Makita 4157KB Cutter with Dust Collection Instruction Manual

Makita 4157KB Cutter with Dust Collection General Power Tool Safety

Warnings
WARNING Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.

CUTTER SAFETY WARNINGS
  1. 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.
  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.
  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 motor’s 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.
  18. 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 a 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.
    • 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.
      • For example, if a 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.
      • 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.
      • 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.
      • 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.

SAVE THESE INSTRUCTIONS.
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 the depth of cut Fig.1
    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.
    CAUTION:
    After adjusting the depth of cut, always tighten the lever securely.
  • Bevel cutting Fig.2
    Loosen the knob on the bevel scale plate on the front of the base. Set for the desired angle (0° – 45°) by tilting accordingly, then tighten the knob securely.
  • Adjusting for accuracy of 90° cut (vertical cut) Fig.3 Fig.4
    This adjustment has been made at the factory. But if it is off, adjust the adjusting screw with a hex wrench while squaring the blade with the base using a triangular rule, try square, etc.
  • Sighting Fig.5
    For straight cuts, align the right edge of the notch in the front of the base with your cutting line on the workpiece. For 45° bevel cuts, align the left edge of the notch in the front of the base with it.
  • 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.6
    To prevent the switch trigger from being accidentally pulled, a lock-off button is provided.
    To start the tool, push in the lock-off button and pull the switch trigger. Release the switch trigger to stop.

ASSEMBLY

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

Installing or removing diamond wheel Fig.7
Use a screwdriver to loosen the two screws which secure the dust box. Then remove the dust box from the tool. After removing the dust box, press the shaft lock so that the diamond wheel cannot revolve and use the hex wrench to loosen the hex socket head bolt counterclockwise.
Fig.8
Then remove the hex socket head bolt, outer flange and the diamond wheel. To install the diamond wheel, follow the removable procedure in reverse. BE SURE TO TIGHTEN THE HEX SOCKET HEAD BOLT SECURELY.
Fig.9
CAUTION:

  • Make sure that the arrow on the wheel should point in the same direction as the arrow on the tool.
  • Use only the Makita wrench to install or remove the wheel.

Rip fence (guide rule) (Accessory) Fig.10
The handy rip fence (guide rule) allows you to do extra-accurate straight cuts. Simply slide the rip fence up snugly against the side of the workpiece and secure it in position with the clamp screw on the front of the base. It also makes repeated cuts of uniform width possible.
Dust extraction Fig.11
This tool is equipped with a dust box to collect dust and cut chips. When the dust box is about two thirds full, empty its contents. To do so, press the lever to unlock the dust cap. Then open it.
Cleaner cutting operations can be performed by connecting this tool to a Makita vacuum cleaner. Remove the rubber cap from the dust cap and connect the vacuum cleaner hose to the dust cap.

OPERATION Fig.12

Grasp the rear handle with your right hand, the front grip with your left. Set the base plate on the workpiece to be cut without the wheel making any contact. Then turn the tool on and wait until the wheel attains full speed. Move the tool forward over the workpiece surface, keeping it flat and advancing smoothly until the cutting is completed. To get clean cuts, keep your cutting line straight and your speed of advance uniform. Never use water when cutting. Water may enter the tool, causing an electric shock hazard.
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.
  • Since excessive cutting may cause overload of the motor, the depth of cut should not be more than 20 mm at a pass. When you wish to cut more than 20 mm deep, make a couple of passes with progressively deeper settings.

MAINTENANCE

CAUTION: 

  • Always be sure that the tool is switched off and unplugged before attempting to perform inspection or maintenance.
  • 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 concrete block and cut in it.
Replacing carbon brushes
Fig.13
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.
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 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 regarding these accessories, ask your local Makita Service Center.
  • Diamond wheels (Dry type)
  • Hex wrench 6
  • Rip fence (Guide rule)
  • 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.

Explanation of general view

  1. Lever
  2. Bevel scale plate
  3. Knob
  4. Base
  5. Adjusting screw
  6. Triangular rule
  7. Notch
  8. For 45 ゚ bevel cuts
  9. For straight cuts
  10. Lock-off button
  11. Switch trigger
  12. Dust box
  13. Screw
  14. Hex wrench
  15. Shaft lock
  16. Diamond wheel
  17. Outer flange
  18. Hex socket head bolt
  19. Inner flange
  20. Rip fence (Guide rule)
  21. Dust cap
  22. Rubber cap
  23. Lever
  24. Rear handle
  25. Front grip
  26. Base
  27. Limit mark
  28. Brush holder cap
  29. Screwdriver

SPECIFICATIONS

Model 4157KB
Wheel diameter 180 mm
 

Max. cutting capacities

90° 58 mm
45° 29 mm
No load speed (min-1) 5,800
Overall length 354 mm
Net weight 5.6 kg
Safety class /II
  • Due to our continuing programme 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 01/2003

Symbols

The following show the symbols used for the equipment. Be sure that you understand their meaning before use.

  • Read the instruction manual.
  • DOUBLE INSULATION
  • Do not use the tool upside down.
  • Do not use the abrasive cut-off wheel.
  • Do not use the saw blade and diamond wheel with grooves and openings.
  • Only for EU countries Do not dispose of electric equipment together with household waste material! In observance of European Directive 2002/96/EC on waste electric and electronic equipment and its implementation in accordance with national law, electric equipment that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility.

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 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 0.31 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) : 100 dB(A)
  • Sound power level (LWA) : 111 dB(A)
  • Uncertainty (K) : 3 dB(A)

Wear ear protection 

Vibration
The vibration total value (tri-axial vector sum) determined according to EN60745:

  • Work mode: concrete cutting
  • Vibration emission (ah) : 4.0 m/s2
  • Uncertainty (K) : 1.5 m/s2
  1. 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.
  2. 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.
  • 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).

For European countries only
EC Declaration of Conformity
We Makita Corporation as the responsible manufacturer declare that the following Makita machine(s):
Designation of Machine:
Cutter with Dust Collection Model No./ Type: 4157KB are of series production and
Conforms to the following European Directives:
2006/42/EC And are manufactured in accordance with the following standards or standardised documents: EN60745 The technical documentation is kept by our authorised representative in Europe who is: Makita International\ Europe Ltd. Michigan Drive, Tongwell,
Milton Keynes, Bucks MK15 8JD, England