Power tools
- Type
- Care And Operation Instructions Manual
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