Makita M2400 User manual

1
ENGLISH (Original instructions)
INSTRUCTION MANUAL
DOUBLE INSULATION
IMPORTANT: Read Before Using.
Portable Cut-Of
f
M2400
012155

2
ENGLISH (Original instructions)
SPECIFICATIONS
Model M2400
Wheel diameter 355 mm
Hole diameter 25.4 mm
No load speed (min-1) 3,800
Dimensions (L x W x H) 500 mm x 280 mm x 620 mm
Net weight 15.7 kg
Safety class /II
• Due to our continuing program of research and development, the specifications herein are subject to change without notice.
• Specifications may differ from country to country.
• Weight according to EPTA-Procedure 01/2003
END201-7
Symbols
The following show the symbols used for the equipment.
Be sure that you understand their meaning before use.
･Read instruction manual.
･DOUBLE INSULATION
･Only for EU countries
Do not dispose of electric equipment
together with household waste material!
In observance of the European Directive,
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.
ENE007-3
Intended use
The tool is intended for cutting in ferrous materials with
appropriate abrasive cut-off wheel. Follow all laws and
regulations regarding dust and work area health and
safety in your country.
ENF002-2
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.
GEA005-3
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.
The term "power tool" in the warnings refers to your
mains-operated (corded) power tool or battery-operated
(cordless) power tool.
Work area safety
1. Keep work area clean and well lit. Cluttered or
dark areas invite accidents.
2. Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools
create sparks which may ignite the dust or fumes.
3. Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
Electrical safety
4. Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power
tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
5. Avoid body contact with earthed or grounded
surfaces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of
electric shock if your body is earthed or grounded.
6. Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
7. Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords
increase the risk of electric shock.

3
8. When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of
a cord suitable for outdoor use reduces the risk of
electric shock.
9. If operating a power tool in a damp location is
unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD reduces
the risk of electric shock.
10. Use of power supply via a RCD with a rated
residual current of 30mA or less is always
recommended.
Personal safety
11.
Stay alert, watch what you are doing and use
common sense when operating a power tool. Do
not use a power tool while you are tired or under
the influence of drugs, alcohol or medication.
A
moment of inattention while operating power tools
may result in serious personal injury.
12. Use personal protective equipment. Always
wear eye protection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions
will reduce personal injuries.
13. Prevent unintentional starting. Ensure the
switch is in the off-position before connecting
to power source and/or battery pack, picking
up or carrying the tool. Carrying power tools with
your finger on the switch or energising power tools
that have the switch on invites accidents.
14. Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may
result in personal injury.
15. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
16. Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing, and gloves
away from moving parts. Loose clothes,
jewellery or long hair can be caught in moving
parts.
17. If devices are provided for the connection of
dust extraction and collection facilities,
ensure these are connected and properly used.
Use of dust collection can reduce dust-related
hazards.
Power tool use and care
18. Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the
rate for which it was designed.
19. Do not use the power tool if the switch does
not turn it on and off. Any power tool that cannot
be controlled with the switch is dangerous and
must be repaired.
20. Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
21. Store idle power tools out of the reach of
children and do not allow persons unfamiliar
with the power tool or these instructions to
operate the power tool. Power tools are
dangerous in the hands of untrained users.
22. Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts
and any other condition that may affect the
power tool’s operation. If damaged, have the
power tool repaired before use. Many accidents
are caused by poorly maintained power tools.
23. Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
24. Use the power tool, accessories and tool bits
etc. in accordance with these instructions,
taking into account the working conditions
and the work to be performed. Use of the power
tool for operations different from those intended
could result in a hazardous situation.
Service
25. Have your power tool serviced by a qualified
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
26. Follow instruction for lubricating and
changing accessories.
27. Keep handles dry, clean and free from oil and
grease.
ENB066-2
ADDITIONAL SAFETY RULES
FOR TOOL
1. Wear protective glasses. Also wear hearing
protection during extended periods of
operation.
2. Use only wheels recommended by the
manufacturer which have a maximum
operating speed at least as high as "No Load
RPM" marked on the tool’s nameplate. Use
only fiberglass-reinforced cut-off wheels.
3. Check the wheel carefully for cracks or
damage before operation. Replace cracked or
damaged wheel immediately.
4. Secure the wheel carefully.
5. Use only flanges specified for this tool.
6. Be careful not to damage the spindle, flanges
(especially the installing surface) or bolt, or
the wheel itself might break.

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7. Keep guards in place and in working order.
8. Hold the handle firmly.
9. Keep hands away from rotating parts.
10. Make sure the wheel is not contacting the
work-piece before the switch is turned on.
11. Before using the tool on an actual workpiece,
let it simply run for several minutes first.
Watch for flutter or excessive vibration that
might be caused by poor installation or a
poorly balanced wheel.
12.
Watch out for flying sparks when operating. They
can cause injury or ignite combustible materials.
13. Remove material or debris from the area that
might be ignited by sparks. Be sure that others
are not in the path of the sparks. Keep a proper,
charged fire extinguisher closely available.
14. Use the cutting edge of the wheel only. Never
use side surface.
15. If the wheel stops during the operation, makes
an odd noise or begins to vibrate, switch off
the tool immediately.
16. Always switch off and wait for the wheel to
come to a complete stop before removing,
securing workpiece, working vise, changing
work position, angle or the wheel itself.
17. Do not touch the workpiece immediately after
operation; it is extremely hot and could burn
your skin.
18. Store wheels in a dry location only.
19.
Ensure that ventilation openings are kept clear
when working in dusty conditions. If it should
become necessary to clear dust, first disconnect
the tool from the mains supply ( use non metallic
objects ) and avoid damaging internal parts.
SAVE THESE INSTRUCTIONS.
INSTALLATION
Securing cut-off
1
2
003980
This tool should be bolted with two bolts to a level and
stable surface using the bolt holes provided in the tool's
base. This will help prevent tipping and possible personal
injury.
FUNCTIONAL DESCRIPTION
CAUTION:
• Always be sure that the tool is switched off and
unplugged before adjusting or checking function on
the tool.
Switch action
1
2
012057
CAUTION:
• Before plugging in the tool, always check to see
that the switch trigger actuates properly and returns
to the "OFF" position when released.
For tool with lock button
To start the tool, simply pull the switch trigger. Release
the switch trigger to stop.
For continuous operation, pull the switch trigger and then
push in the lock button.
To stop the tool from the locked position, pull the switch
trigger fully, then release it.
For tool with lock-off button
To prevent the switch trigger from being accidentally
pulled, a lock-off button is provided.
To start the tool, depress the lock-off button and pull the
switch trigger. Release the switch trigger to stop.
Stopper plate
( except for European countries )
(A)
(B)
1
1
003982
The stopper plate prevents the cut-off wheel from
contacting the workbench or floor. When a new wheel is
installed, set the stopper plate to position (A). When the
wheel wears down to the extent that the lower portion of
the workpiece is left uncut, set the stopper plate to
position (B) to allow increased cutting capacity with a
worn down wheel.
1. Stopper plate
1. Switch trigger
2. Lock button /
Lock-off button
1. Base
2. Bolt holes

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Interval between vise and guide plate
1
2
3
4
003983
003759
The original spacing or interval between the vise and the
guide plate is 0 - 170 mm. If your work requires wider
spacing or interval, proceed as follows to change the
spacing or interval.
Remove the two hex bolts which secure the guide plate.
Move the guide plate as shown in the figure and secure it using
the hex bolts. The following interval settings are possible:
35 - 205 mm
70 - 240 mm
CAUTION:
• Remember that narrow workpieces may not be secured
safely when using the two, wider interval settings.
Setting for desired cutting angle
1
2
3
003984
To change the cutting angle, follow the procedure below:
1. Loosen the two hex bolts.
2. Set the guide plate to the desired angle (0° - 45°).
3. For more accurate angle, use a protractor or
triangle ruler. Keep the handle down so that the
cut-off wheel extends into the base. At the same
time, adjust the angle between the guide plate and
the cut-off wheel with a protractor or triangle ruler.
4. Tighten the hex bolts securely. At this time, make
sure that the guide rule does not move.
5. Check the angle again.
CAUTION:
• Never perform right miter cuts when the guide plate
is set at the 35 - 205 mm or 70 - 240 mm position.
NOTE:
• The scale on the guide plate is only a rough
indication.
ASSEMBLY
CAUTION:
• Always be sure that the tool is switched off and
unplugged before carrying out any work on the tool.
Removing or installing cut-off wheel
(Accessory)
12
3
4
5
012087
To remove the wheel, raise the wheel guard. Press the shaft
lock so that the wheel cannot revolve and use the socket
wrench to loosen the hex bolt by turning it counterclockwise.
Then remove the hex bolt, outer flange and wheel. (Note: Do
not remove the inner flange, ring and O-ring.)
To install the wheel, follow the removal procedures in
reverse.
1
2
3
45
6
7
003762
CAUTION:
• Be sure to tighten the hex bolt securely. Insufficient
tightening of the hex bolt may result in severe injury.
Use the socket wrench provided to help assure
proper tightening.
• Always use only the proper inner and outer flanges
which are provided with this tool.
• Always lower the wheel guard after replacing the
wheel.
1. O-ring
2. Inner flange
3. Ring
4. Spindle
5. Cut-off wheel
6. Outer flange
7. Hex bolt
1. Shaft lock
2. Wheel guard
3. Socket wrench
4. Loosen
5. Tighten
1. Socket wrench
2. Guide plate
3. Hex bolts
1. Socket wrench
2. Guide plate
3. Move
4. Hex bolts

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Securing workpiece
12
3
003986
By turning the vise handle counterclockwise and then
flipping the vise nut to the back, the vise is released from
the shaft threads and can be moved rapidly in and out. To
grip workpieces, push the vise handle until the vise plate
contacts the workpiece. Flip the vise nut to the front and
then turn the vise handle clockwise to securely retain the
workpiece.
CAUTION:
• Always set the vise nut to the front fully when
securing the workpiece. Failure to do so may result
in insufficient securing of the workpiece. This could
cause the workpiece to be ejected or cause a
dangerous breakage of the wheel.
When the cut-off wheel has worn down considerably, use
a spacer block of sturdy, non-flammable material behind
the workpiece as shown in the figure. You can more
efficiently utilize the worn wheel by using the mid point on
the periphery of the wheel to cut the workpiece.
1
003987
When cutting workpieces over 85 mm wide at an angle,
attach a straight piece of wood (spacer) to the guide plate
as shown in the figure. Attach this spacer with screws
through the holes in the guide plate.
1
2
3
003988
If you use a spacer block which is slightly narrower than
the workpiece as shown in the figure, you can also utilize
the wheel economically when worn down the wheel.
1
2
3
4
5
003989
Long workpieces must be supported by blocks of
non-flammable material on either side so that it will be
level with the base top.
11
012058
OPERATION
Hold the handle firmly. Switch on the tool and wait until
the wheel attains full speed before lowering gently into
the cut. When the wheel contacts the workpiece,
gradually bear down on the handle to perform the cut.
When the cut is completed, switch off the tool and WAIT
UNTIL THE WHEEL HAS COME TO A COMPLETE
STOP before returning the handle to the fully elevated
position.
CAUTION:
• Proper handle pressure during cutting and
maximum cutting efficiency can be determined by
the amount of sparks that is produced while cutting.
Your pressure on the handle should be adjusted to
produce the maximum amount of sparks. Do not
force the cut by applying excessive pressure on the
handle. Reduced cutting efficiency, premature
wheel wear, as well as, possible damage to the tool,
cut-off wheel or workpiece may result.
Cutting capacity
Max. cutting capacity varies depending upon the cutting
angle and workpiece shape. Applicable wheel diameter:
355 mm
1. Blocks
1. Diameter of
workpiece
2. Guide plate
3. Spacer block
4. Width of spacer
block
5. Vise plate
1. Guide plate
2. Straight piece of
wood (Spacer)
3. Over 85 mm
long
1. Spacer block
1. Vise plate
2. Vise nut
3. Vise handle

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Cutting
angle
115 mm 119 mm
115 mm 106 mm
Workpiece
shape
102 mm × 194 mm
70 mm × 233 mm
137 mm
115 mm × 103 mm 100 mm
Cutting
angle
Workpiece
shape
012060
Carrying tool
012086
Fold down the tool head to the position where you can
attach the chain to the hook on the handle.
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.
Replacing carbon brushes
1
001145
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.
1
2
012059
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.
1. Brush holder cap
2. Screwdriver
1. Limit mark

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Makita Corporation
Anjo, Aichi, Japan
www.makita.com
885414-937