Random Orbit Sander
MODEL BO6040
003278
DOUBLE
INSULATION
I N S T R U C T I O N M A N U A L
WARNING:
For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
w w w. m a k i t a t o o l s . c o m
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6. Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 ser-
viced before using. Many accidents are
caused by poorly maintained tools.
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.
22. Use only accessories that are recom-
mended by the manufacturer for your
model. Accessories that may be suitable for
one tool, may become hazardous when used
on another tool.
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.
SERVICE
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.
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.
3
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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 num-
ber, the heavier the cord.
Table 1: Minimum gage for cord
Volts
120 V
Total length of cord in feet
Ampere Rating
25 ft.
50 ft.
100 ft.
150 ft.
More Than
Not More Than
AWG
0
6
10
12
6
18
18
16
14
16
16
16
12
16
14
14
14
12
12
10
12
16
Not Recommended
SPECIFIC SAFETY RULES
USB040-4
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.
5. This tool has not been waterproofed, so
do not use water on the workpiece sur-
face.
6. Ventilate your work area adequately when
you perform sanding operations.
7. Use of this tool to sand some products,
paints and wood could expose user to
dust containing hazardous substances.
Use appropriate respiratory protection.
2. Always use safety glasses or goggles.
Ordinary eye or sun glasses are NOT
safety glasses.
3. Hold the tool firmly.
4. Do not leave the tool running. Operate the
tool only when hand-held.
4
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SAVE THESE INSTRUCTIONS
WARNING:
MISUSE or failure to follow the safety rules stated in this
instruction manual may cause serious personal injury.
SYMBOLS
USD205-1
The followings show the symbols used for tool.
V .......................volts
................alternating current
....................no load speed
A .......................amperes
n
˚
Hz .....................hertz
....................Class II Construction
.../min................orbits per minute
5
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FUNCTIONAL
DESCRIPTION
CAUTION:
•
Always be sure that the tool is switched off and
unplugged before adjusting or checking function on the
tool.
003287
Switch action
CAUTION:
•
Before plugging in the tool, always check to see that the
slide switch actuates properly and returns to the “OFF”
position when the rear of the slide switch is depressed.
1
•
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.
1. Slide switch
To start the tool, slide the slide switch toward the “I (ON)”
position. For continuous operation, press the front of the
slide switch to lock it.
To stop the tool, press the rear of the slide switch, then slide
it toward the “O (OFF)” position.
003289
Speed adjusting dial
The rotating speed can be changed 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 direc-
tion of number 5. And lower speed is obtained when it is
turned in the direction of number 1.
Refer to the table for the relationship between the number
settings on the dial and the approximate rotating speed.
003290
1
1. Speed adjusting dial
Number
Orbits per min.
Roto-orbit pad rotating
speed per min.
1
2
3
4
5
1,600
2,100
3,600
5,100
5,800
180
240
420
590
670
CAUTION:
•
If the tool is operated continuously at low speeds for a
long time, the motor will get overloaded, resulting in tool
malfunction.
6
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•
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.
The tools equipped with electronic function are easy to oper-
ate because of the following features.
•
Electronic constant speed control
Possible to get fine finish, because the rotating speed is
kept constantly even under the loaded condition.
•
Soft start feature
Soft start because of suppressed starting shock.
003292
Selecting the action mode
Use the change lever to change the rotation mode.
Roto-orbit mode is orbital action plus rotation action of pad
for rough sanding and polishing.
1
Roto-orbit mode
1. Change lever
003293
Random orbit mode is orbital action of pad for fine sanding.
1
Random orbit mode
1. Change lever
Rotate the change lever counterclockwise for roto-orbit mode
and clockwise for random orbit mode.
CAUTION:
•
Do not rotate the change lever when the tool is running.
The tool will be damaged.
7
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Typical applications for sanding and polishing
003294
Sanding
Use / Material
Mode selection
Speed control setting
Pad
Paintwork:
Sanding
Repairs (scratches, rust spots)
Rough paint stripping
Random
Roto-orbit/Random
Roto-orbit
1 - 3
2 - 3
4 - 5
Soft
Hard
Soft
Plastics:
Soft plastics (PVC/ABS)
Hard plastics (FRP)
Roto-orbit/Random
Roto-orbit
1 - 3
1 - 3
Super soft/Soft
Soft/Hard
Woods:
Softwood
Hardwood
Veneers
Random
Roto-orbit/Random
Random
1 - 3
3 - 5
1 - 2
Super soft/Soft
Soft
Super Soft
Metals:
Non-ferrous metal (aluminum, copper)
Steel
Steel, rust removal
Roto-orbit/Random
Roto-orbit
1 - 3
3 - 5
4 - 5
4 - 5
Soft
Soft/Hard
Super soft
Soft
Roto-orbit
Roto-orbit
Hard metal (stainless steel)
Polishing
Use / Material
Mode selection
Roto-orbit
Roto-orbit
Speed control setting
Pad
Sponge pad
Felt pad
Applying wax
Removing wax
Polishing
2 - 4
4 - 5
4 - 5
Roto-orbit
Wool pad
The above information is intended only as a guide. In each
case, the most appropriate sanding disc grain should be
determined by preliminary trials.
ASSEMBLY
CAUTION:
•
Always be sure that the tool is switched off and
unplugged before carrying out any work on the tool.
003297
Installing side grip (optional accessory)
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.
1
1. Side grip
8
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003302
Installing or removing abrasive disc
CAUTION:
•
Always use hook-and-loop system abrasive discs. Never
use pressure-sensitive abrasive discs.
1
To install the abrasive disc, first remove all dirt or foreign mat-
ter 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.
1. Abrasive disc
To remove the disc from the pad, just pull up from its edge.
003315
Changing pad
2
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 securely.
1
3
1. Screw
2. Hex wrench
3. Pad
003328
Dust collection (optional accessory)
3
1
2
If a Makita hose is used, you can connect the cuff to the dust
outlet directly.
1. Dust outlet
2. Cuff
3. Hose
003329
If other hose with an inner diameter of 24 mm (15/16”),
attach the joint between the dust outlet and the cuff.
1
1. Joint
9
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OPERATION
003338
Sanding operation
CAUTION:
•
•
•
Never switch on the tool when it is in contact with the
workpiece, it may cause an injury to operator.
Never run the tool without the abrasive disc. You may
seriously damage the pad.
Never force the tool. Excessive pressure may decrease
the sanding efficiency, damage the abrasive disc or
shorten tool life.
Hold the tool firmly. Turn the tool on and wait until it attains
full speed. Then gently place the tool on the workpiece sur-
face. Keep the pad flush with the workpiece and apply slight
pressure on the tool.
Polishing operation
CAUTION:
•
•
•
Use only a Makita genuine sponge pad, felt pad or wool
pad (optional accessories).
Always operate the tool at low speed to prevent work
surfaces from damage/burning.
Never force the tool. Excessive pressure may decrease
the polishing efficiency and cause motor overload,
resulting in tool malfunction.
003340
Applying wax
Use an optional sponge pad. Apply wax to the sponge pad or
work surface. Run the tool to smooth out wax.
NOTE:
•
First, wax a non critical portion of the work surface to
make sure that the tool will not scratch the surface or
result in uneven waxing.
1
1. Sponge pad
10
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003342
Removing wax
Use an optional felt pad. Run the tool to remove wax.
1
1. Felt pad
003344
Polishing
Use an optional wool pad. Run the tool and apply the wool
pad gently to the work surface.
1
1. Wool pad
MAINTENANCE
CAUTION:
•
Always be sure that the tool is switched off and
unplugged before attempting to perform inspection or
maintenance.
To maintain product SAFETY and RELIABILITY, repairs, car-
bon brush inspection and replacement, any other mainte-
nance or adjustment should be performed by Makita
Authorized or Factory Service Centers, always using Makita
replacement parts.
11
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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.
•
Hook-and-loop type abrasive discs (with pre-punched
holes)
•
•
•
•
•
•
•
•
Sanding cloth 150
Pad 150 (Super soft, Soft, Hard))
Hook-and-loop type sponge pad
Hook-and-loop type wool pad
Hook-and-loop type felt pad
Side grip
Joint
Hex wrench
12
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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
Fold
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MAIL THIS PORTION
Your answers to the following questions are appreciated.
1.This product was purchased from:
3. How did you learn about this product:
Home Center
Other (
)
Magazine
Radio
Hardware/Lumber Store
Tool Distributor
From Dealer
Newspaper
Store Display
Catalog
Exhibition
From Friend
Previous Usage
Other (
Industrial Supply
Construction Supply
)
2. Use of the product is intended for:
4. Most favored points are:
Construction Trade
Industrial Maintenance
Home Maintenance
Hobby
Design
Repair Service
Durability
Power
Features
Size
Price
Other (
)
Other (
)
Makita Brand
5. Any comments:
DATE PURCHASED
MONTH
MODEL NO.
DAY
YEAR
SERIAL NO.
STATUS
SEX
Married Single
M
F
INTL.
LAST NAME / COMPANY NAME
STREET ADRESS
CITY
AREA
CODE
STATE
ZIP CODE
PHONE
40-49
Under 19
20-29
30-39
50-60
Over 60
AGE:
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
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Paste
Paste
Paste
Paste
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FACTORY SERVICE CENTERS
1-800-4-MAKITA
RETAIN THIS PORTION FOR YOUR RECORDS
ARIZONA
FLORIDA
MISSOURI
PENNSYLVANIA
1704 Babcock Blvd.
Pittsburgh, PA 15209
(412) 822-7370
3707 E. Broadway Rd., Ste. 6
Phoenix, AZ 85040
(602) 437-2850
750 East Sample Road
Pompano Beach, FL 33064
(954) 781-6333
9876 Watson Road
St. Louis, MO 63126-2221
(314) 909-9889
CALIFORNIA
GEORGIA
NEBRASKA
PUERTO RICO
41850 Christy St.
Fremont, CA 94538-5107
(510) 657-9881
4680 River Green Parkway NW
Duluth, GA 30096
(770) 476-8911
4129 S. 84th St.
Omaha, NE 68127
(402) 597-2925
200 Guayama St.
Hato Rey, PR 00917
(787) 250-8776
14930 Northam St.
La Mirada, CA 90638-5753
(714) 522-8088
ILLINOIS
NEVADA
3375 S. Decatur Blvd.
Suites. 22 - 24
Las Vegas, NV 89102
(702) 368-4277
TENNESSEE
1120 Elm Hill P.
Suile 170 Nashville, TN 372
(615) 248-3321
1450 Feehanville Dr.
Mt. Prospect, IL 60056-6011
(847) 297-3100
1970 Fulton Avenue
Sacramento, CA 95825
(916) 482-5197
MARYLAND
TEXAS
7674 Clairemont Mesa Blvd.
San Diego, CA 92111
(858) 278-4471
7397 Washington Boulevard,
Suite 104 Elkridge, MD 21075
(410) 796-4401
NEW JERSEY
12801 Stemmons Fwy Ste. 809
Farmers Branch, TX 75234
(972) 243-1150
251 Herrod Blvd.
Dayton, NJ 08810-1539
(609) 655-1212
16735 Saticoy St., Ste. 105
Van Nuys, CA 91406
(818) 782-2440
12701 Directors Dr.
Stafford, TX 77477-3701
(281) 565-8665
MASSACHUSETTS
232 Providence Hwy.
Westwood, MA 02090
(781) 461-9754
NEWYORK
4917 Genessee Street
Cheektowaga, NY 14225
(716) 685-9503
3453 IH-35 North, Ste. 101
San Antonio, TX 78219
(210) 228-0676
COLORADO
11839 E. 51st Ave.
Denver, CO 80239-2709
(303) 371-2850
MINNESOTA
6427 Penn Ave. South
Richfield, MN 55423
(612) 869-5199
OREGON
828 19th Avenue, N.W.
Portland, OR 97209
(503) 222-1823
WISCONSIN
Lincoln Plaza Shopping Ctr.
2245 S. 108th St. West Allis, WI
53227
(414) 541-4776
CUSTOMER’S RECORD
Date Purchased
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.
Dealer’s Name & Address
Model No.
Serial No.
15
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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
884338B061
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