Makita 51778 User manual

7-iw Hypoid Saw
Blade
diameter
185 mm
17-1/4"1
185 mm (7-1/4") MODEL 51 778
MODEL 5277B
No load speed Overall Net
Max. cutting capacities
50 O 450 (RPMI length weight
439 mm 6.8 kg
4,300 (17-1/4"1 (15.0
Ibs)
62 mm 40 mm 44 mm
(2-3/8") (1-9/16") (1-23/32")
INSTRUCTION MANUAL
DOUBLE
INSU LATlO N

GENERAL SAFETY RULES
(For All Tools)
WARNING! Read and understand all instructions. Failure
to follow
all instructions listed below, may result inelectric
shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
READ ALL INSTRUCTIONS.
1. Keepyour work area cleanand well lit. Cluttered benches and dark areas invite
accidents.
2. Donotoperate power tools inexplosiveatmospheres, suchas inthe presence
of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.
3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to loose control.
4. Double Insulatedtoolsare equipped witha polarizedplug(onebladeiswider
than the other.) This plug will
fit in a polarized outlet only one way. If the
plugdoes not fit fully
in the outlet, reverse the plug. If it still does not fit,
contact a qualified electricianto install a polarized outlet. Do not change
the plug
in any way. Double insulation H eliminates the need for the three
wire grounded power cord and grounded power supply system.
5. Avoid body contactwithgrounded surfaces such as pipes, radiators, ranges
and refrigerators. There is an increased risk of electric shock if your body is
grounded.
6. Don't expose power tools torain or wet conditions. Water entering a power
tool
will increase the risk of electric shock.
7. Do notabuse the cord. Never usethe cordtocarry the tools or pull the plug
from anoutlet. Keepcord away from heat, oil, sharp edges or movingparts.
Replace damaged cords immediately. Damaged cords increase the risk of
electric shock.
8. Whenoperating a powertooloutside, use an outdoor extension cordmarked
"W-A' or "W." These cords are rated for outdoor use and reduce the risk
of electric shock.
9. Stay alert, watchwhat you aredoing andusecommonsensewhenoperating
a power tool. Do not use tool while tired or under the influence of drugs,
alcohol, or medication.
A momentof inattentionwhile operating powertools
may result in serious personal injury.
IO. Dressproperly. Donotwear loose clothingorjewelry. Contain longhair. Keep
your hair, clothing, and glovesaway frommovingparts. Looseclothes, jewelry
or long hair can be caught
in moving parts.
2

11. Avoid accidental starting. Be sure switch is off before plugging in. Carrying
tools withyour finger onthe switch or plugging intools that have the switch
on invites accidents.
12. Remove adjusting keys or switches before turning the tool on. A wrench or
a key that is left attachedto a rotating part of the tool may result inpersonal
injury.
13. Do not overreach. Keepproper footingandbalanceatalltimes. Properfooting
and balance enables better control of the tool in unexpected situations.
14. Use safety equipment. Always wear eye protection. Dust mask, non-skid
safety shoes, hard hat, or hearing protection must be used for appropriate
conditions.
15. Use clamps or other practicalway to secure and support the workpiece to
astable platform. Holdingthe work by handor against your body is unstable
and may lead to
loss of control.
16. Donotforce tool. Use
the correct toolfor your application. The correcttool
will do the job better and safer at the rate for which it is designed.
17. Do not use tool if switch does not turn
it on or off. Any tool that cannot
be controlled with the switch is dangerous and must be repaired.
18. Disconnectthe plug from the powersource before makingany adjustments,
changing accessories, or storing
the tool. Such preventive safety measures
reduce the risk
of starting the tool accidentally.
19. Store idle tools out of reach of children and other untrained persons.
Tools
are dangerous in the hands of untrained users.
20. Maintain tools with care. Keep cutting tools sharp and clean. Properly
maintainedtools, withsharp cutting edges are less likely to bindand are easier
to control.
21. Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the tools operation. If damaged, have
the toolservicebefore using. Many accidents are caused by poorly maintained
tools.
22. Use only accessories that are recommended by the manufacturerfor your
model. Accessories that may be suitable for one tool, may becomehazardous
when used on another tool.
23.
Tool service must be performed only by qualified repair personnel. Service
or maintenance performed by unqualified personnel could result
in a risk of
injury.
24. When servicing a tool, use only identical replacement parts. Follow instruc-
tions in the Maintenance section
of this manual. Use of unauthorized parts
or failure to follow Maintenance Instructions may create a risk of electric shock or
injury.
3

Specific Safety Rules
1. DANGER! Keep hands away from cuttingarea and blade. Keepyour second
hand on auxiliary handle,
or motor housing. If both hands are holding the
saw, they cannot be cut by the blade.
Keep your body positioned to either side of the saw blade,
but not in line
withthe saw blade. KICKBACK couldcause the saw tojump backwards. (See
"Causes and Operator Prevention of Kickback")
Do not reach underneath the work while blade is rotating. The guard can
not protect youfromthe blade below the work. Don't attempttoremovecut
material when blade is moving.
CAUTION: Blades coast after turn off.
2. Check lower guard for proper closing before each use. Do not operate saw
if lower guard does not move freely and close instantly. Never clamp or tie
the lower guard intothe open position. If saw is accidentally dropped, lower
guard may be bent. Raisethe lower guard withthe Retracting Handleand make
sure
it movesfreely and does nottouch the bladeor any other part, inallangles
and depths of cut.
3. Check the operation and condition of the lower guard spring. If the guard
andthe springare notoperating properly, they mustbeservicedbefore
use.
Lower guard may operate sluggishly due to damaged parts gummy deposits,
or
a buildup of debris.
4. Lower guard should be retracted manually only for special cuts such as
"Pocket Cuts" and "Compound Cuts." Raise lower guard by Retracting
Handle.
As soonas bladeentersthe material, lower guardmustbereleased.
For all other sawing, the lower guard should operate automatically.
5. Always observe that the lower guard is covering the blade before placing
saw down on bench or floor. An unprotected, coasting blade
will cause the
saw towalk backwards, cutting whatever is
in itspath. Be awareof the time
it takes for the blade to stop after switch is released.
6. NEVER holdpiecebeingcut in your handsor across your leg. It is important
to support the work properly to minimize body exposure, blade binding, or
loss of control.
7. Holdtoolbyinsulatedgrippingsurfaceswhen performinganoperationwhere
the cutting tool may contact hidden wiring or its own cord. Contact with
a "live" wire will also makeexposed metal parts of the tool "live" and shock
the operator.
8. When ripping always use a rip fence or straight edge guide. This improves
the accuracy of cut and reduces the chance for blade binding.
9. Always use blades with correct size and shape (diamond vs. round) arbor
holes. Blades that do not match the mounting hardware of the saw
will run
eccentrically, causing
loss of control.
IO. Neveruse damaged or incorrect blade washers or bolts. The blade washers
and bolt were specially designedfor your saw, for optimum performance and
safety or operation.
4

11. Causes and Operator Prevention of Kickback:
Kickback is a sudden reaction toa pinched, bound or misaligned saw blade,
causing an uncontrolled saw to lift up and out of the workpiece toward the
operator.
Whentheblade ispinched or bound tightlyby thekerf closing down, theblade
stalls and themotor reaction drives theunitrapidly back toward the operator.
If the blade becomes twisted or misaligned in the cut, the teeth at the back
edge of theblade can dig into the top surface of the wood causing the blade
to climb out of the kerf and jump back toward operator.
Kickback is the result of tool misuse and/or incorrect operating procedures
or conditions and can be avoidedby taking proper precautions
as given below.
Maintainafirm grip withbothhandsonthe saw andpositionyour body and
arm to allow you to resist
KICKBACK forces. KICKBACK forces can be
controlled by the operator, if proper precautions are taken.
When blade is binding, or when interrupting a cut for any reason, release
thetrigger andholdthe saw motionless
in thematerial until the bladecomes
toa completestop. Never attempt toremove the saw from the work or
pull
the saw backward while the blade is in motion or KICKBACK may occur.
Investigateand take corrective actions to eliminatethe cause
of bladebinding.
When restarting a saw in the workpiece, center the saw blade
in the kerf
and check that saw teeth are not engaged into the material.
If saw blade
is binding, it may walk up or KICKBACK from the workpiece as the saw is
restarted.
Support large panels tominiinize the risk of blade pinchingand
KICKBACK.
Large panels tend to sag under their own weight. Supports must be placed
under the panel on both sides, near the line of cut and near the edge
of the
panel as shown in Fig.
1.
To minimizethe risk of blade pinching and kickback. When cutting operation
requires the resting of the saw on the work piece, the saw shall be rested
on the larger portion and the smaller
To avoid kickback, do support board
or panel near the cut.
I
Fig. 1
xecut off.
Don't support board or panel away
or panel near the cut.
Fig. :
5

Do not use dull or damaged blade. Unsharpened or improperly set blades
produce narrow kerf causingexcessivefriction, blade binding and KICKBACK.
Bladedepthandbeveladjustinglockingleversmustbe tightandsecurebefore
making cut. If blade adjustment shifts while cutting, it may cause binding
and KICKBACK.
Use extra caution when makinga "Pocket Cut" intoexisting walls or other
blindareas. The protrudingblade may cut objects
that cancause KICKBACK.
NEVER place your hand or fingers
behind the saw. If kickback occurs,
the saw couldeasilyjump backwards
over your hand, possibly causing
severe injury.
Fig.
12. Adjustments. Beforecutting be sure depthand beveladjustments aretight.
13. Avoid Cutting Nails. Inspect for and remove all nails from lumber before
cutting.
14. When operating the saw, keep the
cordaway from the cutting area and
position
it so that it will not becaught
on the workpiece during the cutting
operation.
Operate with proper hand support,
proper workpiece support, and
supply cord routing away from the
work area.
A typical illustration of proper hand
support, workpiece support, and
supply cord routing.
Fig. 4
WARNIN G :
It isimportant tosupport the workpiece properlyand to holdthe saw firmly
toprevent
loss of controlwhichcouldcausepersonalinjury. Fig. 4 illustrates
typical hand support of the saw.
6

15. Place the wider portion of the saw base on that part of the workpiece which
is solidly supported, not on the section that will fall
off when the cut is made.
As examples, Fig. 5 illustrates the RIGHT way to cut off the end of a board,
and Fig.
6 the WRONG way. If the workpiece is short or small, clamp it down.
DON'T
TRY TO HOLDSHORT PIECES BY HAND!
I I
Fig. 5
16. Never attempttosaw withthe circu-
lar saw held upside down
in a vise.
This isextremely dangerousandcan
lead to serious accidents.
Fig. 1
7

SYMBOLS
Describedbelow are symbolscommonly listed on tools.
v ................................. volts
A ................................. amperes
Hz ................................. herts
kg
................................. kilograms
h
................................. hours
min
................................. minutes
S ................................. seconds
% ................................. alternating current
---- ................................. direct current
% ................................. no load speed
-
................................. alternating or direct current
Dl ................................. Class II Construction
................................. splash-proof construction
Ab ................................. watertight construction
... /min ................................ revolutions or reciprocation per minute
@ ................................. number of blows
8

OPERATION
Removing or installingsaw blade
CAUTION :
Always be sure that the tool is switched off and unpluggedbeforeremoving or installing
the blade.
To remove the blade, press the shaft lock
so that the blade cannot revolve and use
the wrench to loosen the hex bolt clock-
wise. Then remove the hex bolt, outer
flange and blade.
Shaft lock 2
Fig. ~
To installthe blade, follow the removalpro-
cedure in reverse. BE SURE TO TIGHTEN
THE HEX BOLTSECURELY.
CAUTION:
.Be sure the blade
is installed with teeth
pointingup
at the front of the tool.
.Use only the Makita wrenches to install
or removethe blade.
.One side of the inner flange
is for 5/8"
hole diameter or the blade;the other side
is for 13/16" holediameter.
Fig.
Mounting shaft 1 -Hex bolt
Fig. 1
Use the correct side for the hole diameter of the blade you intend to use. Mountingthe
bladeon the wrong side can result indangerousvibration.
9

Adjustingdepth of cut I
Fig. 12
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.
Fig. 11
CAUTION:
0 Use a shallow depthof cut when cutting thin workpiece for cleaner, safer cuts.
0 After adjustingthe depthof cut, always tightenthe lever securely.
Bevel cutting
Loosenthe lever on the bevel
scale plateon
the front of the base.
Set for the desired
angle (0'-45') by tiltingaccordingly,then
tighten the lever securely.
Sighting
The front of the base
is notchedto provide
two guide edges.
For straight cuts, align the edge with
0 en-
graved on
it with your cutting line on the
workp
iece.
For 45' bevel cuts, align the edge with 45'
engraved on
it with your cutting line.
pvelscale plate
Lever
/ /
Fig. 1
10

Switchaction 1
To start the tool, simply pull the trigger.
Release the trigger tostop.
CAUTION
:
Before plugging in the tool, always check
to
see that the switch trigger actuates pro-
perly and returns to the "OFF" position
when released.
Cutting operation
Grasp the rear handlewith your right hand,
the front grip with your left.
Set the base
plate on the workpiece to be cut without
the blade making any contact. Then turn
the tool on and wait until the bladeattains
full speed. Now simply move the tool for-
ward over the workpiece surface, keeping
it flat and advancing smoothly until the
sawing
is completed. To get clean cuts,
keep your sawing line straight and your
speed of advanceuniform.
Rear hand'e
I
Fig. 1
CAUTION :
Always gently keep the tool movingstraight ahead when cutting. Forcingor twisting the
tool will result in overheating of the motor and dangerous kickback, possibly causing
severe injury.
Guide rule
The handy guide rule allows you to do
extra-accurate straigtt cuts. Simply slide
the guide rule 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 uni-
form width possible.
Fig. 16
1J

MA1NTENANCE
CAUTION:
Always be sure that the tool
is switchedoff and unplugged beforeattempting toperform
inspectionor maintenance.
Replacingcarbonbrushes
Remove and check the carbon brushes
regularly. Replace when they wear down
to the limitmark. 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 holdercaps.
CAUTION
:
Never remove the breather
housing.
It is not an oil cap. from the
gear
;Limit mark
L
Fig. 17
7Brush holder cap
I
Fig. 18
///
Fig. 1
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 replacementparts.
12

ACCESSORIES
CAUTION :
These accessories or attachments are recommended for use with your Makita tool specified in this
manual. The use of any other accessories or attachments might present
a risk of injury to persons.
The accessories or attachments should be used only in the proper and intended manner.
0 Guide rule
Part No. 165153-3
A-90037
Wrench 13
Part No. 782016-4
20
7-
114"
(185 ,,,,,,) 518''
0 Chisel tooth combination saw blade
For rip and cross-cut work.
Most frequently used for
general carpentry.
0 Carbide-tipped saw blade
Faster, smoother, longer sawing
without blade sharpening.
Cuts wood, drywall, plastics,
hard wood,
etc.
0 Cornbination saw blade
For ripandcross-cut work
Part
No. 1 Diameter I di::&r 1 ,::h
7-114"
792446-1
I ,185 mm) 1 518'' 1 40
13

Sep.-07-'95 US
185 mm (7-1/4")
HYPOID SAW
Model 5177B/5277B
Note: The switch and other part configurations
may differ from country
to country.
14

MODEL 51778152770 Sep.-07-'95 US
10
11
12
13
14
15
16
17
$& DESCRIPTION
11
21
31
41
51
61
71
81
91
3
1
1
1
1
1
1
1
,&, DESCRIPTION
48
49
50
51
52
53
54
55
56
51
58
59
1
1
1
2
1
1
1
1
1
1
1
1
18
15
20
21
22
24
25
26
27
28
25
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
62 1
63 1
164 1
1
1
1
1
1
1
1
1
2
3
1
Hex Flange Head Bolt M8xZO
Outer Flange 40
Inner Flange 40
Bearing Retainer23-36
Spindle
Woodruff Key 4
Ball Bearing 6003DDW
TensionSpring 4
TappingScrew Bind CT M5x20
Retaining Ring 5-12
Ball Bearing 6201LLB
Flat Washer 12
Hypaid Gear 36
0 Ring 50
011 Seal 17
Bearing Box
LWW
Tapping Screw Bind CT4x12
Breather
Safely Cover
0 Ring 14
Cap 20
0 Ring 5
Pin 6
CompressIanSprlnQ 6
FlatWasher 6
0 Ring 6
C0"W
Grip
TappingScrew BindCT 5x20
Ball Bearing 629LLB
Insulation Washer
ARMATUREASSEMBLY
(With Item 33 34 8 36)
Fall
Bearing Retainer
Ball Bearing 6003LLB
0 Ring 16
011 Seal 22
Ring 17
Retaining Ring 5-17
Gear HOUSI~Q
Pan HeadScrew M5x10 (With Washer)
Blade Case
TappingScrew Bind CT 5x20
Rubber Sleeve 6
RetalnlnQ Rlng 5-42
65
66
67
68
69
70
71
72
73
14
75
76
71
18
79
80
81
82
83
84
85
86
81
88
89
90
91
92
53
1
1
1
1
1
2
4
1
1
2
2
1
1
2
1
1
1
1
1
4
1
1
I
Countersunk Head Screw M6x28
Makita Mark
Baffle Plate
Tapping Screw Flange PT 5x65
FIELD ASSEMBLY
Depth Guide
Flat Washer 8
Lever Plate
Lock Plate
Hex Bolt M8x20
Pan Head Screw M4x8 IWith Washerl
Hex Nut M8
Spring Washer 8
Flat Washer 8
Cap Square Neck Bolt Max24
Screw M6x14
Screw M5x12
Flat Washer 8
Lever Plate
Lock Plate
Hex Nut M8
Pan Head Screw Max8 IWith Washer)
Flat Head Screw M8
Base
Hex Niit M6
Spring Washer 6
Flat Washer 6
Tapping Screw Flange PT 4x20
Tapping Screw FlangePT 5x25
Flat Head Screw M6
Flat Washer 8
Brush Holder Cap
Carbon Brush
Triac Circuit (51778only)
Handle Set [With Item 871
Tapping Screw Flange PT 4x12
Strain Relief
Cord Guard
Cord
Handle Set IWith Item 821
Switch
Tapping Screw Bind CT 5x30
Motor Housing
Name Plate
Breather Retainer
lNot Illustratedl
Pan Head Screw M4x12 IWith Washerl
lNot llluStrated1
Note The Switchand other part specifIcalions may differ from country to country
15

MAKITA LIMED ONE YEAR WARRANTY
Warranty Policy
Every Makita tool is thorou ly inspected and tested before leavingthe factory. It is warranted to
be
free of defects from workanshl and materials for the period of ONE YEAR from the date of
original
urchaae. Should any troubi develop during this one-year period, return the COMPLETE
tool, fr&t prepaid, to one of Makita’s Factory
or Authorized ServiceCenters. If inspection shows
the trouble
is caused by defective workmanahip or material, Makita will repair (or at our option,
replace) without charge.
ThisWarranty does not apply where:
repairs have been made or attempted by others:
repairs are required because of normal wear and tear:
Thetool has been abused, misused or improperly maintained;
alterationshave been made tothe tool.
IN NO EVENT SHALL MAKITA BE LlABLE FOR ANY INDIRECT. INCIDENTAL OR CON-
SEQUENTIAL DAMAGES FROM THE SALEOR
USE OF THE PRODUCT. THlS DISCLAlMER
APPLIES BOTH DURINGAND AFTER THE TERM OFTHlS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE.”
AFTER THE ONE-YEARTERMOF
THIS WARRANTY.
~~~ ~
This Warranty gives you specific legal rights, and you may also have other rights which vary from
state to state. Some states do not allow the exclusion
or limitation of incidentalor consequential
damages,
so the above Limitation or exclusion may. not apply to you. Some states do not allow
limitation on how long an implied warranty lasts,
so the above limitation may not apply to you.
MCA 5-96
MakitaCorporation of America
2650 Buford Hwy., Buford, GA 30518
884044A068
PRINTED IN USA
1997-01-4D