makita 4100KB Dustless Cutter Instruction Manual

makita 4100KB Dustless Cutter

SPECIFICATIONS

• Due to our continuing program of research and development, the specifications herein are subject to change without notice.
• Specifications may differ from country to country.
• Weight according to EPTA-Procedure 01/2014

Intended use

The tool is intended for cutting in brick and concrete without the use of water.

Power supply

The tool should be connected only to a power supply of the same voltage as indicated on the nameplate, and can only be operated on a single-phase AC supply. They are double-insulated and can, therefore, also be used from sockets without earth wire.

For public low-voltage distribution systems of between 220 V and 250 V

Switching operations of electric apparatus cause voltage fluctuations. The operation of this device under unfavorable mains conditions can have adverse effects to the operation of other equipment. With a mains impedance equal or less than 0.37 Ohms it can be presumed that there will be no negative effects. The mains socket used for this device must be protected with a fuse or protective circuit breaker having slow tripping characteristics.

Noise
The typical A-weighted noise level is determined according to EN60745:

• Sound pressure level (LpA): 96 dB(A)
• Sound power level (LWA): 107 dB (A)
• Uncertainty (K) :3dB(A)

WARNING: Wear ear protection.

Vibration

The vibration total value (tri-axial vector sum) determined according to EN60745:
Work mode: concrete cutting
Vibration emission (ah): 6.0 m/s2
Uncertainty (K) : 1.5 m/s2

NOTE: The declared vibration emission value has been measured in accordance with the standard test method and may be used for comparing one tool with another.
NOTE: The declared vibration emission value may also be used in a preliminary assessment of exposure.

WARNING: The vibration emission during actual use of the power tool can differ from the declared emission value depending on the ways in which the tool is used.
WARNING : Be sure to identify safety measures to protect the operator that are based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off and when it is running idle in addition to the trigger time).

EC Declaration of Conformity

For European countries only
The EC declaration of conformity is included as Annex A to this instruction manual.

SAFETY WARNINGS

General power tool safety warnings

WARNING: Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Cutter safety warnings

1. The guard provided with the tool must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator. Position yourself and bystanders away from the plane of the rotating wheel. The guard helps to protect operator from broken wheel fragments and accidental contact with wheel.
2. Use only diamond cut-off wheels for your power tool. Just because an accessory can be attached to your power tool, it does not assure safe operation.
3. The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.
4. Wheels must be used only for recommended applications. For example: do not grind with the side of the cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.
5. Always use undamaged wheel flanges that are of correct diameter for your selected wheel. Proper wheel flanges support the wheel thus reducing the possibility of wheel breakage.
6. The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories cannot be adequately guarded or controlled.
7. The arbour size of wheels and flanges must properly fit the spindle of the power tool. Wheels and flanges with arbour holes that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
8. Do not use damaged wheels. Before each use, inspect the wheels for chips and cracks. If power tool or wheel is dropped, inspect for damage or install an undamaged wheel. After inspecting and installing the wheel, position yourself and bystanders away from the plane of the rotating wheel and run the power tool at maximum no load speed for one minute. Damaged wheels will normally break apart during this test time.
9. Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and shop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high-intensity noise may cause hearing loss.
10. Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a broken wheel may fly away and cause injury beyond immediate area of operation.
11. Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
12. Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning wheel.
13. Never lay the power tool down until the accessory has come to a complete stop. The spinning wheel may grab the surface and pull the power tool out of your control.
14. Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.
15. Regularly clean the power tool’s air vents. The motorʼs fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.
16. Do not operate the power tool near flammable materials. Sparks could ignite these materials.
17. Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

Kickback and related warnings
Kickback is a sudden reaction to a pinched or snagged rotating wheel. Pinching or snagging causes rapid stalling of the rotating wheel which in turn causes the uncontrolled power tool to be forced in the direction opposite of the wheel’s rotation at the point of the binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction of the wheel’s movement at the point of pinching. Abrasive wheels may also break under these conditions.
Kickback is the result of power tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

1. Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up. The operator can control torque reactions or kickback forces, if proper precautions are taken.
2. Never place your hand near the rotating accessory. Accessory may kick back over your hand.
3. Do not position your body in line with the rotating wheel. Kickback will propel the tool in direction opposite to the wheel’s movement at the point of snagging.
4. Use special care when working corners, sharp edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.
5. Do not attach a saw chain, woodcarving blade, segmented diamond wheel with a peripheral gap greater than 10 mm or toothed saw blade. Such blades create frequent kickback and loss of control.
6. Do not “jam” the wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kick-back or wheel breakage.
7. When wheel is binding or when interrupting a cut for any reason, switch off the power tool and hold the power tool motionless until the wheel comes to a complete stop. Never attempt to remove the wheel from the cut while the wheel is in motion otherwise kickback may occur. Investigate and take corrective action to eliminate the cause of wheel binding.
8. Do not restart the cutting operation in the workpiece. Let the wheel reach full speed and carefully re-enter the cut. The wheel may bind, walk up or kickback if the power tool is restarted in the workpiece.
9. Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.
10. Use extra caution when making a “pocket cut” into existing walls or other blind areas. The protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.
11. Before using a segmented diamond wheel, make sure that the diamond wheel has the peripheral gap between segments of 10 mm or less, only with a negative rake angle.

Additional Safety Warnings:

1. Never attempt to cut with the tool held upside down in a vise. This can lead to serious accidents, because it is extremely dangerous.
2. Some material contains chemicals which may be toxic. Take caution to prevent dust inhalation and skin contact. Follow material supplier safety data.
3. Store wheels as per manufacturer recommendations. Improper storage may damage the wheels.

WARNING: DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to safety rules for the subject product. MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury.

FUNCTIONAL DESCRIPTION

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

Adjusting depth of cut

CAUTION: After adjusting the depth of cut, always tighten the lever securely.

Loosen the lever on the depth guide and move the base up or down. At the desired depth of cut, secure the base by tightening the lever.
For cleaner, safer cuts, set cut depth so that the dia-mond wheel projects 2 mm or less below workpiece. Using proper cut depth helps to reduce potential for dangerous KICKBACKS which can cause personal injury.

• Fig.1: 1. Lever

Sighting
Align the edge of the front of the base with your cutting line on the workpiece.

• Fig.2

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.

Fig.3:

1. Switch trigger
2. Lock button / Lock-off button

For tool with lock button

CAUTION: 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, push in the lock button and then release the switch trigger. To stop the tool from the locked position, pull the trigger fully, then release it.
For tool with a lock-off button
To prevent the switch trigger from being accidentally pulled, a lock-off button is provided. To start the tool, press the lock-off button and pull the switch trigger. Release the switch trigger to stop.

WARNING: NEVER use the tool if it runs when you simply pull the switch trigger without press-ing the lock-off button. A switch in need of repair may result in unintentional operation and serious personal injury. Return tool to a Makita service center for proper repairs BEFORE further usage.
WARNING: NEVER defeat the lock-off button by taping down or some other means. A switch with a negated lock-off button may result in unintentional operation and serious personal injury.

CAUTION: Do not pull the switch trigger hard without pressing in the lock-off button. This can cause switch breakage.

ASSEMBLY

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

Hex wrench storage
When not in use, store the hex wrench as shown in the figure to keep it from being lost.

• Fig.4: 1. Hex wrench

Removing or installing diamond wheel

CAUTION: BE SURE TO TIGHTEN THE HEX BOLT SECURELY. Also be careful not to tighten the bolt forcibly. Slipping your hand from the hex wrench can cause a personal injury.
CAUTION : Use only the Makita wrench and hex wrench to install or remove the wheel.

Hold the outer flange with the wrench and loosen the hex bolt with the hex wrench. Then remove the hex bolt, outer flange and diamond wheel.

Fig.5:

1. Hex wrench
2. Hex bolt
3. Wrench 22
4. Loosen
5. Tighten

To install the diamond wheel, follow the removal procedure in reverse. Always install the wheel so that the arrow on the diamond wheel points in the same direction as the arrow on the gear housing.

Fig.6:

1. Hex bolt
2. Outer flange
3. Diamond wheel
4. Inner flange
5. Cup washer

Dust bag

The use of the dust bag makes cutting operations clean and dust collection easy. To attach the dust bag, fit it onto the dust spout.

Fig.7:

1. Dust bag
2. Dust spout

The neck of the dust spout rotates freely. Position the dust bag so that you can operate the tool comfortably.

Fig.8

When the dust bag is about one-third 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 adhering to the insides which might hamper collection.

Fig.9:

1. Fastener

Connecting the vacuum cleaner

When you wish to perform clean cutting operation, connect a Makita vacuum cleaner to your tool.

Fig.10:

1. Hose of the vacuum cleaner
2. Dust spout

OPERATION

CAUTION: THIS TOOL SHOULD ONLY BE USED ON HORIZONTAL SURFACES.
CAUTION: Be sure to move the tool forward in a straight line and gently. Forcing and exerting excessive pressure or allowing the wheel to bend, pinch or twist in the cut can cause overheating of the motor and dangerous kickback of the tool.

Hold the tool firmly. Set the base plate on the workpiece to be cut without the diamond wheel making any con-tact. Then turn the tool on and wait until the diamond wheel attains full speed. Now simply move the tool forward over the workpiece surface, keeping it flat and advancing smoothly until the cutting is completed. Keep your cutting line straight and your speed of advance uniform.

Fig.11

MAINTENANCE

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

NOTICE: Never use gasoline, benzine, thinner, alcohol or the like. Discoloration, deformation or cracks may result.

Dressing diamond wheel

If the cutting action of the diamond wheel begins to diminish, use an old discarded coarse grit bench grinder wheel or concrete block to dress the diamond wheel. To do this, tightly secure the bench grinder wheel or con-crete block and cut in it.

After use

Clean the dust inside of the tool by running the tool at an idle for a while. Brush off accumulation of dust on the base. Accumulation of dust in the motor or on the base may cause a malfunction of the tool.

Replacing carbon brushes

Check the carbon brushes regularly.
Replace them 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.

Fig.12:

1. Limit mark

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.

Fig.13:

1. Screwdriver
2. Brush holder cap

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.

OPTIONAL 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 regard-ing these accessories, ask your local Makita Service Center.

• Diamond wheels (Dry type)
• Wrench 22
• Hex wrench
• Guide rail
• Guide rail adapter
• Safety goggles

NOTE: Some items in the list may be included in the tool package as standard accessories. They may differ from country to country.

Makita Europe N.V.
Jan-Baptist Vinkstraat 2, 3070 Kortenberg, Belgium

Makita Corporation
3-11-8, Sumiyoshi-cho,
Anjo, Aichi 446-8502 Japan

www.makita.com

References

• MAKITA Industrial Power Tools - The Leader In Cordless with 18V LXT Lithium-Ion

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