Makita 419lDWA Instruction manual
Contents
1. yal aids Cordless Cutter 85 mm 3 3 8 MODEL 4191DZ 85 mm 3 3 8 MODEL 4191DWA With Battery Cartridge and Fast Charger INSTRUCTION MANUAL SPECIFICATIONS e Model 4191D a ae depth No load speed Overall RPM length B E N 1 000 316 mm O 15 16 Oo 11 16 12 1 2 e Battery Cartridge 1222 e Model 001410 Fast Charger 12 V A C only 50 60 Hz D C 7 2 V 14 4 V 1 Hr Manufacturer reserves the right to change specifications without notice Note Specifications may differ from country to country WARNING For your personal safety READ and UNDERSTAND before using SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE Blade diameter 2 1 kg 4 6 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 10 11 12 13 READ ALL INSTRUCTIONS Ta 2 KEEP WORK AREA CLEAN Cluttered areas and benches invite injuries CONSIDER WORK AREA ENVIRONMENT Don t use power tools in damp or wet locations Keep work area well lit Don t expose power tools to rain Don t use tool in presence of flammable liquids or gases KEEP CHILDREN AWAY All visitors should be kept away from work area Don t let visitors contact tool or extension cord STORE IDLE TOOLS When not in use tools should be stored in2. a V or has been strained excessively after installing the water supply loosen the screw B and adjust the position of the tank to alle viate the bent pinched or strained condition 10 Hex wrench storage When not in use the hex wrench can be conveniently stored Hex wrench Adjusting the depth of cut 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 0 bevel cutting only At the desired depth of cut secure the base by tightening the screw Depth guide Depth guide g Top of notch Graduation CAUTION eUse a shallow depth of cut when cutting thin workpiece for cleaner safer cuts eAfter 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 by tilting accordingly then tighten the clamp screw securely Bevel scale plate CAUTION After adjusting the depth of cut and bevel cutting angle be sure to tighten the screw 11 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 For 45 bevel cuts align the edge with 45 engraved on it with your cutting line For straight cuts For 45
3. dry and high or locked up gdace out of reach of children DON T FORCE TOOL It will do the job better and safer at the rate for which it was intended 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 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 USE SAFETY GLASSES Also use face or dust mask if cutting operation is dusty DON T ABUSE CORD Never carry tool by cord or yank it to disconnect from receptacle Keep cord from heat oil and sharp edges SECURE WORK Use clamps or a vise to hold work It s safer than using your hand and it frees both hands to operate tool DON T OVERREACH Keep proper footing and balance at all times MAINTAIN TOOLS WITH CARE Keep tools sharp and clean for better and safer performance Follow instructions for lubricating and changing acces sories Inspect tool cords periodically and if damaged have repaired by autho rized service facility Inspect extension cords periodically and replace if damaged Keep handles dry clean and free from oil and grease DISCONNECT TOOLS when not in use before servicing and when chang ing accessories such as blades bi
4. nut provided as shown in the figure Pan head screw Set plate Installing or removing the battery cartridge 1200 1201 1201A 1202 and 1202A eAlways switch off the tool before insertion or removal of the battery cartridge eTo 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 eTo 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 fully before using the tool Battery cartridge Do not use force when inserting the battery cartridge If the cartridge does not slide in easily it is not being inserted correctly 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 ePlug the fast charger into the proper A C voltage source The charging light will flash Charging light In green color ensert the battery cartridge so that the plus and minus terminals on the battery car tridge are on the same sides as their respective markings on the fast charger Insert the cartridge fully into the port so that it rests on the charger port floor eWhen 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 dur
5. the battery 1 Remove the battery from the tool 2 a Take the battery to your nearest Makita Factory Service Center or b Take the battery to your nearest Makita Authorized Service Center or Distributor that has been designated as a Makita battery recycling location e 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 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 defects from workmanship and materials for the period of ONE YEAR from the date of original purchase Should any trouble develop during this one year period return the COMPLETE tool freight prepaid to one of Makita s Factory or Authorized Service Centers If inspection shows the trouble is caused by defective workmanship or material Makita will repair or at our option replace without charge This 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 IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT INCIDENTAL OR CON SEQUENTIAL DAMAGES FROM THE SALE OR USE OF THE PRODUCT THIS DISCLAIMER APPLIES BOTH DURING AND A
6. 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 full speed before cutting 9 Stop operation immediately if you notice anything abnormal 10 Do not attempt to lock the trigger in the ON position 11 Never attempt to cut with the tool held upside down in a vise This can lead to serious accidents because it is extremely dangerous 12 Before setting the tool down after completing a cut be sure that the wheel has come to a complete stop SAVE THESE INSTRUCTIONS Installing or removing the battery cartridge 1222 eAlways switch off the tool before insertion or removal of the battery cartridge eTo remove the battery cartridge withdraw it from the tool while pressing the buttons Battery cartridge on both sides of the cartridge eTo 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 a little click Do not use force when inserting the battery cartridge If the cartridge does not slide in easily it is not being inserted correctly Installing the set plate Always install the set plate when using bat tery cartridges 1200 1201 1201A 1202 or 1202A install the set plate on the tool with the screw and
7. 4 4 1 DC Motor 12 V 36 1 Retaining Ring S 8 5 1 Motor Housing 37 1 Helical Gear 33 6 1 Cap 38 1 Flat Washer 8 7 1 Tank 39 1 Ball Bearing 608LB 8 1 Pan Head Screw M4x25 With Washer 40 1 Compression Spring 7 9 1 Tank Hoider 41 1 Pin 5 10 1 Rubber Washer 12 42 i Water Supply Cock Complete 11 1 Cap 43 1 Screw M5x10 12 4 Vinyl Tube 5 44 1 Screw M5x10 13 1 Nut 45 1 Spring Washer 5 14 1 Compression Spring 4 46 1 Flat Washer 15 3 Tapping Screw 4x18 47 1 Base 16 1 Lock Off Lever 48 1 Spring Pin 4 40 17 1 Housing Set With Item 22 49 1 Flat Washer 5 18 1 Rubber Sheet 50 1 Spring Washer 5 19 1 Battery Holder 51 1 Screw M5x10 20 1 High Capacity Battery 1222 52 1 Stop Ring E 4 21 1 Rubber Sheet 53 1 Nozzle 22 1 Housing Set With Item 17 54 1 Woodruff Key 3 23 1 Pan Head Screw M4x25 With Washer 55 1 Spindle 24 1 Makita Label 56 i Ball Bearing 6000LLB 25 2 Tapping Screw Flange PT 4x30 57 1 Blade Case 26 k Tapping Screw Flange PT 4x30 58 3 Tapping Screw 4x18 27 1 Hex Nut M5 59 1 Bearing Box 28 3 Tapping Screw 4x18 60 1 Packing 29 1 Switch 61 1 Retainer 30 1 Hex Nut M4 62 1 Inner Flange 28 31 1 Switch Lever 63 1 Outer Flange 28 32 1 Plane Bearing 4 64 1 Hex Socket Head Bolt M5x12 Note The switch and other part specifications may differ from country to country 17 Recycling the Battery ORY The only way to dispose of a Makita battery is amp amp to recycle it The law prohibits any other method of disposal Ni Cd To recycle
8. FTER THE TERM OF THIS WARRANTY MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A SPECIFIC PURPOSE AFTER THE ONE YEAR TERM OF 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 incidental or 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 Makita Corporation of America 2650 Buford Hwy Buford GA 30518 PRINTED IN USA MCA 6 96 884068A064 1996 7 4D
9. bevel cuts 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 trig ger 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 OFF position when released Water supply 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 Cap 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 a gentle flow of water Move the tool forward over the workpiece surface keeping it flat and advancing 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 10 mm 3 8 thick cut at about 300 mm min 11 13 16 min Also slow down as you complete a cut to avoid breaking or cracking the workpi
10. ece being cut CAUTION Be sure to hold the workpiece firmly down on a stable bench or table during operation eDo 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 is recommended to attach a rubber plate optional accessory on the base of the tool to prevent the workpiece surface from being scratched eThe wheel for Model 4191D DW is a wet type wheel for glass and tile applications Be sure to feed water to the wheel during operation elf the cutting action of the wheel begins to diminish dress the cutting edge of the wheel using an old discarded coarse grit bench grinder whee or concrete block Dress by press ing lightly on the outer edge of the wheel CAUTION If the tool is operated continuously until the battery cartridge has discharged allow the tool to rest for 15 minutes before proceeding with a fresh battery 13 MAINTENANCE CAUTION Always be sure that the charger is unplugged and the battery cartridge is removed before 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 14 OPTIONAL ACCESSORIES The accessories listed in th
11. ing charging eWhen charging is completed the charging light color will change from red to green eAfter charging unplug the charger from the power source Refer to the table below for the charging time Fast charger DC1410 Battery cartridge 1200 Approx 40 min 1201 1201A Approx 50 min 1202 1202A 1222 Approx 60 min CAUTION eThe fast charger Model DC1410 is for charging Makita battery cartridge Never use it for other purposes or for other manufacturer s batteries eWhen you charge a new battery cartridge or a battery cartridge which has not been used for a long period of time it may not accept a full charge This is normal condition and does not indicate a problem You can recharge the battery cartridge fully after discharging it completely and recharging a couple of times elf you charge a battery cartridge from a just operated tool or a battery cartridge which has been left in a location exposed to direct sunlight or heat for a 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 elf 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 elf you wish to charge
12. is 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 tool 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 e Hex wrench e Battery cartridge 1200 Part No 783202 0 Part No 192271 4 e High capacity battery 1201 1202 Part No 192296 8 1201 Part No 192536 4 1202 e Fast charger Model DC1410 Part No 113150 3 e Power display battery High cap 1201A 1202A Part No 192407 5 1201A Part No 192537 2 1202A e Battery cover Part No 414938 7 High capacity battery 1222 Part No 192598 2 e Diamond wheel e Set plate Part No 343579 1 K Part No Hole Diameter diameter ae mm mm YP 85 15 85 15 General For glass 15 Feb 29 S6 US 85 mm 3 3 8 CORDLESS CUTTER Model 4191D Note The switch and other part configurations may differ from country to country 16 MODEL 4191D Feb 29 96 US ITEM ITEM NO DESCRIPTION NO USED DESCRIPTION MACHINE MACHINE 1 1 Band B 33 1 Gear Complete 8 68 2 1 Pan Head Screw M4x25 With Washer 34 1 Thin Washer 4 3 1 Name Plate 35 1 Plane Bearing
13. olarized plug one blade is wider than the other This plug will fit in a polarized outlet only one way If the plug does not fit fully in the outlet reverse the plug If it still does not fit contact a qualified electrician to install the proper outlet Do not change the plug in any way 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 in SERIOUS INJURY to the user as well as damage to the tool If in doubt DO NOT PLUG IN THE TOOL Using a power source with voltage less than the nameplate rating is harmful to the motor IMPORTANT SAFETY INSTRUCTIONS 10 11 12 FOR CHARGER amp BATTERY CARTRIDGE SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for battery charger Before using battery charger read all instructions and cautionary markings on 1 battery charger 2 battery and 3 product using battery CAUTION To reduce risk of injury charge only MAKITA Battery Cartridge 7000 7001 7002 9000 9001 9002 9100 9101 9101A 9102 9102A 9122 1200 1201 1201A 1210 1211 1202 1202A 1222 amp 1422 Other types of batteries may burst causing personal injury and damage Do not expose charger to rain or snow Use of an attachment not recommended or s
14. old by the battery charger manufacturer may result in a risk of fire electric shock or injury to persons To reduce risk of damage to electric plug and cord pull by plug rather than cord when disconnecting charger Make sure cord is located so that it will not be stepped on tripped over or otherwise subjected to damage or stress An extension cord should not be used unless absolutely necessary Use of improper extension cord could result in a risk of fire and electric shock If extension cord must be used make sure a That pins on plug of extension cord are the same number size and shape as those of plug on charger b That extension cord is properly wired and in good electrical condition and c That wire size is at least as large as the one specified in the table below TABLE 1 RECOMMENDED MINIMUM AWG SIZE FOR EXTENSION CORDS FOR BATTERY CHARGERS Length of Cord Feet 25 50 100 150 TANG Sie of Gord 18 18 18 16 Do not operate charger with damaged cord or plug replace them im mediately Do not operate charger if it has received a sharp blow been dropped or other wise damaged in any way take it to a qualified serviceman Do not disassemble charger or battery cartridge take it to a qualified serviceman when service or repair is required Incorrect reassembly may result in a risk of electric shock or fire To reduce risk of electric shock unplug charger from outlet before attemp
15. t ing any maintenance or cleaning Turning off controls will not reduce this risk ADDITIONAL SAFETY RULES FOR CHARGER amp BATTERY CARTRIDGE Do not charge Battery Cartridge when temperature is BELOW 10 C 50 F or ABOVE 40 C 104 F Do not attempt to use a step up transformer an engine generator or DC power receptacle Do not allow anything to cover or clog the charger vents Always cover the battery terminals with the battery cover when the battery cartridge is not used A battery short can cause a large current flow overheating possible burns and even a breakdown 1 Do not touch the terminals with any conductive material 2 Avoid storing battery cartridge in a container with other metal objects such as nails coins etc 3 Do not expose battery cartridge to water or rain Do not store the tool and Battery Cartridge in locations where the tempera ture may reach or exceed 35 C 95 F Do not incinerate the Battery Cartridge even if it is severely damaged or is completely worn out The battery cartridge can explode in a fire ADDITIONAL SAFETY RULES 1 Be aware that this is always in an operating condition because it does not 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
16. ts cutters 14 15 16 We 18 19 20 21 REMOVE ADJUSTING KEYS AND WRENCHES Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on AVOID UNINTENTIONAL STARTING Don t carry tool with finger on switch Be sure switch is OFF when plugging in OUTDOOR USE EXTENSION CORDS When tool is used outdoors use only extension cords intended for use outdoors and so marked STAY ALERT Watch what you are doing use common sense Don t operate tool when you are tired CHECK DAMAGED PARTS Before further use of the tool a guard or other part that is damaged should be carefully checked to determine that it will 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 if switch does not turn it on and off GUARD AGAINST ELECTRIC SHOCK Prevent body contact with grounded surfaces For example pipes radiators ranges refrigerator enclosures REPLACEMENT PARTS When servicing use only identical replacement parts POLARIZED PLUGS To reduce the risk of electric shock this equipment has a p
17. two battery cartridge allow 15 minutes between chargings on the fast charger installing or removing diamond wheel CAUTION 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 Diamond wheel Press the shaft lock so that the wheel can not revolve Use the hex wrench to tighten Shaft lock the bolt securely Tighten Hex wrench To remove the wheel follow the installation procedure in reverse CAUTION eVWhen installing the wheel be sure to tighten the bolt securely eUse only the Makita hex wrench to install or remove the wheel installing water supply Attach the tank holder on the tank The tank Ul hha holder should be attached around the por tion shown with the dotted line Tighten the screw A to the extent that the tank can still turn within the tank holder Screw B Tank holder Attach the tank holder onto the motor hous ing Tighten the screw B securely Screw B Connect the cap on the end of the polyvinyl tube to the mouth of the tank Turn the tank clockwise when making the connection Then tighten the screw A securely to secure the tank CAUTION lf you find the polyvinyl tube is bent like
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