Makita 3803A User Manual

Groove Cutter

MODEL 3803A

INSTRUCTION MANUAL

WARNING:

For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

004818

SPECIFICATIONS

Model 3803A

Max. cutter blade size 46 mm x 120 mm (1-13/16” x 4-3/4”)

Max. cutting depth 31 mm (1-7/32”)

No load speed (RPM) 9,000/min.

Overall length 411 mm (16-3/16”)

Net weight 6.8 kg (15 lbs)

• Manufacturer reserves the right to change specifications without notice.

• Specifications may differ from country to country.

GENERAL SAFETY RULES USA001-3

(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 A re a

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. Powe r

tools create sparks which may ignite the dust
or fumes.

3. Keep bystanders, children, and visitors
away while operating a power tool. Dis-

tractions can cause you to lose control.

2

Electrical Safety

4. Grounded tools must be plugged into an
outlet properly installed and grounded in
accordance with all codes and ordi­nances. Never remove the grounding
prong or modify the plug in any way. Do
not use any adaptor plugs. Check with a
qualified electrician if you are in doubt as
to whether the outlet is properly
grounded. If the tools should electrically mal-

function or break down, grounding provides a
low resistance path to carry electricity away
from the user.

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 cloth­ing 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.

3

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: Use only three-wire extension cords that have
three-prong grounding-type plugs and three-pole receptacles that accept the tool's
plug. Make sure your extension cord is in good condition. Replace or repair damaged
or worn cord immediately. 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

Ampere Rating

More Than Not More Than AWG

0 6 18 16 16 14

6 10 18161412
10 12 16 16 14 12
12 16 14 12 Not Recommended

Volts Total length of cord in feet

120 V 25 ft. 50 ft. 100 ft. 150 ft.

GROUNDING INSTRUCTIONS:

This tool should be grounded while in use to protect the operator from electric shock.
The tool is equipped with a three-conductor cord and three-prong grounding type
plug to fit the proper grounding type receptacle. The green (or green and yellow) con­ductor in the cord is the grounding wire. Never connect the green (or green and yel­low) wire to a live terminal. Your unit is for use on 120 volts and has a plug that looks
like Fig. “A”.

Grounding

Blade

Cover of Grounded

Outlet Box

Fig. A

4

SPECIFIC SAFETY RULES USB084-1

DO NOT let comfort or familiarity with product (gained from
repeated use) replace strict adherence to groove cutter safety
rules. If you use this tool unsafely or incorrectly, you can suffer
serious personal injury.

1. Inspect for and remove nails or foreign
matter from the workpiece before opera­tion.

2. Check the cutter blade carefully for cracks
or damage before operation. Replace
cracked or damaged cutter blade immedi­ately.

3. Secure the workpiece firmly.

4. Do not wear gloves during operation.

5. Hold the tool firmly with both hands.

6. Keep hands away from the underside of

the belt cover and the cutting blade. Also
keep the cord away from them.

7. Never force the tool or cut too fast for
existing conditions.

8. Release the switch immediately if the cut­ter blade binds or the tool stalls.

9. Never remove the tool from a cut while the
cutter blade is rotating.

10. Never leave the tool running unattended.

11. Never attempt to cut with the tool held

upside down in a vise. This is extremely
dangerous and can lead to serious acci­dents.

12. Switch off and unplug the tool and wait for
the cutter blade to come to a complete
stop before removing wood chips if wood
chips are jammed in the chip chute.
Always use a wooden stick, etc. to
remove them.

13. Some material contains chemicals which
may be toxic. Take caution to prevent
dust inhalation and skin contact. Follow
material supplier safety data.

SAVE THESE INSTRUCTIONS

WARNING:

MISUSE or failure to follow the safety rules stated in this
instruction manual may cause serious personal injury.

5

FUNCTIONAL
DESCRIPTION

1

1. Depth indicator

2. Indication plate

3. Knob

2

3

1. Cutting line

2. Arrow for conventional cutter
blades and four teeth cutter blade

3. Arrow for dado cutter baldes

4. Width of cut

5. Direction of cut

2

3

1

4

5

CAUTION:

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

004819

Adjusting the depth of cut

Loosen the knob on the belt cover. Move the handle up or
down until the indication plate indicates the graduation for
the depth of cut desired. The tighten the knob securely. Each
increment on the depth indicator indicates 3 mm (1/8”) cut­ting depth.

004820

Cutting position

This tool may be operated with conventional cutter blades,
four teeth cutter blades for grooving or dado cutter blades.
There are two arrows on the scale plate located on the front
edge of the tool’s base plate. The arrow on the cutter cover
side is for conventional cutter blades or four teeth cutter
blades. The arrow on the belt cover side is for dado cutter
blades. Align the appropriate arrow with the cutting line.
These arrows are to be used to guide along your desired cut­ting line. They accurately indicate the left edge of your cut as
you are cutting. The width of cut may vary according to the
width of cutter blade selected. (3 mm; 1/8” per graduation on
the scale plate)

004821

1

2

1. When using cutter blades 120 mm
(4-3/4”) in dia.

2. Depth indicator

3. Indication plate

3

6

Adjusting the indication plate

Adjust the indication plate as follows when replacing the cut­ter blade.

• Loosen the knob on the belt cover. Move the handle up
or down until the cutter blade tips are flush with the
underside of the tool base while revolving the cutter
blade by turning the drive belt by hand. Then tighten the
knob securely. Adjust the indication plate so that it points
to the “0” graduation.

004822

1

• When using cutter blades 110 mm (4-3/8”) in diameter,
simply re-install the indication plate upside down and
adjust it so that it points to the “0” graduation.

23

1. When using cutter blades 110 mm
(4-3/8”) in dia.

2. Depth indicator

3. Indication plate

004823

Adjusting the scale plate

Loosen the screws which secure the scale plate. Adjust the
scale plate right or left so that the arrow on the scale plate is
aligned with the side of the cutter blade using the guide rule
as shown in the figure. Tighten the screws securely.

12 34

1. Screw

2. Scale plate

3. Cutter balde

4. Guide rule

004824

Switch action

1

CAUTION:

2

• Before plugging in the tool, always check to see that the
switch trigger actuates properly and returns to the “OFF”
position when released.

To start the tool, simply pull the switch trigger. Release the

1. Lock button

2. Swtch trigger

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, and then release it.

ASSEMBLY

CAUTION:

• Always be sure that the tool is switched off and
unplugged before carrying out any work on the tool.

7

1. Wrench 19

2. Wrench 21

3. Hex nut

12

1. Hex nut

2. Cutter balde

3. Flange

4. Flange

12 3

34

004825

Installing or removing cutter blade

To remove the cutter blade, loosen the wing bolt and take off

1

2

3

the cutter cover. Hold the outer flange with wrench 21 and
loosen the hex nut with wrench 19 by turning counterclock­wise. Remove the hex nut, outer flange and cutter blade.

004826

To install the cutter blade, mount the flange, cutter blade,
flange and hex nut onto the spindle in that order, making
sure that the cutter blade is installed with teeth pointing up at
the front of the tool.

WARNING:

• Remove all wood chips or foreign matter adhering to the
spindle, flanges, etc. before installing the cutter blade.

004827

When using cutter blades 7.5 mm (5/16”) wide or less, install
a flange 35 between the cutter blade and the flange as
shown in the figure.

1. Hex nut

2. Flange 35

3. Flange

4. Flange

5. Cutter balde

1. Wrench 21

2. Wrench 19

3. Hex nut

8

45

004828

1

2

3

Use the two wrenches to tighten the hex nut securely.

1

2

1. Belt cover

2. Drive belt

3. Cutter cover

4. Side plates

Side plates

The side plates help to prevent splintering of workpiece. This
tool is equipped with two side plate 21 - 30 (originally
installed on the tool), a side plate 2.4 - 18 (provided as a
standard equipment) and a side plate 33 - 46 (provided as a
standard equipment). Use the correct combination for the
cutter blade to be used. Refer to the table below.

Width of cutter blade to

be used

2.4 - 18 mm

(3/32” - 23/32”)

21 - 30 mm

(13/16” - 1-3/16”)

33 - 46 mm

(1-5/16” - 1-13/16”)

004829

When installing the side plates, adjust them so that the clear-

On cutter cover side On belt cover side

Side plate 2.4 - 18 Side plate 21 - 30

Side plate 21 - 30 Side plate 21 - 30

Side plate 33 - 46 Side plate 21 - 30

Correct combination

ances between the side of the cutter blade and the side

3

plates are approx. 0.1 mm (0.004”). Slowly revolve the cutter
blade by turning the drive belt by hand to make sure that the
clearances are adequate. There must be no contact when
rotated.

4

C00105

3

1. Guide rule

2. Screwdriver

3. Shiplapping attachment

004830

Shiplapping attachment

Use the shiplapping attachment when cutting the edge of the
workpiece. Attach the shiplapping attachment to the guide
rule using the screws.

1

2

9

1

4
5

1. Depth of cut

2. Guide rule

3. Shiplapping attachment

4. Width of cut

5. Width of cutter blade

3

1

1. Cutting line

2. Foot plate

3. Miter guide rule (Angle guide)

A

1

2

1. Cutter blade

2. Indicator

2

A-0.5 mm(0.02”)

004831

Align the right side of the cutting blade with the cutting line.
Move the guide rule until the shiplapping attachment con­tacts the side of the workpiece. Then tighten the wing bolt
firmly to secure the guide rule.

2

3

004832

Miter guide rule (optional accessory)

Loosen the wing bolt on the miter guide rule. Place the miter
guide rule on the workpiece and adjust it so that the edge of
the miter guide rule is aligned with the cutting line. Securely
tighten the wing bolt on the miter guide rule. Then position
the miter guide rule so that the arrow on the scale plate on
the tool is aligned with the cutting line.
Secure the miter guide rule by stepping on the foot plate on
the miter guide rule. Move the tool gently forward along the
miter guide rule. Be especially careful to maintain proper bal­ance and footing, or else loss of control and subsequent
injury may result.

004833

Also, the miter guide rule position can be determined using
the indicator on the miter guide rule. Adjust the indicator so
that its length is 0.5 mm (0.02”) shorter than the distance (A)
between the edge of the tool base and the side of the cutter
blade. With this adjustment, the indicator will project toward
the cutter blade within 0.5 mm (0.02”) of it as the edge of the
tool slides along the edge of the miter guide rule. Secure the
miter guide rule at the position where the indicator tip is

0.5 mm (0.02”) away from the cutting line.

CAUTION:

• Unplug the tool and re-adjust the indicator when
changing the miter angle of the miter guide rule.

10

1

2

34

1. Straight board

2. Dado cutting guide rule

3. Approx. 150 mm (5-29/32”)

4. Cutting line

004834

Dado cutting guide rule (optional accessory)

Firmly clamp a straight board to the workpiece parallel to the
cutting line and use it as a guide against the dado cutting
guide rule. Adjust the dado cutting guide rule so that the
arrow on the scale plate is aligned with the cutting line. The
best distance between the cutting line and the guide (straight
board) is approximately 150 mm (5-29/32”).

OPERATION

2

1. Cutting line

2. Rib

WARNING:

• Be sure to clamp or secure the workpiece before cutting.
It allows both hands to grip both handles. This helps to
maintain secure control of the tool - especially if a
kickback occurs.

• Always be sure that the cutter blade is secured firmly
before cutting.

004835

Hold the tool firmly with both hands. Rest the front end of the

1

tool base on the workpiece surface and align the arrow on
the scale plate with the cutting line without the cutter blade
making any contact with the workpiece. Switch on and wait
until the cutter blade attains full speed. Then move the tool
gently forward.
Hold the tool base flush with the workpiece at all times. Be
alert and maintain firm control of the tool by holding both
handles securely. Do not cut “one-handed”. When the cut is
complete, do not move the tool away from the workpiece
until the cutter blade has coasted to a complete stop.

NOTE:

• The cutter blade does not contact the workpiece until the
rib on the tool base passes the end of the workpiece.

11

1

2

1. Wing bolt

2. Scale plate

3. Cutting line

4. Guide rule

004836

Guide rule

The handy guide rule allows you to make accurate straight
cuts parallel to a straight edge of a workpiece. Loosen the
wing bolt which secures the guide rule. Align the appropriate
arrow on the scale plate with the cutting line. Move the guide

3

4

rule until it contacts the side of the workpiece. Tighten the
wing bolt to secure the guide rule.

MAINTENANCE

1

1. Limit mark

1

1. Screwdriver

2. Brush holder cap

CAUTION:

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

001145

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.

004837

Use a screwdriver to remove the brush holder caps. Take out
the worn carbon brushes, insert the new ones and secure

2

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.

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. 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.

• Cutter blades

C00106

6.0

(1/4”)

15.0

(5/8”)

36.0

(1-3/8”)

For
groove
cutting

Dia.

120 mm

(4-3-4”)

For dado

cutting

Dia.

110 mm

(4-3/8”)

2.4

(3/32”)

7.5

(5/16”)

16.5

(11/16”)

39.0

(1-7/16”)

3.0

(1/8”)

9.0

(3/8”)

18.0

(3/4”)

42.0

(1-21/32”)

Width (mm)

3.9

(5/32”)

10.5

(7/16”)

21.0

(7/8”)

46.0

(1-13/16”)

4.5

(3/16”)

12.0

(1/2”)

30.0

(1-1/8”)

5.5

(7/32”)

13.5

(9/16”)

33.0

(1-5/16”)

• Guide rule (For groove cutting, for dado cutting)

• Shiplapping scale

• Miter guide rule

• Flange 35

(For blade width 2.4 mm (3/32”) - 7.5 mm (5/16”))

13

Memo

14

Memo

15

Memo

16

Cut

Makita Canada Inc.
1950 Forbes Street,
Whitby, Ontario
L1N 7B7

Fold

Stamp
Timbre

17

Your answers to the following questions are appreciated.

1. This product was purchased from?

Hardware/lumber Store

2. Use of the product is intended for?

Construction trade

5. Any comments?

Industrial Supply

Other ( )Tool Distributor

Home maintenance

Other ( )Industrial maintenance

3. How did you first learn of Makita Power Tools?

4. Most favored points are?

Certificate of Warranty

Mail to Makita

Date Purchased Model No.

Month Day Year 20

Serial No.

Magazine/Newspaper

Store display

Design

Price

Catalog

Other ( )From dealer

Makita Brand

Powe rFeatures

Other ( )Size

Initial Last Name

Street Address

City Province

AGE:

Under 19 20-29 30-39 40-49 Over 50

Occupation:

Dealer's Name & Address:

Paste Paste Paste Paste Paste Paste

18

Paste Paste Paste Paste Paste Paste Paste Paste

Male Female MarriedSingle

Postal Code

Paste Paste Paste Paste Paste Paste

Factory Service Centres

Head Office: 1950 Forbes St., Whitby, Ontario, L1N 7B7

Regional Office: 11771 Hammersmith Way, Richmond

Regional Office: 6389 boul. Couture, St. Leonard, Quebec

Dartmouth: 202 Brownlow Avenue

Ville St. Laurent: 1140 Rue Bégin, Ville St. Laurent, Quebec

Les Saules: 1200 St. Jean Baptiste, Unit 106, Les Saules,

Nepean: 210 Colonnade Road, Unit 11, Nepean,

Whitby: 1950 Forbes St., Whitby, Ontario, L1N 7B7

London: 317 Adelaide St. S., Unit 117, London,

Mississauga: 6350 Tomken Rd., Unit 8, Mississauga,

Calgary: #8-6115 Fourth St. S.E., Calgary

Edmonton: 11614-149 Street, Edmonton, Alberta,

Richmond: 11771 Hammersmith Way, Richmond, B.C.,

Coquitlam: 2131 Hartley Ave., #103

Winnipeg: 1670 St. James Street, Winnipeg, Manitoba,

Saskatoon: 206A-2750 Faithful Avenue Saskatoon,

For the authorized service centre nearest you please refer to the local yellow pages directory under “tools” or con­tact our customer service department (Tel) 1-800-263-3734

(905) 571 - 2200 1-800-263-3734

(604) 272 - 3104 1-800-663-0909B.C. V7A 5H6

(514) 323 - 1223 1-800-361-7049H1P 3J5(Montreal)

(902) 468 - 7064 1-888-625-4821Dartmouth, N.S., B3B 1T5

(514) 745 - 5025 1-888-745-5025H4R 1X1(Montreal)

(418) 871 - 5720 1-800-663-5757Quebec, G2E 5E8(Quebec)

(613) 224 - 5022 1-888-560-2214Ontario, K2E 7M1(Ottawa)

(905) 571 - 2200 1-800-263-3734

(519) 686 - 3115 1-800-571-0899Ontario, N5Z 3L3

(905) 670 - 7255 1-888-221-9811Ontario, L5T 1Y3

(403) 243 - 3995 1-800-267-0445Alberta, T2H 2H9

(780) 455 - 6644 1-888-455-6644T5M 3R3

(604) 272 - 3104 1-800-663-0909V7A 5H6

(604) 525 - 7434 1-800-266-7738Coquitlam, B.C. V3K 2Z3

(204) 694 - 0402 1-800-550-5073R3H 0L3

(306) 931 - 0111 1-888-931-0111Saskatchewan, S7K 6M6

CUSTOMER RECORD

When you need service...

• Explain the problem in a letter

• Enclose the letter with the tool

• Package carefully and send prepaid

to the nearest Makita factory or
authorized service centre

DATE

PURCHASED:

DEALER’S NAME

& ADDRESS:

MODEL NO.:

SERIAL NO.:

19

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 Centres.
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 normal maintenance is required,

• repairs have been made or attempted by others,

• 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.

“The Makita Warranty is the only and the entire written warranty given by Makita for the Makita tools. No dealer or his agent
or employee is authorized to extend or enlarge upon this warranty by any verbal or written statement or advertisement.”

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 rights. The provisions contained in this warranty are not intended to limit, modify, take away

from, disclaim or exclude any warranties set forth in any provincial legislation. To the extent required by law, the provisions in
any provincial or federal legislation with respect to warranties take precedence over the provisions in this warranty.”

883844-239

Makita Corporation

3-11-8, Sumiyoshi-cho,

Anjo, Aichi 446-8502 Japan