Makita 4403 User manual

1
ENGLISH (Original instructions)
INSTRUCTION MANUAL
DOUBLE INSULATION
IMPORTANT: Read Before Using.
Sash Router
4403
006822

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ENGLISH (Original instructions)
SPECIFICATIONS
Model 4403
Collet chuck capacity 6 mm (1/4")
No load speed (min-1) 30,000
Max. width of work 123 mm
Max. width of work (45°) 77 mm
Max. height of work 185 mm
Transverse travel of table (bed) 113 mm
Longitudinal travel of table (bed) 73 mm
Overall dimensions (Lx W x H) 327 mm x 350 mm x 355 mm
Net weight 16 kg
Safety class /II
• Due to our continuing programme of research and development, the specifications herein are subject to change without notice.
• Specifications may differ from country to country.
• Weight according to EPTA-Procedure 01/2003
END201-5
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 European Directive
2002/96/EC on waste electric and
electronic equipment and its
implementation in accordance with
national law, electric equipment that
have reached the end of their life must
be collected separately and returned to
an environmentally compatible recycling
facility.
ENE011-1
Intended use
The tool is intended for use in working aluminum sashes.
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.

3
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.
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.
ENB054-1
ADDITIONAL SAFETY RULES
1. Hold tool by insulated gripping surfaces when
performing an operation where the cutting tool
may contact hidden wiring or its own cord.
Contact with a "live" wire will make exposed metal
parts of the tool "live" and shock the operator.
2. Wear hearing protection during extended
period of operation.
3. Handle the bits very carefully.

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4. Check the bit carefully for cracks or damage
before operation. Replace cracked or
damaged bit immediately.
5. Avoid cutting nails. Inspect for and remove all
nails from the workpiece before operation.
6. Hold the tool firmly.
7. Keep hands away from rotating parts.
8. Make sure the bit is not contacting the
workpiece before the switch is turned on.
9. Before using the tool on an actual workpiece,
let it run for a while. Watch for vibration or
wobbling that could indicate improperly
installed bit.
10. Be careful of the bit rotating direction and the
feed direction.
11. Do not leave the tool running. Operate the tool
only when hand-held.
12. Always switch off and wait for the bit to come
to a complete stop before removing the tool
from workpiece.
13. Do not touch the bit immediately after
operation; it may be extremely hot and could
burn your skin.
14. Always lead the power supply cord away from
the tool towards the rear.
15. Do not smear the tool base carelessly with
thinner, gasoline, oil or the like. They may
cause cracks in the tool base.
16. Draw attention to the need to use cutters of
the correct shank diameter and which are
suitable for the speed of the tool.
SAVE THESE INSTRUCTIONS.
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
006614
CAUTION:
• Before plugging in the tool, always be sure that the
tool is switched off.
To start the tool, move the switch lever to the I (ON)
position. To stop the tool, move the switch lever to the O
(OFF) position.
ASSEMBLY
CAUTION:
• Always be sure that the tool is switched off and
unplugged before carrying out any work on the tool.
Installing or removing the bit
12
006823
CAUTION:
• Use only the wrenches provided with the tool.
• Do not tighten the collet nut without inserting the bit.
The collet cone will break.
Insert the bit all the way into the collet cone and tighten
the collet nut securely with the two wrenches.
To remove the bit, follow the installation procedure in
reverse.
1. Wrench 10
2. Wrench 17
3. Tighten
4. Loosen
1. Switch lever

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Adjusting the motor height
1
2
3
006824
Loosen the knob and turn the crank handle to raise or
lower the motor. After obtaining the desired height,
always retighten the knob to secure the motor.
OPERATION
1
2
34
5
6
7
006826
Grip the workpiece in the vise. Use spacer blocks or
pieces of scrap to prevent deformation of the aluminum
workpiece if necessary. Operate the two feed handles
when cutting the workpiece. For better cutting action,
coat the aluminum workpiece with the oil provided.
CAUTION:
• Never apply the oil when the bit is rotating.
When cutting rectangular cutouts, proceed as follows.
1. Hold the crank handle with your right hand and
loosen the knob with your left hand.
2. Hold the transvers feed handle with your left hand
so that the table (bed) does not move. Turn the
crank handle to drill a hole in the workpiece.
3. Tighten the knob to secure the motor in this
position. Then operate the two feed handles to cut
the rectangular cutouts.
Angle gauge
1
2
006827
Use the angle gauge for the angle work. Secure it to the
table (bed) using the wing nut. Then fasten the workpiece
in position as shown in the figure. If the workpiece is big
or long, remove the chip guard (chip deflector).
Adjusting for smooth motor travel
1
2
3
006828
If the motor does not travel smoothly, proceed as follws.
1. Loosen the screw (A).
2. Tighten the screw (B) (2 pcs.) evenly until you
cannot turn the crank handle easily.
3. Tighten the screw (A) until you can turn the crank
handle smoothly.
NOTE:
• Clean the contacting portions and occasionally
lubricate them.
Adjusting for smooth table (bed) travel
1
006829
If the table (bed) does not travel smoothly in the
longitudinal direction, tighten the brake screw
accordingly.
Using as a trimmer
006830
To use as a trimmer, remove the motor from the tool and
attach the trimmer base assembly (optional accessory)
to the motor as shown in the figure.
1. Trimmer base assembly (optional accessory)
2. Motor
3. Trimme
r
1. Brake screw
1. Screw (A)
2. Screw (B) (2
pcs.)
3. Crank handle
1. Wing nut
2. Angle gauge
1. Chip guard
2. Workpiece
3. Transverse feed
handle
4. Longitudinal
feed handle
5. Table
6. Vise
7. Crank handle
1. Knob
2. Thumb screw
3. Crank handle