Makita 4191DZ User manual

Cordless Cutter
85 mm
13-318")
85 mm (3-3/8") MODEL 4191DZ 85 mm (3-3/8") MODEL 419lDWA
With Battery Cartridge and Fast Charger
0 ~ 24 mm 0 ~ 18 mm 316 mm 2.1 kg
(12-1/2") (4.6
Ibs)
1,000
(0 ~ 15/16") (0 - 11/16")
INSTRUCTION MANUAL
Battery Cartridge 1222
S PECl FI CAT1 0 N S
Model DC1410 Fast Charger
Model 4191D
12 v
weight
Blade Cutting depth
No load speed Overall
(RPM) length
900 450
diameter
A.C. only 50
- 60 Hz D.C. 7.2 V ~ 14.4 V 1 Hr.
Voltage
I Input I output I Charging time

IMPORTANT
SAFETY INSTRUCTIONS
(For All Tools)
WARNING: WHEN USING ELECTRIC TOOLS, BASICSAFETY
PRECAUTIONSSHOULD ALWAYS BE FOLLOWEDTO 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
lit. Don't expose power tools to rain.
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 IDLETOOLS. When not in use, tools should bestored in dry, and high
or locked-up@ace
- out of reach of children.
5. DON'T FORCETOOL. It will dothejob better and safer atthe ratefor which
it was intended.
6. USE RIGHT TOOL. Don't force small tool or attachment to do the job of a
heavy-dutytool. Don't usetoolfor purpose notintended; for example, don't
use circular saw for cutting tree limbs or logs.
7. DRESS PROPERLY. Don't wear loose clothing orjewelry. They can be caught
in moving parts. Rubber gloves and non-skid footwear are recommended
when working outdoors. Wear protective hair covering tocontain long hair.
8. USE SAFETY GLASSES. Also use face or dust mask if cutting operation is
dusty.
9. DON'T ABUSECORD. Nevercarry toolby cord or yank it todisconnect from
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
it frees both hands to operate tool.
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 acces-
sories. Inspect tool cords periodicallyand
if damaged, haverepairedby autho-
rized service facility. Inspect extension cords periodically and replace if
damaged. Keep handles dry, clean, and free from
oil and grease.
13. DISCONNECT TOOLS when not in use, before servicing, and when chang-
ingaccessories,
such as blades,bits, cutters.
2

14. REMOVEADJUSTING KEYS AND WRENCHES. Form habit of checking to
see that keys and adjusting wrenches are removed from tool before turning
it on.
15. AVOID UNINTENTIONALSTARTING. Don't carry toolwithfinger onswitch.
Be sure switch is
OFF when plugging in.
16. OUTDOORUSE EXTENSIONCORDS. When tool is usedoutdoors, use only
extension cords intended for use outdoors and
so marked.
17. STAY ALERT. Watch what you are doing, usecommon 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
it will
operate properly and perform its intended function. Check for alignment of
moving parts, bindingof movingparts, breakageof parts. mounting, andany
other conditions that may affect its operation. A guard or other part that
isdamaged should be properly repaired or replacedbyan authorized service
center unlessotherwise indicatedelsewhere inthis instruction manual. Have
defective switches replaced by authorized service center. Don't use tool
if
switch does not turn it on and off.
19. GUARDAGAINST ELECTRIC SHOCK. Prevent body contact with grounded
surfaces. For example; pipes, radiators, ranges, refrigerator enclosures.
20. REPLACEMENTPARTS.When servicing, useonly identical replacement parts.
21. POLARIZEDPLUGS. To reducethe risk of electric shock, thisequipment has
a polarized plug (one blade is wider than the other). This plug will fit
in a
polarizedoutlet only one way.
If the plugdoes not fit fully inthe 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 toa 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 toolcan result
in SERIOUS INJURY tothe user - as well as damage to
the tool.
If in doubt, DO NOT PLUG INTHE TOOL. Using a power source with
voltage less than the nameplate rating is harmful to the motor.

IMPORTANT SAFETY INSTRUCTIONS
FOR CHARGER
&
BATTERY CARTRIDGE
I. SAVE THESE INSTRUCTIONS - This manual
Length of Cord (Feet) 25
AWG Size of Cord
18
50 100
150
18 18
16
4

ADDITIONAL SAFETY RULES
FOR CHARGER & BATTERY CARTRIDGE
1. Do not charge Battery Cartridge when temperature is BELOW 10°C (5OOF)
2. Donotattempt touse astep-up transformer, anenginegenerator or DC power
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
5. A battery short can cause a large current flow, overheating, possible burns
or ABOVE 4OoC
(104OF).
receptacle.
cartridge is not used.
and even a breakdown.
(1 1 Do not touch the terminals with any conductive material.
(21 Avoidstoring battery cartridge inacontainer with other metalobjects such
(3) Do not expose battery cartridge to water or rain.
ture may reach or exceed
35OC (95OF).
completely worn out. The battery cartridge can explode in a fire.
as nails, coins, etc.
6. Do not store the tool and Battery Cartridge in locations where the tempera-
7. Do not incinerate the Battery Cartridge even if it is severely damaged or is

ADDITIONAL SAFETY RULES
1. Be aware that this is always inan 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 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 contactingthe workpiece before the switch is
8. Wait until the wheel attains full speed before cutting.
9. Stop operation immediately if you notice anything abnormal.
turned on.
IO. Do not attempt to lock the trigger in the "ON" position.
11. Never attempt tocut withthe tool
held upside down
in a vise. This
can lead to serious accidents,
because
it isextremely dangerous.
12. Before settingthe tooldownafter completing a cut, be sure that the wheel
has come to a complete stop.
SAVE THESE INSTRUCTIONS.
6

Installing or removingthe battery cartridge 1222
*Always switch off the tool before insertionor removal of the batterycartridge.
*To remove the batterycartridge, withdraw
itfrom the tool while pressing the buttons
on both sides of the cartridge.
*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
a little click.
*Do not use force when inserting the battery cartridge. If the cartridge does not slide in
easily, it is not being insertedcorrectly.
Installingthe set plate
Always install the set plate when using bat-
tery cartridges 1200, 1201, 1201A, 1202or
1202A. Install the set plate on the tool with
the screw and nut provided as shown in
the figure.
.
/ Pan headscrew
Set plate
Installing or removingthe battery cartridge 1200,1201,1201A, 1202 and 1202A.
*Always switch off the tool before insertionor 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 thetool.
*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. If the cartridge does not slide in
easily, it is not being insertedcorrectly.
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 charginglight will flash
in green color.
*Insert the batterycartridge
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 charser ~ort floor.
~
1201 / 1201A
Charging light
-
Approx. 50 min.
-I
*When the battery cartridge is inserted, the charging light color will changefrom green to
*When charging is completed, the charginglight color will changefrom red to green.
*After charging, unplug the charger from the power source. Refer to the table below for
red and chargingwill begin. The charging light will remain lit steadily during charging.
the chargingtime.
1202 I1202A / 1222
DC1410
Approx. 60 min.
I 1200 I ADDrox. 40 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
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 rechargethe batterycartridge fully after discharging
it completely and recharging
a couple of times.
*If you charge
a batterycartridgefrom a just-operated tool or a battery cartridgewhich has
been left in a locationexposed to direct sunlight or heatfor
a longtime, the charginglight
mayflash 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 charginglight 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 batterycartridge is worn out or damaged.
*If you wish to charge two battery cartridge, allow 15 minutes betweenchargings on the
fast charger.
8

Installingor removingdiamond wheel
CAUTION :
Always be sure that the tool is switched off and the battery cartridge is removed before
installingor 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 so that the wheel can-
not revolve. Use the hex wrench to tighten
- Diamond wheel
Shaft lock -,
the bolt securely
n
- Hex wrench
To remove the wheel, follow the installationprocedure in reverse.
CAUTION:
*When installingthe wheel, be sure to tighten the bolt securely.
*Use only the Makita hex wrench to install or remove the wheel.

installingwater supply
Attach the tank holder on the tank. The tank
Attach the tank holderonto the motor hous-
ing.Tighten the screw
(B) securely.
-Tank
Tank holder
installing portion -,
Connect the cap on the end of the polyvinyl
tube to the mouth
of the tank. Turnthe tank
clockwise when making the connection.
Then tighten the screw
(A) securely to
secure the tank.
CAUTION:
If
you find the polyvinyl tube is bent like a "V" or has been strained excessively after
installingthe water supply, loosenthe screw (B) and adjust the positionof the tank to alle-
viate the bent, pinched or strained condition.
10

Hex wrenchstorage
When not in use, the hex wrench can be
convenientlystored.
Hex wrench
4b
Adjusting thedepth 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 bytightening the screw.
Depth auide
CAUTION:
*Use
a shallow depth of cut when cutting thin workpiece for cleaner, safer cuts.
*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") by tilting accordingly, then
tighten the clamp screw securely.
CAUTION:
After adjusting the depth of cut and bevel cutting angle, besure
to tighten the screw.

Sighting
The front of the base is notched to provide
twoguide edges.
For straight cuts, align the edge with 0"
engravedon it with your cutting line on the
workpiece.
For
45" bevel cuts, align the edge with 45"
engravedon it with your cutting line.
Switchaction
To prevent the trigger from being acciden-
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. Releasethe trigger to stop.
Lock-offlever
Switch trigger
CAUTION:
Before inserting the battery cartridge into the tool, always check to see that the switch
trigger actuates properly and returnsto the "OFF" positionwhen released.
Water supply
Removethe 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
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. (Whencutting 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 breakingor cracking the
workpiece being cut.
CAUTION:
*Be sure to holdthe 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 work-
*Do not use the tool with the wheel in an upward or sideways position.
*When cutting glass plate, it
is recommendedto attacha rubber plate (optionalaccessory)
on the baseof the tool to prevent the workpiece surfacefrom being scratched.
*The wheel for Model
41 91 D/DW 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 beginsto diminish, dress the cutting edge of the wheel
using an old discardedcoarse grit bench grinder wheel or concrete block.Dress by press-
ing lightly on the outer edge of the wheel.
piece may break.
CAUTION:
If the tool is operated continuously until the battery cartridge has discharged, allow the
tool to rest for 15 minutes before proceedingwith
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, maintenanceor adjustment should
be performed by Makita Authorized or Factory Service Centers, always using Makita
replacement parts.
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 packedwith your
tool.
CAUTION:
These accessories or attachments are recommendedfor 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 beused only inthe proper and intendedmanner.
Hex wrench
Part No. 783202-0
Fast charger
Model DC1410
Part No. 113150-3
Battery cover
Part No. 414938-7
Diamond wheel
Battery cartridge 1200
High capacity battery 1201, 1202
Part No. 192271-4
Part
No. 192296-8 (1201)
Part
No. 192536-4 (1 202)
Power display battery (High cap.) 1201A. 1202A
Part No. 192407-5 (1201A)
Part
No. 192537-2 (1 202A)
Highcapacity battery 1222
Part No. 192598-2
*Set plate
Part No. 343579-1
Part
No. 1 Dimfr I diF?r 1 E 1 Use
General
724950-8c (3-318") (1 9/32") purpose
85 15 For glass
724950-8B I (3-318") I (19132") I Wet I cutting
15

Feb -29-'96 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
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
I:"," $& DESCRIPTION
1 Motor Housing 37 1
1
Cap 38 1
1 Tank 39 1
1 Pan
Head Screw M4x25 IWith Washerl 40 I
1 Tank Holder 41 1
1
Rubber Washer 12 42 1
1 cap 43
I
1 VinylTube 5 44 1
1 Nut 45 1
1 Compression Spring 4 46 1
3 Tapping
Screw 4x 18 47 1
1 Lock Oft Lever
48 1
1 Housing Set IWith Item 221 49 1
1 Rubber Sheet 50 1
1 Battery Holder 51 1
1 High Capacity Batlery 1222 52 1
1 Rubber Sheet 53 1
1 Houslng Set IWith Item 171 54 1
1 Pan Head Screw M4x25 IWifh Washer) 55 1
1 Makita Label 56 1
2 Tapping Screw Flange PT 4x30 57 1
1 Tapping Screw Flange PT 4x30 58 3
1 Hex Nul M5 59 1
3 Tapping Screw 4x18 60 1
1 Switch
61 1
1 Hex Nut M4 62 1
1 Swtch Lever 63 1
1 Plane Bearing 4 64 1
'i\M A:D DESCRIPTION
MACHINE
1 1
Band B
j i 1 Pan Head Screw M4x25 IWith Washer)
Name Plate
4 DC Motor 12 V
MACHINE
__
Gear Complete 8-68
Thin Washer 4
Plane Bearing 4
Retaining
Ring 5-8
Helical Gear 33
Flat
Washer 8
Ball Bearing 608LB
Pl" 5
Water Supply Cock Complete
Screw M5x10
Screw M5x10
Spring
Washer 5
Flat Washer 5
Base
Spring Pin 4-40
Flat Washer 5
Sprlog Washer 5
Screw M5x10
Stop
Ring E-4
Nozzle
Woodruff Key 3
Splndle
Ball Bearing 6OOOLLP
Blade Case
Tapping Screw 4x18
Bearing Box
Packing
RetalW,
Inner Flange 28
Outer
Flange 28
Hex Socket Head Bolt M5x12
COmpreSSlOn
Spring 7
17

Recycling the Battery
The only way to dispose of a Makita battery is
to recycle it. The law prohibits any other
method
of disposal.
I Ni-Cd I
To recyclethe battery:
1. Remove the battery from the tool.
2. a). Take the batteryto 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.
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 leavingthe 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 ServiceCenters. If inspection shows
the trouble is caused by defective workmanship or material, Makita
will repair (or at our option,
replace) without charge.
This Warranty doesnot apply where:
e repairs have been made or attemptedby others:
e repairs are required because of normal wear and tear:
e The tool has been abused, misused or improperly maintained;
e alterationshave been made to the tool.
IN NO EVENT SHALL MAKITA Bk. LIABLE FOR ANY INDIRI:CT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES FROM THE SALE OR USE
OF THE PRODUCT. THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THE TERM OFTHIS WARRANTY.
RANTIES, INCLUDING IMPLIED
S FOR A SPECIFIC PURPOSE;'
y also have other
limitation of inci
MakitaCorporation of America
2650 Buford Hwy., Buford,GA30518
MCA6/96 884068A064
PRINTED IN USA
19%-7-4D