Makita 4190D User manual

1
ENGLISH (Original instructions)
INSTRUCTION MANUAL
WARNING:
For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
Cordless Cutter
4190D
003503

2
ENGLISH
SPECIFICATIONS
Model 4190D
Wheel diameter 80 mm
90° 0 - 18 mm
Cutting depth 45° 0 - 16 mm
No load speed (min-1) 1,000
Overall length 313 mm
Net weight 1.9 kg
Rated voltage D.C. 9.6 V
• Due to our continuing programme of research and development, the specifications herein are subject to change without notice.
• Specifications and battery cartridge may differ from country to country.
• Weight, with battery cartridge, according to EPTA-Procedure 01/2003
END004-3
Symbols
The following show the symbols used for the equipment.
Be sure that you understand their meaning before use.
･Read instruction manual.
･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.
ENE025-1
Intended use
The tool is intended for cutting in glass and masonry
materials with a diamond wheel and water.
GEA006-2
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.
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 ground fault circuit
interrupter (GFCI) protected supply. Use of an
GFCI reduces the risk of electric shock.

3
Personal safety
10. 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.
11. 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.
12. 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.
13. 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.
14. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
15. 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.
16. 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
17. 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.
18. 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.
19. 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.
20. 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.
21. 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.
22. Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
23. 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.
Battery tool use and care
24. Recharge only with the charger specified by
the manufacturer. A charger that is suitable for
one type of battery pack may create a risk of fire
when used with another battery pack.
25. Use power tools only with specifically
designated battery packs. Use of any other
battery packs may create a risk of injury and fire.
26. When battery pack is not in use, keep it away
from other metal objects, like paper clips,
coins, keys, nails, screws or other small metal
objects, that can make a connection from one
terminal to another. Shorting the battery
terminals together may cause burns or a fire.
27. Under abusive conditions, liquid may be
ejected from the battery; avoid contact. If
contact accidentally occurs, flush with water. If
liquid contacts eyes, additionally seek medical
help. Liquid ejected from the battery may cause
irritation or burns.
Service
28. 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.
29. Follow instruction for lubricating and
changing accessories.
30. Keep handles dry, clean and free from oil and
grease.
GEB053-2
CORDLESS CUTTER SAFETY
WARNINGS
1. Read all safety warnings, instructions,
illustrations and specifications provided with
this power tool. Failure to follow all instructions
listed below may result in electric shock, fire
and/or serious injury.

4
2. Always use guard provided with the tool. The
guard must be securely attached to the power
tool and positioned for maximum safety, so
the least amount of wheel is exposed towards
the operator. The guard helps to protect operator
from broken wheel fragments and accidental
contact with wheel.
3. Use only diamond cut-off wheel for your power
tool. Just because the accessory can be attached
to your power tool, it does not assure safe
operation.
4. The rated speed of the wheel must be at least
equal to the maximum speed marked on the
power tool. Wheels running faster than their
rated speed can break and fly apart.
5. Always use undamaged wheel flanges that are
of correct diameter for your selected wheel.
Proper wheel flanges support the wheel thus
reducing the possibility of wheel breakage.
6. The outside diameter and the thickness of
your wheel must be within the capacity rating
of your power tool. Incorrectly sized wheels
cannot be adequately guarded or controlled.
7. The arbour size of wheels and flanges must
properly fit the spindle of the power tool.
Wheels and flanges with arbour holes that do not
match the mounting hardware of the power tool
will run out of balance, vibrate excessively and
may cause loss of control.
8. Do not use damaged wheels. Before each use,
inspect the wheels for chips and cracks. If
power tool or wheel is dropped, inspect for
damage or install an undamaged wheel. After
inspecting and installing the wheel, position
yourself and bystanders away from the plane
of the rotating wheel and run the power tool at
maximum no load speed for one minute.
Damaged wheels will normally break apart during
this test time.
9. Wear personal protective equipment.
Depending on application, use face shield,
safety goggles or safety glasses. As
appropriate, wear dust mask, hearing
protectors, gloves and shop apron capable of
stopping small abrasive or workpiece
fragments. The eye protection must be capable
of stopping flying debris generated by various
operations. The dust mask or respirator must be
capable of filtrating particles generated by your
operation. Prolonged exposure to high intensity
noise may cause hearing loss.
10. Keep bystanders a safe distance away from
work area. Anyone entering the work area
must wear personal protective equipment.
Fragments of workpiece or of a broken wheel may
fly away and cause injury beyond immediate area
of operation.
11. Hold power tool by insulated gripping
surfaces only, when performing an operation
where the wheel may contact hidden wiring.
Wheel contacting a "live" wire may make exposed
metal parts of the power tool "live" and give the
operator an electric shock.
12. Position the cord clear of the spinning wheel.
If you lose control, the cord may be cut or
snagged and your hand or arm may be pulled into
the spinning wheel.
13. Never lay the power tool down until the wheel
has come to a complete stop. The spinning
wheel may grab the surface and pull the power
tool out of your control.
14. Do not run the power tool while carrying it at
your side. Accidental contact with the spinning
wheel could snag your clothing, pulling the wheel
into your body.
15. Regularly clean the power tool's air vents. The
motor's fan will draw the dust inside the housing
and excessive accumulation of powdered metal
may cause electrical hazards.
16. Do not operate the power tool near flammable
materials. Sparks could ignite these materials.
17. Never attempt to cut with the tool held upside
down in a vise. This can lead to serious
accidents, because it is extremely dangerous.
18. Some material contains chemicals which may
be toxic. Take caution to prevent dust
inhalation and skin contact. Follow material
supplier safety data.
Kickback and related warnings
Kickback is a sudden reaction to a pinched or snagged
rotating wheel. Pinching or snagging causes rapid
stalling of the rotating wheel which in turn causes the
uncontrolled power tool to be forced in the direction
opposite of the wheel's rotation at the point of the
binding.
For example, if a wheel is snagged or pinched by the
workpiece, the edge of the wheel that is entering into the
pinch point can dig into the surface of the material
causing the wheel to climb out or kick out. The wheel
may either jump toward or away from the operator,
depending on direction of the wheel's movement at the
point of pinching. The wheels may also break under
these conditions.
Kickback is the result of power tool misuse and/or
incorrect operating procedures or conditions and can be
avoided by taking proper precautions as given below.

5
1. Maintain a firm grip on the power tool and
position your body and arm to allow you to
resist kickback forces. Always use auxiliary
handle, if provided, for maximum control over
kickback or torque reaction during start-up.
The operator can control torque reactions or
kickback forces, if proper precautions are taken.
2. Never place your hand near the rotating wheel.
Wheel may kickback over your hand.
3. Do not position your body in line with and
behind the rotating wheel. Kickback will propel
the tool in direction opposite to the wheel's
movement at the point of snagging.
4. Use special care when working corners, sharp
edges etc. Avoid bouncing and snagging the
wheel. Corners, sharp edges or bouncing have a
tendency to snag the rotating wheel and cause
loss of control or kickback.
5. Do not attach a saw chain woodcarving blade
or toothed saw blade. Such blades create
frequent kickback and loss of control.
6. Do not "jam" the wheel or apply excessive
pressure. Do not attempt to make an
excessive depth of cut. Overstressing the wheel
increases the loading and susceptibility to twisting
or binding of the wheel in the cut and the
possibility of kickback or wheel breakage.
7. When wheel is binding or when interrupting a
cut for any reason, switch off the power tool
and hold the power tool motionless until the
wheel comes to a complete stop. Never
attempt to remove the wheel from the cut while
the wheel is in motion otherwise kickback may
occur. Investigate and take corrective action to
eliminate the cause of wheel binding.
8. Do not restart the cutting operation in the
workpiece. Let the wheel reach full speed and
carefully reenter the cut. The wheel may bind,
walk up or kickback if the power tool is restarted in
the workpiece.
9. Support panels or any oversized workpiece to
minimize the risk of wheel pinching and
kickback. Large workpieces tend to sag under
their own weight. Supports must be placed under
the workpiece near the line of cut and near the
edge of the workpiece on both sides of the wheel.
10. Use extra caution when making a "pocket cut"
into existing walls or other blind areas. The
protruding wheel may cut gas or water pipes,
electrical wiring or objects that can cause
kickback.
SAVE THESE INSTRUCTIONS.
WARNING:
DO NOT let comfort or familiarity with product
(gained from repeated use) replace strict adherence
to safety rules for the subject product. MISUSE or
failure to follow the safety rules stated in this
instruction manual may cause serious personal
injury.
ENC004-1
IMPORTANT SAFETY
INSTRUCTIONS
FOR BATTERY CARTRIDGE
1. Before using battery cartridge, read all
instructions and cautionary markings on (1)
battery charger, (2) battery, and (3) product
using battery.
2. Do not disassemble battery cartridge.
3. If operating time has become excessively
shorter, stop operating immediately. It may
result in a risk of overheating, possible burns
and even an explosion.
4. If electrolyte gets into your eyes, rinse them
out with clear water and seek medical
attention right away. It may result in loss of
your eyesight.
5. Always cover the battery terminals with the
battery cover when the battery cartridge is not
used.
6. Do not short the battery cartridge:
(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.
A battery short can cause a large current
flow, overheating, possible burns and
even a breakdown.
7. Do not store the tool and battery cartridge in
locations where the temperature may reach or
exceed 50 ﾟC (122 ﾟF).
8. 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.
9. Be careful not to drop or strike battery.
SAVE THESE INSTRUCTIONS.

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Tips for maintaining maximum battery life
1. Charge the battery cartridge before completely
discharged.
Always stop tool operation and charge the
battery cartridge when you notice less tool
power.
2. Never recharge a fully charged battery
cartridge.
Overcharging shortens the battery service life.
3. Charge the battery cartridge with room
temperature at 10 ﾟC - 40 ﾟC (50 ﾟF - 104 ﾟF).
Let a hot battery cartridge cool down before
charging it.
4. Charge the Nickel Metal Hydride battery
cartridge when you do not use it for more than
six months.
FUNCTIONAL DESCRIPTION
CAUTION:
• Always be sure that the tool is switched off and the
battery cartridge is removed before adjusting or
checking function on the tool.
Installing or removing battery cartridge
1
2
003507
• Always switch off the tool before installation 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
battery cartridge while withdrawing it from the tool.
• To install 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 to prevent the battery cartridge from
accidentally falling out of the tool.
• Do not use force when inserting the battery
cartridge. If the cartridge does not slide in easily, it
is not being inserted correctly.
Adjusting the depth of cut
1
2
3
003509
Loosen the bolt (A) on the depth guide with the hex
wrench and move the base up or down. At the desired
depth of cut, secure the base by tightening the bolt (A).
Bevel cutting
1
23
003514
Loosen the bolt (A) on the depth guide and the bolt (B)
on the bevel scale plate with the hex wrench. Set for the
desired angle (0° - 45° ) by tilting accordingly, then
tighten the bolts (A) and (B) securely.
CAUTION:
• After adjusting depth of cut and bevel cutting angle,
be sure to tighten the bolts (A) and (B) securely.
Sighting
AB
1
2
003519
For straight cuts, align the "A" position on the front of the
base with your cutting line. For 45° bevel cuts, align the
"B" position with it.
1. Blade case
2. Base
1. Bevel scale
plate
2. Bolt (B)
3. Bolt (A)
1. Depth guide
2. Bolt (A)
3. Hex wrench
1. Set plate
2. Battery
cartridge

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NOTE:
• When making bevel cuts, view the cutting line on
the workpiece through the window in the blade
case in order to cut more accurately. If you have
difficulty seeing it because of the water tank, adjust
the position of the tank by tilting it backward
slightly.
Switch action
1
2
003522
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.
To prevent the switch trigger from being accidentally
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 switch trigger. Release the switch
trigger to stop.
ASSEMBLY
CAUTION:
• Always be sure that the tool is switched off and the
battery cartridge is removed before carrying out
any work on the tool.
Installing or removing diamond wheel
12
3
003526
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 blade stopper pin and insert it through the hole
in the wheel so that the wheel cannot revolve. Use the
hex wrench to tighten the bolt securely.
To remove the wheel, follow the installation procedure in
reverse.
1
2
003527
CAUTION:
• When installing the wheel, be sure to tighten the
bolt securely.
• Use only the Makita wrench to install or remove the
wheel.
Hex wrench storage
1
003533
When not in use, store the hex wrench as shown in the
figure to keep it from being lost.
Installing water supply
1
3
4
5
2
003538
Attach the tank holder on the tank. The tank holder
should be attached around the portion shown with the
dotted line. Tighten the screw (A) to the extent that the
tank can still turn within the tank holder.
Attach the tank holder onto the motor housing. Tighten
the screw (B) securely.
1. Tank holder
installing portion
2. Tank
3. Screw (B)
4. Screw (A)
5. Tank holder
1. Hex wrench
1. Hex wrench
2. Blade stopper
pin
1. Bolt
2. Flange
3. Diamond wheel
1. Lock-off lever
2. Switch trigger

8
1
003539
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.
003541
CAUTION:
• If you find the polyvinyl tube is bent like a "V" or
has been strained excessively after installing the
water supply, loosen the screw (B) and adjust the
position of the tank to alleviate the bent, pinched or
strained condition.
Water supply
1
003542
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.
OPERATION
1
003544
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 thick, cut at about 250 mm/min. When cutting tile
10 mm thick, cut at about 300 mm/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 a
stable bench or table during operation.
• Do not twist or force the tool in the cut, or the motor
may be overloaded or the workpiece 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.
• The wheel for this tool is a wet-type wheel for glass
and tile applications. Be 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 pressing lightly on the
outer edge of the wheel.
NOTE:
• 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.
1. Base
1. Cap
1. Screw (B)

9
MAINTENANCE
CAUTION:
• Always be sure that the tool is switched off 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,
any other maintenance or adjustment should be
performed by Makita Authorized Service Centers,
always using Makita replacement parts.
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. Only use accessory or
attachment for its stated purpose.
If you need any assistance for more details regarding
these accessories, ask your local Makita Service Center.
• Diamond wheels
• Hex wrench 4
• Rubber plate
• Various type of Makita genuine batteries and
chargers

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Makita Corporation
883627I9