Cordless Cutter
85
mm
(3-3/8")
MODEL 4191DZ
85
mm
With Battery Cartridge and Fast Charger
(3-3/8")
MODEL 419lDWA
INSTRUCTION
S
PECl
FI
CAT1 0 N
Model 4191D
Blade Cutting depth
diameter
85
mm
13-318")
Battery Cartridge
Voltage
12
S
900
0
~
24
~
1222
mm
15/16")
(0
I
v
450
0
~
18
(0
Model DC1410 Fast Charger
A.C. only 50
mm
-
11/16")
Input
-
60 Hz D.C. 7.2 V ~ 14.4
MANUAL
No
load speed Overall
(RPM)
1,000
I
output
length
316
mm
(12-1/2") (4.6
I
V
weight
2.1 kg
Charging time
1 Hr.
Ibs)
IMPORTANT
SAFETY INSTRUCTIONS
(For
All
Tools)
WARNING:
WHEN
USING ELECTRIC TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE
THE RISK OF FIRE, ELECTRIC SHOCK, AND PERSONAL
INJURY, INCLUDING THE FOLLOWING:
READ ALL INSTRUCTIONS.
1.
KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries.
2.
CONSIDER WORK AREA ENVIRONMENT. Don't use power tools in damp
or wet locations. Keep work area well
Don't use tool in presence of flammable liquids or gases.
3.
KEEP CHILDREN AWAY. All visitors should be kept away from work area.
Don't let visitors contact tool or extension cord.
4.
STORE IDLE TOOLS. When not
or locked-up@ace
5.
DON'T FORCE TOOL.
it
was intended.
6.
USE RIGHT TOOL. Don't force small tool or attachment to do the job of a
heavy-duty tool. Don't use tool for purpose not intended; for example, don't
use circular saw for cutting tree limbs or logs.
7.
DRESS PROPERLY. Don't wear loose clothing or jewelry. They can be caught
in moving parts. Rubber gloves and non-skid footwear are recommended
when working outdoors. Wear protective hair covering to contain long hair.
8.
USE SAFETY GLASSES. Also use face or dust mask
dusty.
9.
DON'T ABUSE CORD. Never carry tool by cord or yank
receptacle. Keep cord from heat, oil, and sharp edges.
IO.
SECURE WORK. Use clamps or a vise to hold work. It's safer than using
your hand and
11.
DON'T OVERREACH. Keep proper footing and balance at all times.
12.
MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and
safer performance. Follow instructions for lubricating and changing accessories. Inspect tool cords periodically and
rized service facility. Inspect extension cords periodically and replace if
damaged. Keep handles dry, clean, and free from
13.
DISCONNECT
ing accessories,
-
out of reach of children.
It
it
frees both hands to operate tool.
TOOLS
when not in use, before servicing, and when chang-
such
as
in
will do the job better and safer at the rate for which
blades, bits, cutters.
lit.
Don't expose power tools to rain.
use, tools should be stored
if
cutting operation is
it
to disconnect from
if
damaged, have repaired by autho-
oil
and grease.
in
dry, and high
2
14.
REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to
see that keys and adjusting wrenches are removed from tool before turning
it
on.
15.
AVOID UNINTENTIONAL STARTING. Don't carry tool with finger on switch.
Be sure switch is
16.
OUTDOOR USE EXTENSION CORDS. When tool is used outdoors, use only
extension cords intended for use outdoors and
17.
STAY ALERT. Watch what you are doing, use common sense. Don't operate
tool when you are tired.
18.
CHECK DAMAGED PARTS. Before further use of the tool, a guard or other
part that is damaged should be carefully checked to determine that
operate properly and perform its intended function. Check for alignment of
moving parts, binding of moving parts, breakage of parts. mounting, and any
other conditions that may affect its operation. A guard or other part that
is damaged should be properly repaired or replaced by an authorized service
center unless otherwise indicated elsewhere in this instruction manual. Have
defective switches replaced by authorized service center. Don't use tool
switch does not turn
19.
GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded
surfaces. For example; pipes, radiators, ranges, refrigerator enclosures.
20.
REPLACEMENT PARTS. When servicing, use only identical replacement parts.
21.
POLARIZED PLUGS. To reduce the risk of electric shock, this equipment has
a polarized plug (one blade is wider than the other). This plug will fit
polarized outlet only one way.
the plug. If
proper outlet.
OFF
when plugging in.
it
on and off.
it
still does not
Do
not change the plug
so
marked.
If
the plug does not
fit,
contact a qualified electrician to install the
in
fit
any way.
fully in the outlet, reverse
it
will
in
if
a
VOLTAGE WARNING: Before connecting the tool to a power source (receptacle,
outlet, etc.) be sure the voltage supplied is the same as that specified on the
nameplate of the tool. A power source with voltage greater than that specified
for the tool can result
the tool.
voltage less than the nameplate rating is harmful to the motor.
If
in
doubt,
in
SERIOUS INJURY to the user - as well as damage to
DO
NOT PLUG IN THE TOOL. Using a power source with
IMPORTANT SAFETY INSTRUCTIONS
FOR CHARGER
&
BATTERY CARTRIDGE
I.
SAVE THESE INSTRUCTIONS
-
This manual
18
150
16
50
Length of Cord (Feet) 25
AWG Size of Cord
4
18
100
18
ADDITIONAL
SAFETY
RULES
FOR CHARGER & BATTERY CARTRIDGE
1.
Do not charge Battery Cartridge when temperature is
or ABOVE 4OoC
2.
Do not attempt to use a step-up transformer, an engine generator or DC power
receptacle.
3.
Do
not allow anything to cover or clog the charger vents.
4.
Always cover the battery terminals with the battery cover when the batter.y
cartridge is not used.
5.
A battery short can cause a large current flow, overheating, possible burns
and even a breakdown.
(1
1
Do
not touch the terminals with any conductive material.
(21
Avoid storing battery cartridge in a container
as nails, coins, etc.
(3)
Do not expose battery cartridge to water or rain.
6.
Do not store the tool and Battery Cartridge in locations where the temperature may reach or exceed
7.
Do not incinerate the Battery Cartridge even
completely worn out. The battery cartridge can explode in a fire.
(104OF).
35OC
(95OF).
with
if
it
BELOW
other metal objects such
is severely damaged or is
10°C
(5OOF)
ADDITIONAL SAFETY RULES
1.
Be aware that this is always in an operating condition, because
have to be plugged into an electrical outlet.
2.
Check the wheel carefully for cracks or damage before operation. Replace
cracked or damaged wheel immediately.
3.
Use only flanges specified for this tool.
4.
Be careful not to damage the spindle, flanges (especially the installing
surface) or bolt. Damage to these parts could result in wheel breakage.
5.
Hold the tool firmly.
6.
Keep hands away from rotating parts.
7.
Make sure the wheel is not contacting the workpiece before the switch is
turned on.
8.
Wait
until
the wheel attains
9.
Stop operation immediately if you notice anything abnormal.
IO.
Do not attempt to lock the trigger
11.
Never attempt to cut with the tool
held upside down
can lead to serious accidents,
because
it
is extremely dangerous.
in
a vise. This
full
speed before cutting.
in
the
"ON"
position.
it
does not
12.
Before setting the tool down after completing a cut, be sure that the wheel
has come to a complete stop.
SAVE THESE INSTRUCTIONS.
6
Installing or removing the battery cartridge 1222
*Always switch off the tool before insertion or removal of the battery cartridge.
*To
remove the battery cartridge, withdraw
it from the tool while pressing the buttons
on
both sides
*To
insert the battery cartridge, align the
tongue on the battery cartridge with the
groove in the housing and slip it until it is
locked with
*Do
not use force when inserting the battery cartridge. If the cartridge does not slide in
easily, it is not being inserted correctly.
of
the cartridge.
a
little click.
Installing the set plate
Always install the set plate when using battery cartridges
1202A. Install the set plate on the tool with
the screw and nut provided as shown in
the figure.
1200,
1201, 1201 A, 1202 or
.
Pan head screw
Set
/
plate
Installing or removing the battery cartridge 1200,1201,1201A, 1202 and 1202A.
*Always switch off the tool before insertion or removal of the battery cartridge.
*To
remove the battery cartridge, pull out
the set plate on the tool and grasp both
sides of the cartridge while withdrawing it
from the tool.
*To
insert the battery cartridge, align the
tongue on the battery cartridge with the
groove in the housing and slip it into place.
Snap the set plate back into place. Be sure
to close the set plate fulty before using the
tool.
*Do
not use force when inserting the battery cartridge.
easily, it is not being inserted correctly.
If
the cartridge does not slide in
7
Charging
*Your new battery cartridge
is
not charged.
You will need to charge it before use. Use
the fast charger Model DC1410 to charge
the battery cartridge.
*Plug the fast charger into the proper NC
voltage source. The charging light will flash
Charging light
-
in green color.
so
*Insert the battery cartridge
that the plus
and minus terminals on the battery cartridge are on the same sides as their
respective markings on the fast charger.
Insert the cartridge fully into the port
that it rests on the charser
-I
~ort
floor.
so
*When the battery cartridge is inserted, the charging light color will change from green to
red and charging will begin. The charging light will remain lit steadily during charging.
*When charging is completed, the charging light color will change from red to green.
*After charging, unplug the charger from the power source. Refer to the table below for
the charging time.
DC1410
I
1200
~
1201 / 1201A
1202 I1202A / 1222
I
ADDrox. 40 min.
Approx.
50
min.
Approx.
60
min.
I
CAUTION:
*The fast charger Model DC1410
is
for charging Makita battery cartridge. Never use it for
other purposes or for other manufacturer’s batteries.
*When you charge
for
a
long period of time, it may not accept a full charge. This is normal condition and
does not indicate a problem,
it completely and recharging
*If you charge
been left in a location exposed to direct sunlight or heat for
a
new battery cartridge or a battery cartridge which has not been used
You
can recharge the battery cartridge
a
couple of times.
a
battery cartridge from a just-operated tool or a battery cartridge which has
a
fully
after discharging
long time, the charging light
may flash in red color. If this occurs, wait for a while. Charging will begin after the battery
cartridge cools. The battery cartridge will cool faster if you remove the battery cartridge
from the fast charger.
*If the charging light flashes alternately in green and red color, a problem exists and charg-
ing is not possible. The terminals on the charger or battery cartridge are clogged with
dust or the battery cartridge is worn out or damaged.
*If you wish to charge two battery cartridge, allow 15 minutes between chargings on the
fast charger.
8
Installing or removing diamond wheel
CAUTIO N
Always be sure that the tool is switched off and the battery cartridge is removed before
installing or removing the wheel.
To install the wheel, first loosen the bolt
with the hex wrench and remove the bolt
and the flange. Then mount the wheel, the
flange and the bolt. The wheel should be
mounted with the Makita name on the
flange side.
:
-
Press the shaft lock
not revolve. Use the hex wrench to tighten
the bolt securely
To
remove the wheel, follow the installation procedure in reverse.
CAUTION:
*When installing the wheel, be sure to tighten the bolt securely.
*Use only the Makita hex wrench to install or remove the wheel.
so
that the wheel can-
-
Hex wrench
Shaft
Diamond
lock
-,
n
wheel
installing water
Attach the tank holder on the tank. The tank
Attach the tank holder onto the motor housing. Tighten the screw
supply
(B)
securely.
Tank
holder
installing
portion
-,
-Tank
Connect the cap on the end of the polyvinyl
tube to the mouth
clockwise when making the connection.
Then tighten the screw
secure the tank.
CAUTION:
you
find the polyvinyl tube is bent like
If
installing the water supply, loosen the screw
viate the bent, pinched or strained condition.
10
of
the tank. Turn the tank
(A)
securely to
a
"V"
or has been strained excessively after
(B)
and adjust the position of the tank to alle-
Hex wrench storage
When not in use, the hex wrench can be
conveniently stored.
Hex wrench
4b
Adjusting the depth
Loosen the screw on the depth guide and move the base up or down. You can read the
depth of cut by aligning the top of the notch in the depth guide with the graduations on its
right side. (Note: This can be done for
secure the base by tightening the screw.
CAUTION:
*Use
a
shallow depth
*After adjusting the depth of cut, always tighten the clamp screw securely.
Bevel
cutting
Loosen the screw on the bevel scale plate
on the front of the base. Set for the desired
angle
(0"
-
45")
tighten the clamp screw securely.
of
cut
0"
bevel cutting only.) At the desired depth
of
cut when cutting thin workpiece for cleaner, safer cuts.
by tilting accordingly, then
Depth
auide
of
cut,
CAUTION:
After adjusting the depth of cut and bevel cutting angle, be sure
to
tighten the screw.
Sighting
The front
of
the base is notched to provide
two guide edges.
For straight cuts, align the edge with
0"
engraved on it with your cutting line on the
workpiece.
45"
For
bevel cuts, align the edge with
45"
engraved on it with your cutting line.
Switch action
To
prevent the trigger from being acciden-
Switch
trigger
Lock-off lever
tally pulled, a lock-off lever is provided.
To
start the tool, slide the lock-off lever in
the direction of the arrow and pull the trigger. Release the trigger to stop.
CAUTION:
Before inserting the battery cartridge into the tool, always check to see that the switch
trigger actuates properly and returns to the
Water
supply
"OFF"
position when released.
Remove the cap on the tank and fill through
the hole. Recap the tank. Be sure that the
water cock is turned off when filling the
tank with water.
CAUTION:
When filling the tank with water, be careful not to let the tool get wet
12
Operation
Hold the tool firmly. Set the base plate on
the workpiece to be cut without the wheel
making any contact. Then turn the tool on
and wait until the wheel attains full speed.
Feed water to the wheel by adjusting the
water cock to obtain
Move the tool forward over the workpiece
surface, keeping
smoothly until the cutting is completed.
Keep your cutting line straight and your
speed of advance uniform.
For fine, clean cuts, cut slowly. (When cutting glass plate 5 mm (3/16”) thick, cut at about
250 mm/min (9-7/8”/min). When cutting tile
(1 1-13/16”/min). Also slow down as you complete a cut to avoid breaking or cracking the
workpiece being cut.
CAUTION:
*Be sure to hold the workpiece firmly down on
*Do not twist or force the tool in the cut, or the motor may be overloaded or the work-
piece may break.
*Do not use the tool with the wheel in an upward or sideways position.
*When cutting glass plate, it
on the base of the tool to prevent the workpiece surface from being scratched.
*The wheel for Model
sure to feed water to the wheel during operation.
*If the cutting action of the wheel begins to diminish, dress the cutting edge of the wheel
using an old discarded coarse grit bench grinder wheel or concrete block.Dress by press-
ing lightly on the outer edge of the wheel.
a
gentle flow of water.
it
flat and advancing
is
recommended to attach a rubber plate (optional accessory)
41
91
D/DW is a wet-type wheel for glass and tile applications. Be
10
mm (3/8”) thick, cut at about
a
stable bench or table during operation.
300
mm/min
CAUTION:
If the tool is operated continuously until the battery cartridge has discharged, allow the
a
tool to rest for 15 minutes before proceeding with
fresh battery.
13
MAINTENANCE
CAUTION:
Always be sure that the charger
attempting to perform inspection or maintenance.
After
use
Brush off accumulation of dust on the base
To
maintain product SAFETY and RELIABILITY, repairs, maintenance or adjustment should
be performed by Makita Authorized or Factory Service Centers, always using Makita
replacement parts.
is
unplugged and the battery cartridge is removed before
14
OPTIONAL ACCESSORIES
The accessories listed in this manual are available at an extra cost from your Makita distributor or
Makita factory service center. Service centers are listed on the warranty card packed with your
CAUTION:
These accessories or attachments are recommended for use with your Makita
manual. The use of any other accessories or attachments might present a risk of injury
The accessories or attachments should be used only in the proper and intended manner.
Hex wrench
Part
No.
783202-0
Fast charger
Model DC1410
Part
No.
11 31 50-3
Battery cover
Part No. 414938-7
Battery cartridge 1200
Part
No.
192271-4
High capacity battery 1201, 1202
Part
No.
192296-8 (1201)
No.
192536-4 (1
Part
Power display battery (High cap.) 1201A. 1202A
Part
No.
192407-5 (1201A)
No.
192537-2 (1
Part
202)
202A)
tool
specified in this
to
persons.
tool.
Diamond wheel
Part
No.
1
Dimfr
724950-8c
724950-8B
(3-318")
I
(3-318") I (19132")
85
I
diF?r
(1
1
E
9/32") purpose
15
I
Wet
High capacity battery
Part
No.
192598-2
1
Use
General
For glass
I
cutting
1222
*Set plate
Part No. 343579-1
15
85
mm
(3-3/8")
CORDLESS CUTTER
Model 4191D
Feb
-29-'96
US
16
Note: The switch and other part configurations
may differ from country
to
country.
MODEL 4191D
I:","
$&
DESCRIPTION
'i\M
A:D
DESCRIPTION
Feb.-29-'96
US
MACHINE
1 1
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
21
28
29
30
31
32
Band
j
B
i
1
Pan
Head
Screw
M4x25
Name
Plate
DC
Motor 12
1
Motor
1
1 Tank
1 Pan
1
1
1 cap 43
1
1
1
3 Tapping
1
1
1
1 Battery
1
1
1
1
1
2
1
1
3
1
1
1
1
Housing
Cap
Head
Screw
Tank
Holder
Rubber Washer
VinylTube
5
Nut 45 1
Compression Spring 4
Screw
Lock
Oft
Lever
Housing
Set
Rubber
Sheet
Holder
High
Capacity
Rubber
Sheet
Houslng
Set
Pan
Head
Screw
Makita
Label
Tapping
Screw
Tapping
Screw
Hex
Nul M5
Tapping
Screw
Switch
Hex
Nut
M4
Swtch
Lever
Plane
Bearing
IWith Washer)
V
M4x25
IWith Washerl
12 42 1
4x 18
IWith
Item
221
Batlery
1222
IWith
Item
171 54 1
M4x25
IWifh Washer)
Flange PT 4x30 57
Flange PT 4x30
4x18
4
MACHINE
__
37 1
38 1
39 1
40
41 1
44
46 1
47 1
48 1
49 1
50
51
52
53 1
55 1
56
58
59
60
61
62
63
64 1
I
I
1
1
1
1
1
1
3
1
1
1
1
1
Gear
Complete 8-68
Thin Washer
Plane
Bearing
Retaining
Ring
Helical
Gear
33
Flat
Washer
8
Ball
Bearing
608LB
COmpreSSlOn
Pl"
5
Water
Supply Cock Complete
Screw
M5x 10
Screw
M5x10
Spring
Washer
Flat
Washer
5
Base
Spring Pin 4-40
Flat
Washer
5
Sprlog
Washer
Screw
M5x 10
Stop
Ring
E-4
Nozzle
Woodruff
Key 3
Splndle
Ball
Bearing
6OOOLLP
Blade
Case
Tapping
Screw
Bearing
Box
Packing
RetalW,
Inner Flange
28
Outer
Flange
Hex
Socket
Head
4
4
5-8
Spring
5
5
4x18
28
7
Bolt M5x12
17
Recycling the Battery
The
only
way to dispose
to recycle it. The law prohibits any other
of
method
To
recycle the battery:
1.
Remove the battery from the tool.
2.
a). Take the battery to your nearest Makita Factory Service Center
disposal.
or
to
b). Take the battery
your nearest Makita Authorized Service Center or
Distributor that has been designated as a Makita battery recycling location.
Call your nearest Makita Service Center or Distributor to determine the location
that provides Makita battery recycling. See your local Yellow Pages under
"Tools- Electric'
of
a Makita battery is
I
Ni-Cd
I
MCA 6/96
MAKITA
LIMITED
ONE
YEAR
WARRANTY
Warranty Policy
Every Makita tool is thoroughly inspected and tested before leaving the factory. It is warranted to
be free
of
original purchase. Should any trouble develop during this one-year period, return the COMPLETE
tool, freight prepaid,
the trouble is caused by defective workmanship or material, Makita
replace) without charge.
This
e
e
e
e
IN
SEQUENTIAL DAMAGES FROM THE SALE OR USE
APPLIES BOTH DURING AND AFTER THE TERM OF THIS WARRANTY.
defects from workmanship and materials for the period
to
one of Makita's Factory or Authorized Service Centers. If inspection shows
Warranty does not apply where:
repairs have been made or attempted by others:
repairs are required because of normal wear and tear:
The tool has been abused, misused or improperly maintained;
alterations have been made to the tool.
NO EVENT SHALL MAKITA
Bk.
LIABLE FOR ANY INDIRI:CT, INCIDENTAL OR CON-
Makita Corporation
2650 Buford
Hwy.,
Buford, GA30518
884068A064
of
ONE YEAR from the date of
will
repair (or at our option,
OF
THE PRODUCT. THIS DISCLAIMER
RANTIES, INCLUDING IMPLIED
S
FOR A SPECIFIC PURPOSE;'
y also have other
limitation of inci
of
America
PRINTED
IN
USA
19%-7-4D
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