Instruction Manual
Contents
1. 21 Replacing the return spring pack Replacing the starter spring Remove the fan housing see Replacing the starter cable Remove the air guide from the fan housing see Replacing the starter cable Detension the return spring on the cable drum and remove the cable drum see Replacing the starter cable Note Unspool the starter cable from the drum only Do not pull it out of the cable drum or the starter grip CAREFUL Injury hazard The return spring can pop out Always wear eye protection and protective gloves Lightly tap the fan housing on a wooden surface with the entire surface of the hollow side and hold it down Now lift the fan housing carefully and in small steps This will allow the return spring pack 13 which should now have fallen out to relax in a controlled manner if the return spring has popped out of the plastic pack If the return spring pops out it can be wound back into the cassette as shown 15 Make sure the direction of winding is correct Carefully insert a new return spring cassette and press down until it engages Put the cable drum 5 and spring back on and turn it slightly until the return spring catches Put on the carrier 8 and bolt it on with bolt 7 Tension the return spring see Replacing the starter cable Replacing the starter spring NOTE If the spring 6 in the Featherlight Starting system is broken more effort will be requi2. 23 Spare parts Reliable long term operation as well as the safety of your Power Cut depend among other things on the quality of the spare parts used Use only original MAKITA parts marked ZX MA Only original parts are from the same production line as the original unit and therefore ensure the highest possible quality of materi als dimensions functioning and safety Only original spare parts and accessories guarantee the highest quality in material dimensions and function Original spare parts and accessories can be obtained from your local dealer He will also have the spare part lists to determine the required spare part numbers and will be constantly informed about the latest improvements and spare part innovations Please bear in mind that if parts other than original MAKITA spare parts are used this will automatically invalidate the MAKITA product guarantee We will furthermore not accept any liability damages arising from the use of non MAKITA spare parts Guarantee MAKITA guarantees the highest quality and will therefore reimburse all costs for repair by replacement of damaged parts resulting from material or production faults occurring within the guarantee period after purchase Please note that in some countries particular guarantee conditions may exist If you have any questions please contact your salesman who is responsible for the guarantee of the product Please note that we cannot accept any responsibility for dam
3. and wear protective gloves CAUTION Start the Power Cut only after complete assembly and inspection 17 VL aes SERVICE IMPORTANT Because many of the parts and assemblies not mentioned in this Instruction Manual are vital to the safety of the unit and because all parts are subject to a certain amount of wear and tear it is important for your own safety that you have the unit checked and maintained regularly by a MAKITA service center IMPORTANT If the cutting wheel breaks during cutting the A Power Cut must be repaired by a MAKITA service centre before being used again Changing the V belt Loosen bolts 1 and remove belt cover 2 Move the V belt pulley into the position shown Insert the Allen key into the hole 3 to block the V belt pulley 5 Note Make sure that the V belt pulley remains blocked Use the combination tool to turn the nut 4 about one turn counter clockwise Use the combination tool to turn the eccentric 6 forcefully counter clockwise to the position shown Remove the old V belt 7 or belt fragments Clean out the interior with a brush Insert a new V belt Use the combination tool to turn the eccentric 6 forcefully clockwise to its original position V belt is now tight Tighten the nut 4 Remove Allen key from hole 3 Put the belt cover 2 on and tighten the bolts 1 Note The V belt is highly elastic so it i
4. shortens the service life of the engine Whenever possible wet cut with water when working in concrete and stone to bind the dust Loosen both bolts 1 and remove the filter cover 2 Take the air filter cover 3 out of the cover 5 Loosen the six bolts 4 on the cover and remove the cover Remove the inner filter 6 When reassembling make sure that the two lugs 7 of the filter cover engage in the cover 5 Inner filter Wash out the dirty inner filter 6 Order No 315 173 020 in lukewarm soapy water with regular dishwashing liquid Let the inner filter dry thoroughly Air filter insert paper cartridge The air filter insert 3 Order No 315 173 010 filters the intake air through a very fine paper filter lamella system For this reason the cartridge must never be washed or cleaned with compressed air Clean the air filter insert once per month To clean the air filter insert spread it out slightly and carefully tap it against a clean surface Replace the air filter insert every 500 operating hours Re place it immediately if there is a drop in power drop in speed or smoke in the exhaust Before installing the filter system check the intake opening to make sure no dirt particles have fallen in If they have remove them 19 Replacing the spark plug Gro CAUTION Do not touch the spark plug or plug cap if the engine is running high voltage Switch off the engine before starting a
5. 3 8 mm length 1000 mm as shown in the illustration don t forget the washer 10 and knot both ends as shown Pull the knot 11 into the cable drum 5 and press it into the space Pull knot 12 into the starter grip 9 Put the cable drum and spring back on and turn it slightly until the return spring catches Guide the hole 16 in the carrier 8 over the end of the spring press down the carrier and turn it slightly counter clockwise until it is flush on the cable drum Insert screw 7 and tighten Guide the cable into the slot 14 on the cable drum and turn the drum with the cable clockwise three times Hold the cable drum with your left hand and with your right hand untwist the cable pull it tight and hold it Carefully release the cable drum The spring will wind the cable around the drum Repeat the procedure once The starter grip should now stand straight up on the fan housing NOTE With the cable pulled all the way out it must still be possible to turn the pulley another 1 4 turn against the return spring CAUTION Danger of injury Secure the cable grip when pulled out It will whip back if the cable pulley is released by accident Mounting the fan housing Insert the air guide 3 in the fan housing so that the five re cesses 4 engage Position the fan housing on the machine apply slight counter pressure and pull the starter grip until the starter mechanism engages Tighten screws 1
6. Se 7 EFY Delivery inventory ve ou rwnd Power Cut Cutting disc not in the general scope of delivery Country specific Screwdriver for carburetor adjustment Offset screwdriver Universal wrench 13 19 Instruction manual not shown Symbols You will notice the following symbols on the Power Cut and in the Instruction Manual In case one of the parts listed should not be included in the delivery inventory please consult your sales agent h 2 PP Oe gt Read instruction manual and follow the warning and safety precautions Particular care and caution Forbidden Wear helmet and eye respiratory and hearing protection Wear protective gloves Wear respiratory protection Hazardous dust and or gas emission Fire hazard from flying sparks No smoking No open fire Direction of cutting wheel rotation Warning the max peripheral speed of the cutting disc is 80 m s Cutting disc dimensions oP aheo SA fO A MA K Never use circular saw blades Never use damaged cutting discs Combination switch Choke On Stop Safety position Start engine Stop engine Warning Kickback Fuel and oil mixture First aid Recycling CE Marking SAFETY PRECAUTIONS Note The illustrations in the safety precautions are not identical with the product Intended use Power Cut Use the Power Cut cutoff saw outdoors
7. Throttle lever Combination switch Choke On Stop I O Fuel tank fill level window Starter housing with starter Stand Muffler Cutting disc Disc bolt Spring washer AQQ PUTTING INTO OPERATION CAUTION Always turn off the engine and pull off the spark plug cap before doing any work on the Power Cut Always wear protective gloves CAUTION Start the Power Cut only after complete assembly and inspection Sequence Vw VWF OWE For the the following work use the assembly tools included with delivery 1 13 19 AF combination wrench 2 Allen key 3 Carburetor adjustment screwdriver Place the Power Cut on a stable surface and carry out the fol lowing assembly steps Mounting the cutting disc Inspect the disc for damage A See SAFETY INSTRUCTIONS Page 6 Unscrew screw 9 and remove the spring washer 8 Place the cutting disc 5 on the arbour 7 NOTE The arbor hole of the cutting disc must be an exact fit with the arbor or shaft For cutoff discs with 25 4 mm 1 arbor holes use the correct size disc holder supplied only with cutoff discs with 25 4 mm 1 arbor holes aS Make sure the cutting disc is installed so it turns in the right direction if a direction is marked on the disc Place the spring washer 8 on the arbour and insert the screw 9 and tighten by hand Slowly turn the cutoff disc until a hole 11 in the V belt pulley is v
8. into previous cuts have the Power Cut running at top speed Always cut at top speed Always support the workpiece so that the cut is under tension 16 so that the cut does not press together and jam the cutting disc as it proceeds through the material When starting a cut apply the disc to the workpiece with care Do not just shove it into the material Never cut more than one piece at a time When cutting make sure that no other workpiece comes into contact Working behavior Method of working Before starting work check the work area for any hazards electrical wires inflammable substances Clearly mark the work area for example with warning signs or by cordoning off the area When working with the Power Cut hold it firmly by the front and rear handles Never leave the Power Cut unattended Use the Power Cut at high speed as far as possible see Tech nical Data Only use the Power Cut during good light and visibility periods Be aware of slippery or wet areas and of ice and snow risk of slipping Never work on unstable surfaces Make sure that there are no obstacles in the working area risk of stumbling Always ensure that you have a safe footing Never cut above your shoulder height 17 Never stand on a ladder to cut 17 Never use the Power Cut while standing on scaffolding Do not lean over too far when working When putting down and picking up the Power Cut do not bend over from the waist but instea
9. of the Power Cut It is necessary to wear a protective helmet whenever working with the Power Cut The protective helmet A is to be checked in regular intervals for damage and is to be replaced after 5 years at the latest Use only approved protective helmets The helmet visor B protects the face from dust and material grains In order to prevent injuries to eyes and face always wear protective goggles C or visor when using the Power Cut To prevent hearing damage always wear suitable personal hearing protection ear muffs D ear plugs etc Octave brand analysis upon request When dry cutting dust producing materials such as stone or concrete always wear approved respiratory protection E Work gloves F of tough leather are part of the required work kit of the Power Cut and must always be worn when working with the Power Cut Always wear Safety shoes or boots G with steel toes non skid soles and leg protectors when working with the Power Cut Safety shoes equipped with a protective layer provide protection against cuts and ensure a secure footing Always wear a work suit H of tough material with sufficient flame retardant qualities whenever working with the cutoff saw Fuels Refuelling Go to a safe level place before refuelling Never refuel while on scaffolding on heaps of material or in similar places Switch off the engine before refuelling the Power Cut Do not
10. only for trimming and cutting suitable materials using cutting discs rated for this machine Improper use Never use the cutoff saw cutting discs for grinding or sanding us ing the side of the cutting disc to remove material The disc can break Never use the Power Cut with saw blades cutter blades brushes etc Unauthorised users Persons unfamiliar with the Instruction Manual children young people and persons under the influence of alcohol drugs or medi cations must not use the Power Cut General precautions The operator MUST read this instruction manual to ensure safe operation even if you already have experience in us ing cutoff saws It is important to be familiar with the opera tion of this particular cutoff saw Users insufficiently informed will endanger themselves as well as others due to improper handling Letonly persons who have experience in using cutoff saws work with this unit When letting another person use the Power Cut this instruction manual must be provided along with it First time operators should ask a specialist to instruct them in working with gasoline powered cutoff saws Children and persons under 18 years of age must not be allowed to use this Power Cut Persons over the age of 16 years may however use the Power Cut for the purpose of being trained as long as they are under the supervision of a qualified trainer Working with the Power Cut requires high concentration
11. your Power Cut and to ensure your personal safety we would request you to perform the following Read this instruction manual carefully before putting the Power Cut into operation for the first time and strictly observe the safety regulations Failure to observe these precautions can lead to severe injury or death EU Conformity Declaration The undersigned Tomoyasu Kato as authorized by MAKITA Corporation declare that the MAKITA machines Type 315 Power Cut EK6100 EK6101 manufactured by MAKITA Corporation 3 11 8 Sumiyoshi Cho Anjo Aichi 446 8502 Japan conforms to the basic safety and health requirements of the applicable EU Directives EU Machinery Directive 2006 42 EG EU EMC Directive 2004 108 EG Outdoor Noise Directive 2000 14 EG The most important standards applied to properly meet the re quirements of the above EU Directive were EN 19432 CISPR 12 EN ISO 14982 DIN EN 61000 4 The conformity assessment procedure 2000 14 EG was per formed per Annex V The measured noise level Lwa is 114 dB A The guaranteed noise level L4 is 115 dB A The technical documentation is on file at MAKITA International Europe Ltd Michigan Drive Tongwell Milton Keynes Bucks MK15 8JD England Anjo 20 8 2012 for MAKITA Corporation Tomoyasu Kato Managing Director Table of contents Page Packing Delivery inventory Symbols SAFETY PRECAUTIONS Intended use General precautions Protective equipment F
12. 2 966 244632 1 Cutting disc for masonry dia 350 25 4 mm 3 994290250 1 Hex screw M8x25 4 965 300 501 1 V belt EK6100 965300510 1 V belt EK6101 5 963601122 1 Suction head 6 315114350 1 Tank cap compl fuel 8 315173020 1 __ Inner filter 9 315173010 1 Air filter insert paper cartridge 10 395405000 1 Disk 5 11 965603021 1 Spark plug 12 395164010 1 Starter cable 9 3 8x1000 mm 13 181164010 1 Starter grip 14 181163050 1 Return spring in housing 15 181163080 1 Spring 16 181163090 1 Driver 17 941719131 1 Universal wrench SW 13 19 18 940827000 1 Offset screwdriver T27 19 944340001 1 Screwdriver carburetor Accessories not delivered with the Power Cut Diamond cutting disc 22 966 1 Please consult your MAKITA dealer 26 957802600 1 Pressure water tank cpl 949000035 1 Combined can for 5I fuel 2 51 oil 27 To find your local distributor please visit www makita outdoor com Vyas MAKITA Corporation 3 11 8 Sumiyoshi Cho Anjo Aichi 446 8502 Japan Specifications subject to change without notice Form 995 704 531 2012 10 GB
13. ILOILO Instruction Manual Original Instruction Manual EK6100 EK6101 Important Read this instruction manual carefully before putting the Power Cut into operation and strictly observe the safety regulations Keep this instruction manual Thank you for purchasing a MAKITA product Congratulations on choosing a MAKITA Power Cut cutoff saw Like our chain saws the MAKITA Power Cuts feature spe cially designed high performance engines with outstanding power to weight ratios for heavy duty yet lightweight tools Other advantages of the MAKITA Power Cuts Sturdy construction and high reliability Maintenance free electronic ignition hermetically sealed to protect against dust and moisture Vibration damping with the MAKITA 2 mass system D2M for tireless working even when guiding the Power Cut by hand Multilevel air filter system with turbo cyclone filter for depen dable function even under very dusty conditions The Featherlight Start system lets you start the cutter effort lessly with a spring loaded starting assist Extensive range of resin bonded and diamond grit cutting discs The following industrial property rights apply DE 202010000143 U1 DE 202011050393 U1 DE 202011050396 U1 DE 202011050394 U1 DE 202010004275 U1 DE 202009010557 U1 DE 202009006860 U1 DE 202008003781 U1 We want you to be satisfied with your MAKITA product In order to guarantee the optimal function and performance of
14. Operate the Power Cut only if you are in good physical condition If you are tired your attention will be reduced Be especially careful at the end of a working day Perform all work calmly and carefully The user has to accept liability for others Never work while under the influence of alcohol drugs medica tion or other substances which may impair vision dexterity or judgement A fire extinguisher must be available in the immediate vicinity when working in easily inflammable vegetation or when it has not rained for a long time danger of fire Asbestos and other materials that can release toxins may be cut only with the necessary safety precautions and after notification of the proper authorities and under their supervision or that of a person appointed by them The use of dust reduction devices is urgently recommended see Accessories pressure water tank water tank Protective equipment In order to avoid head eye hand or foot injuries as well as to protect your hearing the following protective equipment must be used during operation of the Power Cut Thekind of clothing should be appropriate i e it should be tight fitting but not be ahindrance Clothing in which grains of material can accumulate trousers with cuffs jackets and trousers with wide open pockets etc must not be worn particularly when cutting metal Do not wear any jewellery or clothing that can get caught or distract from the operation
15. accordance with your local disposal regulations To protect unusable cutting discs from misuse destroy them before disposal When the Power Cut is worn out or damaged beyond repair have it disposed of or recycled in an environmentally sound manner If necessary consult your local authorities 10 ODA 27 ILE d SERVICE 28 29 Technical data Displacement Bore 47 47 Stroke mm 35 Max power operating speed kW 1 min 3 2 9 500 3 2 9 500 Max torque Nm 3 9 3 9 Idling speed 1 min 2 600 2 600 Clutch engagement speed 1 min 3 900 3 900 Engine speed limitation 1 min 9 850 150 9 850 150 Max spindle speed 1 min 5 100 4 400 Sound pressure level Lpa eg per EN 19432 4 dB A 99 6 Kpa 2 5 99 6 Kya 2 5 Sound power level Lwa e per EN 19432 dB A 108 6 Kwa 2 5 108 6 Kwa 2 5 Vibration acceleration an e per EN 19432 1 Tubular handle m s 3 0 K 2 2 7 K 2 Rear handle m s 3 6 K 2 3 5 K 2 Carburetor diaphragm carburetor Type ZAMA C3 Ignition system with speed limitation Type electronic Spark plug Type NGK BPMR 7A Electrode gap mm 0 5 0 5 Fuel consumption at max load per ISO 8893 kg h 1 42 1 42 Specific consumption at max load per ISO 8893 g kWh 430 430 Fuel tank capacity l 0 7 0 7 Mixtu
16. age caused by Disregard of the instruction manual Non performance of the required maintenance and cleaning Incorrect carburetor adjustment Normal wear and tear Obvious overloading due to permanent exceeding of the upper performance limits The use of other than original MAKITA cutting discs Use of force improper use misuse or accidents Damage from overheating due to dirt on the fan housing Work on the Power Cut by unskilled persons or inappropriate repairs Use of unsuitable spare parts or parts which are not original MAKITA parts insofar as they have caused the damage Use of unsuitable or old oil Damage related to conditions arising from lease or rent contracts Damages caused by disregarding loose outer bolted connections Cleaning servicing and adjustment work is not covered by the guarantee All repairs covered by the guarantee must be performed by a MAKITA service centre 24 Troubleshooting Malfunction System Observation Cause Cutting disc does not start turning Clutch Engine runs Damage to clutch Cutting disc runs in idle Carburetor Cutting disc runs Incorrect idle speed clutch blocked clutch V belt Belt has insufficient tension V belt is worn Engine does not start or only with difficulty Ignition system Ignition spark No ignition spark Malfunction in fuel supply system com pression system mechanical malfunction Switch on STOP fault or short circuit i
17. ation switch will revert to the ON position again The engine is switched off but can be turned on again without moving the combination switch IMPORTANT To cut off the ignition current push the combina tion switch all the way down past the resistance point to the safety position 16 Adjusting the carburetor NOTE The grinding parts are equipped with an electronic ignition to limit the speed At the factory the idling speed has been set to approx 2600 rpm but the running in process of a new engine may require slight readjustment of the idling speed Adjustments to the adjusting screws L and H may only be made by an authorised MAKITA service centre Tr 5 k j For correct adjustment of the idling speed the following steps must be carried out Start the engine and run it until it is warm about 3 5 minutes Adjust the carburetor with the screwdriver 7 Order No 944 340 001 included with the Power Cut It has a lug that helps with adjustment Readjust the idling speed If the cutoff disc turns when the engine is idling turn the throttle stop screw T counter clockwise in small increments until the disc no longer turns If the engine suddenly stops in idle turn the screw back slightly clockwise Switch off the engine MAINTENANCE CAUTION Before doing any work on the Power Cutturn off the engine remove the cutting disc pull the plug cap off the spark plug
18. ck the disc if you hear or feel any change in cutting behaviour Turn off the Power Cut when taking a break or stopping work 14 Place the unit in such a way that the disc is not touching anything and cannot endanger anyone Do not put the overheated Power Cut in dry grass or on any inflammable objects The muffler is very hot danger of fire IMPORTANT After wet cutting first turn off the water feed and then let the disc run at least 30 seconds to fling off the remaining water and prevent corrosion 10 on AY Refuelling Changing cutoff discs Stopping work Transport Putting out of function Maintenance Kickback and lock in When working with the Power Cut there is a danger of kickback and lock in Kickback occurs when the top of the cutting disc is used for cutting 15 This causes the Power Cut to be thrown back toward the user with great force and out of control Risk of injury To prevent kickback observe the following Never cut with the section of the cutting disc shown in figure 15 Be especially careful when reinserting the disc into cuts that have already been started Lock in occurs when the cut narrows crack or workpiece under stress This causes the Power Cut to suddenly jump forward out of control and with great force Risk of injury To prevent lock in observe the following When reinserting the disc
19. d bend in the knees Save your back Guide the Power Cut in such a way that no part of your body is within the extended swing range of the disc 18 Use cutting discs only for the materials for which they are de signed Use cutting discs only for the materials for which they are de signed Do not use the Power Cut to lift up and shovel away pieces of material and other objects Important Before cutting remove all foreign objects such as rocks gravel nails etc from the cutting area Otherwise such objects can be flung away by the disc with great speed Injury hazard When cutting workpieces down to length use a firm support If necessary secure the workpiece from slipping but do not steady it with your foot or allow another person to hold it When cutting round items always secure them against rota tion 15 18 When using synthetic resin cutting discs always ob serve the following CAUTION Synthetic resin cutting discs can absorb moisture This moisture can cause the disc to become unbalanced at high speed This imbalance can cause the disc to break Do not cool resin cutting discs with water or other fluids Do not expose resin cutting discs to high humidity or rain Do not use resin cutting discs past their use by date expira tion date The date quar
20. e clogged It is recommended to replace the suction head once every three months in order to ensure unimpeded fuel flow to the carbure tor Unscrew the tank cap 6 pull the retainer out of the opening Empty fuel tank Use a wire hook to pull the suction out of the tank opening for replacement Caution Do not allow fuel to come into contact with skin 20 Replacing the starter cable Unscrew four screws 1 Remove fan housing 2 Insert a small screwdriver through the ventilation slit on the back of the fan housing 2 near the holder 15 Bend the air guide tab 4a slightly to the side and carefully remove the air guide 3 from the fan housing CAREFUL Injury hazard Do not unscrew screw 7 if the return spring is under tension If the starter cable is to be replaced although it is not broken it will be necessary to first de tension the cable drum return spring 13 To do this use the grip to pull the cable all the way out of the fan housing Hold the cable drum with one hand and with the other push the cable into the space 14 Carefully let the drum turn until the return spring is no longer under tension Unscrew screw 7 and remove the carrier 8 Remove any pieces of old line and take out the spring 6 Carefully remove the cable drum 5 Put the spring 6 back in the cable drum so that its lower end fits in the notch see the arrow in the close up Thread a new cable dia
21. espon sible authorities or the builder of the structural member Reinforcement rods must be cutin the prescribed sequence and in accordance with applicable safety regulations NOTE Mortar stone and concrete develop large quantities of dust during cutting To increase the lifetime of the cutting disc by cooling to improve visibility and to avoid excessive dust creation we strongly recommend wet cutting instead of dry cutting S 4 ae ME ges TN EN Za cal NS BID CA E i aS Y 4 SA Pa 20 In wet cutting the disc is wetted at an equal rate on both sides by a trickle of water MAKITA offers the right accessories for all wet cutting applications see also SPECIAL ACCESSORIES Remove foreign objects such as sand stones and nails found within the working area Caution Watch out for electric wires and cables The rapid rotation of the cutting disc at the point of contact throws fragments out of the cut groove at high speed For your safety swing the protection hood down as far as pos sible 23 so that material fragments are thrown forward away from the operator Mark the cut and then make a groove about 5 mm just under 1 5 along the entire length of the planned cut This groove will then guide the Power Cut accurately guring the actual cutoff Perform the cut with a steady back and forth motion When cutting slabs to size you need
22. gine off There are two basic types of cutoff discs For metal hot cutting For masonry cold cutting NOTE When using diamond cutoff discs always make sure to observe the direction of rotation markings Diamond discs should only be used for cutting masonry brick concrete etc Cutoff discs are intended only for radial loading i e for cutting Do not grind with the sides of the cutting disc This will break the disc 10 Caution Never change direction turning radius less than 5 meters 5 1 2 yards exert lateral sideways pressure or tip the Power Cut during cutting 11 Use a cutting disc only for cutting the materials it is intended for The proper type of disc must be used for either metals or masonry The arbor hole of the cutting disc must be an exact fit with the arbor or shaft If the arbor hole is larger it must be fitted with an adapter ring available as an accessory The cutting disc must be rated for freehand cutting at up to 4370 rpm or 80 m sec for 350 mm discs or up to 5100 rpm or 80 m s for 300 mm discs Use only cutting discs that comply with EN 12413 EN 13236 The disc must be free of defects 12 Do not use defective cut ting discs Always tighten the cutting disc mounting bolt to a torque of 30 Nm Otherwise the cutting disc can twist Before starting the cutting disc make sure you have a steady footing Putthe Power Cut into operation only as described in this in
23. isible in the counter holding opening 10 of the cutting arm Insert the Allen key 2 as far as it will go The shaft is now blocked Tighten the screw with the combination wrench 1 NOTE Tighten the screw firmly 30 2 Nm as otherwise the cutting wheel may slip during cutting Remove the Allen key and combination tool 13 Fuel CAUTION This saw is powered by mineral oil products gasoline and oil Be especially careful when handling gasoline Avoid all flame or fire Do not smoke explosion hazard Fuel mixture This tool is powered by a high performance air cooled two stroke engine It runs on a mixture of gasoline and two stroke engine oil The engine is designed for unleaded regular gasoline with a min octane value of 91 ROZ In case no such fuel is available you can use fuel with a higher octane value This will not affect the engine In order to obtain an optimum engine output and to protect your health and the environment use unleaded fuel only To lubricate the engine use a synthetic oil for two stroke air cooled engines quality grade JASO FC or ISO EGD which has to be added to the fuel The engine has been designed for use of MAKITA high performance two stroke engine oil and a mixture ratio of only 50 1 to protect the environment In addition along service life and reliable operation with a minimum emission of exhaust gases are ensured MAKITA high performance two stroke engine
24. n putting cutting discs in storage be careful to Cleanand dry them well CAUTION Do NOT clean synthetic resin cutting discs with water or other fluids Store them lying down flat Avoid dampness freezing temperatures direct sunshine high temperatures and temperature fluctuations as these can cause breakage and splintering Before re using a resin cutting disc make sure of the use by expiration date quarter and year stamped on the arbor ring If this date has been exceeded do NOT use the cutting disc Always check new cutting discs or cutting discs that have been in storage to make sure that they are free of defects and before the first cut test run the tool at top speed for at least 60 seconds Keep body parts and people well away out of range of the direction of the cutting disc during this test Maintenance Before performing maintenance work switch off the Power Cut 27 and pull out the plug cap Always check the Power Cut before using it to make sure that it is in good working order In particular make sure that the cutting disc is properly mounted Make sure that the cutting wheel is undamaged and suitable for the job it will be used for Operate the Power Cut only at a low noise and emission level For this ensure the carburetor is adjusted correctly Clean the Power Cut regularly Check the fuel tank cap regularly for good sealing Observe the accident prevention i
25. n the wiring plug cap or spark plug defective dies immediately Fuel supply Fuel tank is filled Choke in wrong position carburetor defective suction head dirty fuel line bent or interrupted Compression Inside Cylinder base packing ring defective radial system shaft packings defective cylinder or piston rings defective Outside Spark plug does not seal Mechanical Starter does not engage Spring in starter broken broken parts malfunction inside the engine Warm start difficulties Carburetor Fuel tank is filled Wrong carburetor adjustment Ignition spark Engine starts but Fuel supply Fuel tank is filled Wrong idling adjustment suction head or carburetor dirty Tank venting defective fuel line interrupted cable defective STOP switch defective Decompression valve dirty Several systems may be involved simultaneously Insufficient power Engine is idling Air filter dirty wrong carburetor adjustment muffler clogged exhaust channel in cylinder clogged SPECIAL ACCESSORIES Diamond cutting discs MAKITA diamond cutting discs meet the highest demands in working safety ease of operation and economical cut ting performance They can be used for cutting all materials except metal The high durability of the diamond grains ensures low wear and thereby a very long service life with almost no change in disc diameter over the lifetime of the disc This gives consistent cutting performance and th
26. ne speed they have a lower effective circumfer ential speed and therefore do not cut as well Cut l beams and L bars in steps see Figure 21 Cut bands and plates like pipes along the wide side with a long cut Whencutting material under stress supported material or mate rial in structures always make a notch in the thrust pressure side and then cut from the tension side so that the disc does not lock in Secure cutoff material from falling CAUTION If there is a chance that the material is under stress be pre pared for it to kick back Make sure you can get out of the way if you have to Be particularly careful in scrap metal yards junkyards at ac cident sites and with haphazard piles of material Precariously balanced pieces or pieces under stress can actin unpredictable ways and may slide jump out or burst Secure cutoff material from falling Always exercise extreme caution and use only equipment that is in perfect working order Observe the accident prevention rules and regulations of your employer and or insurance organization 8 Cutting masonry and concrete IMPORTANT Always wear approved respiratory protection Asbestos and other materials that can release toxic sub stances may be cut only after notifying the proper authorities and under their supervision or that of a person appointed by them When cutting prestressed and reinforced concrete piles follow the instructions and standards of the r
27. not cut through the entire material thickness creating unnecessary dust Instead simply make a shallow groove and then knock off the excess material cleanly on a flat surface 25 CAREFUL When cutting into lengths cutting through material making cutouts etc always make sure to plan the direction and sequence of cuts in such a way that the disc does not get jammed by the cut off piece and that no persons can be injured by falling pieces Transport and storage Always turn off the Power Cut when transporting it or moving it from place to place on a site 26 Never carry or move the unit with the engine on or the disc moving Carry the unit only by the tubular middle handle with the cut ting disc pointing behind you 26 Avoid touching the exhaust muffler burn hazard When moving the Power Cut over longer distances use a wheelbarrow or wagon When transporting the Power Cut in a vehicle make sure it is securely positioned in such a way that no fuel can leak out Always remove the cutting disc before transporting the unit in a vehicle The Power Cut should be stored safely in a dry place It must not be left outdoors Always dismount the cutting disc before storage Keep the Power Cut away from children Before long term storage and before shipping the Power Cut follow the instructions in the chapter on Periodic care and maintenance ALWAYS empty the fuel tank and run the carburetor dry Whe
28. nstructions issued by trade associations and insurance companies NEVER make any modifications to the Power Cut You will only be putting your own safety at risk Perform only the maintenance and repair works described in the instruction manual All other work must be carried out by MAKITA Service Use only original MAKITA spares and accessories The use of non MAKITA spares accessories or cutting discs increases the risk of accident We cannot accept any respon sibility for accidents or damage occurring in association with the use of cutting discs or accessories other than original MAKITA First aid For the event of a possible accident please make sure that a firstaid kitis always immediately available close by Immediately replace any items used from the first aid box When calling for help give the following information Place of the accident What happened Number of injured people Kind of injuries Your name NOTE Individuals with poor circulation who are exposed to excessive vibration may experience injury to blood vessels or the nervous system Vibration may cause the following symptoms to occur in the fin gers hands or wrists Falling asleep numbness tingling pain stabbing sensation alteration of skin colour or of the skin If any of these symptoms occur see a physician Disposal and environmental protection Be mindful of the environment Dispose of worn out or defective cutting discs in
29. ny maintenance work A hot engine can cause burns Wear protective gloves The spark plug Order No 965 603 021 must be replaced in case of damage to the insulator electrode erosion burn or if the electrodes are very dirty or oily Remove the filter cover and hood See Cleaning changing the air filter Pull the plug cap 1 off the spark plug Use only the combination wrench supplied with the saw to remove the spark plug CAUTION To prevent damage to the decompression valve 8 when unscrewing the spark plug position the combina tion tool in such a way that it does not impact the valve Electrode gap The electrode gap must be 0 5 mm CAUTION Use only NGK BPMR 7A spark plug t Other spark plugs can damage the 95mm ignition system Checking the ignition spark Insert the combination tool 2 between the ventilation hood and cylinder only as shown in the illustration CAUTION Do not insert the combination tool into the spark plug hole but make contact only with the cylinder otherwise you may damage the engine Using insulated pliers hold the spark plug 3 unscrewed but with the plug cap on against the combination tool away from the spark plug hole Switch the combination switch 4 to ON Pull the starter cable hard If the function is correct an ignition spark must be visible near the electrodes Replacing the suction head The felt filter 5 of the suction head can becom
30. oil is available in the following sizes to suit your individual requirements 100 ml order number 980 008 606 1 order number 980 008 607 In case MAKITA high performance two stroke engine oil is not available it is urgently recommended to use a mixture ratio of 50 1 with other two stroke engine oils quality grade JASO FC or ISO EGD as otherwise optimum operation of the engine cannot be guaranteed Caution Do not use ready mixed fuel from petrol stations The correct mixture ratio 50 1 when using MAKITA high performance two stroke engine oil i e mix 50 parts gasoline with 1 part oil 50 1 when using other synthetic two stroke engine oils quality grade JASO FC or ISO EGD i e mix 50 parts gasoline with 1 part oil NOTE For preparing the fuel oil mixture first mix the entire oil quantity with half of the fuel required then add the remaining fuel Thoroughly shake the mixture before filling it into the chain saw tank Caution Open the tank cap carefully as pressure might have built up inside A Gasoline 50 1 50 1 1000 cm 1 litre 20 cm 20 cm 5000 cm 5 litre 100 cm 100 cm 10000 cm 10 litre 200 cm 200 cm It is not wise to add more engine oil than specified to ensure safe operation This will only result in a higher production of combus tion residues which will pollute the environment and clog the exhaust channel in the cylinder as well as the muffler In ad dition fuel con
31. our own There must be someone around in case of an emergency within shouting distance Observe all anti noise regulations when working in residential areas Never use the Power Cut near inflammable materials or explosive gases The Power Cut can create sparks leading to fire or explosion Make sure that all persons within 30 meters 33 yards such as other workers are wearing protective gear see Protective Equipment 8 Children and other unauthorized persons must remain more than 30 meters away from the working area Keep an eye out for animals as well 9 Before starting work the Power Cut must be checked for perfect function and operating safety according to the pre scriptions In particular make sure that the cutting wheel is in good condition replace immediately if torn damaged or bent the cutting wheel is properly mounted the protective hood is locked in place the hand guard is properly mounted the throttle moves easily and the half throttle lock button functions properly the grips are clean and dry and the combination switch functions properly Start Stop I O switch choke Start the Power Cut only after complete assembly and inspec tion Never use the Power Cut when it is not completely as sembled 7 d gt 5 8 l 1 wearing Protective Equipment Cutoff discs The protection hood must always be on Change discs only with the en
32. re ratio fuel two stroke oil when using MAKITA oil 50 1 50 1 when using other oils quality grade JASO FC or ISO EGD 50 1 50 1 when using Aspen Alkylat two stroke fuel 50 1 2 50 1 2 Cutting disc for 80 m sec 300 20 0 5 350 20 0 5 9 Cutting disc for 80 m sec 350 25 4 5 Arbor diameter 20 0 20 0 V belt 965 300 501 965 300 510 Overall weight tanks empty without cutting disc Data apply to idle and rated speed operation at a ratio of 1 7 to 6 7 2 Circumference speed at max engine speed 9 Outside diameter arbor hole thickness 4 At the workplace at user s ear 5 Country specific Uncertainty K Data apply rated speed operation 8 5 8 8 1 Denomination of components Identification plate 9 Indicate when ordering spare parts Tnakita EK6101 2012 123456 I Makita Corporation Anjo Aichi Japan Serial number XXX Madein Germary XXX XXX Tmo Handle Air filter cover Tubular handle Protection hood Water set Adjusting screw Hold opening Fuel tank with handle 1 2 3 4 5 6 7 8 9 Identification plate o Tank cap fuel Carburetor adjustment opening N Holder for combination tool and 1 2 hose wo Starter grip I ll Year of manufacture Tua kita a 4 4 Air intake Fuel pump Primer Safety locking button
33. red to start the engine and you will notice some resistance when pulling the starter cable If you notice this check the spring 6 and replace if neces sary Mounting the fan housing Insert the air guide 3 in the fan housing so that the five re cesses 4 engage Position the fan housing on the machine apply slight counter pressure and pull the starter grip until the starter mechanism catches Tighten screws 1 22 Instructions for periodic maintenance To ensure long life prevent damage and ensure the full functioning of the safety features the following maintenance must be per formed regularly Guarantee claims can be recognized only if this work is performed regularly and properly Failure to perform the prescribed maintenance work can lead to accidents Users of the Power Cut must not perform any maintenance work not described in this Instruction Manual All such work must be carried out by a MAKITA service centre Page General Entire Power Cut Clean exterior check for damage In case of damage have repaired by a qualified service centre immediately Cutting disc Inspect regularly for damage and wear 6 Clutch Have inspected at a service center Protection hood Clean 19 Before each start Cutting disc Inspect for damage and make sure the cutting wheel is 6 right for the job Protective hood Adjust position 16 Combination switch Functional check Safety locking bu
34. s not necessary to retighten it A worn V belt causes the cutoff disc turns at the lowest idle speed In this case the V belt must be replaced 18 Cleaning the protection hood Over time the inside of the protective hood can become caked with material residue especially from wet cutting which if allowed to accumulate can hinder the free rotation of the cut ting disc For this reason the hood must be cleaned out from time to time Take off the cutting wheel with spring washer and remove the accumulated material from inside the hood with a strip of wood or similar implement Clean the shaft and all removed parts AQQ NOTE To install the cutting wheel see Mounting the cutting wheel Cleaning changing the air filter CAUTION Turn off the engine before cleaning the air filter Never clean out the air filter with compressed air Do not use fuel to clean the air filter insert 3 and inner filter 6 The service life of the engine depends on the condition and regular maintenance of the filter elements Failure to perform maintenance and cleaning at the prescribed intervals will cause increased wear inside the engine If the air filter becomes damaged replace immediately Pieces of cloth or large dirt particles can destroy the engine Do not work in dusty conditions when it can be avoided The fine dust generated when dry cutting concrete and stone is hazardous to the health of the operator and also
35. smoke or work near open fires 6 Let the engine cool down before refuelling Fuels can contain substances similar to solvents Eyes and skin should not come in contact with mineral oil products Always wear protective gloves when refuelling not the regular work gloves Frequently clean and change protective clothes Do not breathe in fuel vapors Inhalation of fuel vapours can be hazardous to your health Do not spill fuel If a spill occurs clean off the Power Cut im mediately Fuel should not come in contact with clothes If your clothes have come in contact with fuel change them at once Ensure that no fuel oozes into the soil environmental protection Use an appropriate base Refuelling is not allowed in closed rooms Fuel vapors will ac cumulate near the floor explosion hazard Ensure to firmly tighten the screw cap of the fuel tank Before starting the engine move to a location at least 3 meters approx 3 1 4 yards from where you fuelled the Power Cut 7 but not within the extended swing range of the cutting disc direction of sparks Fuel cannot be stored for an unlimited period of time Buy only as much as will be consumed in the near future When making up the gasoline oil mixture always put the oil in the mixing container first and then the gasoline Use only approved and marked containers for the transport and storage of fuel Keep fuel away from children Putting into operation Do not work on y
36. struc tion manual 13 Always place your left foot in the rear handle and grasp the other handle firmly with thumb and fingers Other starting methods are not allowed When starting the Power Cut it must be well supported and securely held The cutting disc must not be touching anything Ifthe cutting disc is new test it by running it at least 60 seconds at top speed When doing this make sure that no persons or body parts are in the extended swing range of the disc in case itis defective and flies apart When working with the Power Cut always hold it with both hands Take the back handle with the right hand and the tubu lar handle with the left hand Hold the handles tightly with your thumbs facing your fingers CAUTION When you release the throttle lever the disc will keep spinning for a short period of time free wheeling effect Continuously ensure that you have a safe footing Hold the Power Cut such that you will not breathe in the exhaust gas Do not work in closed rooms or in deep holes or ditches danger of poisoning by fumes Switch off the Power Cut immediately if you observe any changes in its operating behavior Switch off engine before refuelling changing the cutoff disc work breaks transporting or moving the Power Cut taking it out of operation or dealing with malfunctions Before any maintenance work move the combination switch to the lock symbol 14 Turn off the engine immediately and che
37. sumption will rise and performance will decrease The Storage of Fuel Fuels have a limited storage life Fuel and fuel mixtures age through evaporation especially at high tempera tures Aged fuel and fuel mixtures can cause starting problems and damage the engine Purchase only that amount of fuel which will be consu med over the next few months At high temperatures once fuel has been mixed it should be used up in 6 8 weeks Store fuel only in proper containers in dry cool secure locations AVOID SKIN AND EYE CONTACT Mineral oil products degrease your skin If your skin comes in contact with these substances repeatedly and for an extended period of time it will desiccate Various skin deseases may result In addition allergic reactions are known to occur Eyes can be irritated by contact with oil If oil comes into your eyes immediately wash them with clear water If your eyes are still irritated see a doctor immediately 14 Fuel mixture Refuelling IMPORTANT FOLLOW THE SAFETY PRECAUTIONS Be careful and cautious when handling fuels The engine must be turned off and cooled down Carefully clean the area around the fuel tank filler neck to keep dirt from getting in the tank Place the Power Cut on an even surface Unscrew the tank cap and fill tank with fuel mixture Take care to avoid spilling Screw the tank cap back on hand tight Clean screw cap and tank after refuelling Never star
38. t or op erate the Power Cut in the same place as it was fuelled If fuel gets on your clothing change clothes immediately Starting the engine NOOO Ler i necessary CAUTION Observe the SAFETY INSTRUCTIONS on page 4 and 5 Start the Power Cut only after complete assembly and inspection Move at least 3m away from the place where you fuelled the Power Cut Make sure you have a good footing and place the Power Cut on the ground in such a way that the cutting disc is not touching anything Move the protective hood 1 into the proper position for the work you intend to do see illustration The protective hood 1 can be moved between the stops in both directions Note A water supply line from a pressurized water tank or other source is connected by the water set on the protective hood The water flow rate can be adjusted with the adjusting screw 2 Press the 1 2 hose into the holder 2a For a slower flow turn the adjusting screw clockwise For a faster flow turn it counter clockwise ll Cold start Choke ON t Warn start ON Engine off Combination switch in safety position ignition current cut off necessary for all maintenance repair and installation work Cold starting Grasp front handle firmly with one hand and press the Power Cut against the ground Place left toe in the rear handguard Prime the fuel pump 4 by pressing i
39. t several times until you can see fuel in the pump Move the combination switch 3 up choke position This also actuates the half throttle lock Pull starter handle smoothly and evenly until you hear the first ignition but max 3 5 pulls CAUTION Do not pull the starter cable more than about 50 cm 20 out and let it back in slowly by hand Move the combination switch 3 to the central ON position Pull the starter handle smoothly and evenly again As soon as the engine is running grasp the rear handle the safety lock button 5 is actuated by the palm of the hand and press the throttle trigger 6 The half throttle lock will disengage and the engine will now idle Warmstart As described above for cold starting but before starting push the combination switch 3 up Choke position and then right away back to the middle ON position This is only to engage the half throttle lock If the engine doesn t start after 2 or 3 pulls repeat the entire starting procedure as described for cold starting NOTE If the engine was switched off only for a short time the saw can be started without using the combination switch Important If the fuel tank has been completely emptied and the engine has stopped due to lack of fuel prime the fuel pump 4 by pressing it several times until you can see fuel in the pump Stopping the engine Depress the combination switch 3 NOTE After being pressed down the combin
40. ter and year is stamped on the disc s arbor ring EXAMPLE 04 2013 This cutting disc can be used through the end of the fourth quarter of 2013 if properly stored and correctly used Cutting metals IMPORTANT Always wear approved respiratory protection Materials that can release toxic substances may be cut only after notifying the proper authorities and under their supervi sion or that of a person appointed by them CAUTION The rapid rotation of the cutting disc heats metal and melts it at the point of contact Swing the guard as far down as pos sible 19 in order to direct the stream of sparks forward away from the operator fire hazard Determine the cut line mark the cut and apply the disc to the material at moderate speed to cut a guide groove before going to top speed and applying more pressure to the Power Cut Keep the disc straight and vertical Do not tip it as this can break it The best way to get a good clean cut is to pull or move the Power Cut back and forth Do not simply press the disc into the material Thick round stock is best cut in stages 20 Thin tubing and pipes can be cut with a simple downward cut Cut large diameter pipes as for round stock To prevent tipping and for better control do not let the disc sink too deeply into the material Instead always cut shallow around the whole piece Worn discs have a smaller diameter than new discs so that at the same engi
41. tton Functional check Throttle lever Functional check 16 Tank cap Check for tightness Every day Idle speed Check cutting disc must not turn on idle 17 Every week Starter housing Clean to ensure proper air cooling 12 Starter cable Check for damage 21 V belt Inspect for damage and wear 18 Spark plug Check and replace if necessary 20 Muffler Check tightness of mounting 12 Screws and nuts Check their condition and that they are firmly secured Monthly Air filter insert Clean replace after 500 operating hours 19 Every 3 months Suction head Replace 20 Fuel tank Clean Annually Entire Power Cut Check at an authorized service centre Storage Entire Power Cut Clean exterior check for damage In case of damage have repaired by a qualified service centre immediately Cutting disc Remove and clean 13 Fuel tank Empty and clean Carburetor Run empty Service spare parts and guarantee Maintenance and repair The maintenance and repair of modern cutoff saws and their safety related components requires qualified technical training and a workshop equipped with special tools and testing devices We therefore recommend that you consult a MAKITA service centre for all work not described in this instruction manual The MAKITA service centres have all the necessary equipment and skilled and experienced personnel who can work out cost effective solutions and advise you in all matters To find your local distributor please visit www makita outdoor com
42. uels Refuelling Putting into operation Cutting discs Kickback and lock in sat Working behavior Method of working cccceseeeeees 7 Always observe the following when using synthetic resin cutting discs Cutting metal ee Cutting masonry and concrete Transport and storage Maintenance First aid Disposal and environmental protection ccceee 10 Technical data Denomination of components PUTTING INTO OPERATION Mounting the Cutting GiSC vseen iiaei 13 Fuels Refuelling Starting the engine Cold starting Warm starting Stop engine ry Adjusting the carburetor cccccseseseeeseeeseeeteeees 17 MAINTENANCE Changing the V belt Cleaning the protection hood Cleaning changing the air filter Replacing the spark plug Checking the ignition spark Replacing the suction head Replacing the starter cable Replacing the return spring Replacing the start spring Instructions for periodic maintenance Service spare parts and guarantee Troubleshooting SPECIAL ACCESSORIES Diamond cutting discs water tank cece 25 Extract from spare parts list 0c ccecseeeeeees 26 27 Packing Your MAKITA Power Cut is packed in a cardboard box to pre vent shipping damage Cardboardis a basic raw material and is consequently reuseable or suitable for recycling waste paper recycling Q NE p I
43. us high economy The outstanding cutting qualities of the discs make cutting easier The metal disc plates give highly concentric running for minimal vibration during use The use of diamond cutting discs reduces cutting time sig nificantly This in turn leads to lower operating costs fuel consumption wear on parts repairs and last but not least environmental damage Pressurized water tank To keep down dust and for better cutting disc cooling MAKITA offers several options for wetting the disc during operation The pressurized water tank is connected to the Power Cut by the water set on the protective hood See Accessories for order number 25 Extract from the spare parts list EK6100 Use only original MAKITA parts For repairs and EK6101 replacement of other parts see your MAKITA service centre Tr 4 k j 14 Extract from the spare parts list EK6100 Use only original MAKITA parts For repairs and EK6101 replacement of other parts see your MAKITA service centre Tra 5 k j Pos MAKITA No Qty Denomination Synthetic resin cutting disc 1 966121150 1 Cutting disc for steel dia 300 20 mm 966141150 1 Cutting disc for steel dia 350 20 mm 966144150 1 Cutting disc for steel dia 350 25 4 mm 1 966121120 1 Cutting disc for masonry dia 300 20 mm 966 141120 1 Cutting disc for masonry dia 350 20 mm 966144120 1 Cutting disc for masonry dia 350 25 4 mm Diamond cutting disc 2
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