Makita BCS550 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 Metal Cutter
BCS550
007522

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ENGLISH
SPECIFICATIONS
Model BCS550
Blade diameter 136 mm
Max. Cutting depth 51 mm
No load speed (min-1) 3,600
Overall length 348 mm
Net weight 2.6 kg
Rated voltage D.C. 18V
• 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.
ENE066-1
Intended use
The tool is intended for cutting in mild steel and
aluminum only with appropriate saw blades.
ENG102-3
Noise
The typical A-weighted noise level determined according
to EN60745:
Sound pressure level (LpA) : 101 dB(A)
Sound power level (LWA) : 112 dB(A)
Uncertainty (K) : 3 dB(A)
Wear ear protection
ENG235-1
Vibration
The vibration total value (tri-axial vector sum)
determined according to EN60745:
Work mode : cutting steel pipe
Vibration emission (ah) : 3.0 m/s2
Uncertainty (K) : 1.5 m/s2
ENH101-13
For European countries only
EC Declaration of Conformity
We Makita Corporation as the responsible
manufacturer declare that the following Makita
machine(s):
Designation of Machine:
Cordless Metal Cutter
Model No./ Type: BCS550
are of series production and
Conforms to the following European Directives:
98/37/EC until 28th December 2009 and then with
2006/42/EC from 29th December 2009
And are manufactured in accordance with the following
standards or standardised documents:
EN60745
The technical documentation is kept by our authorised
representative in Europe who is:
Makita International Europe Ltd,
Michigan, Drive, Tongwell,
Milton Keynes, MK15 8JD, England
30th January 2009
000230
Tomoyasu Kato
Director
Makita Corporation
3-11-8, Sumiyoshi-cho,
Anjo, Aichi, JAPAN
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.

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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.
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.

4
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.
GEB058-1
CORDLESS METAL CUTTER
SAFETY WARNINGS
DANGER:
1. Keep hands away from cutting area and the
blade. Keep your second hand on auxiliary
handle, or motor housing. If both hands are
holding the tool, they cannot be cut by blade.
2. Do not reach underneath the workpiece. The
guard cannot protect you from the blade below the
workpiece.
3. Adjust the cutting depth to the thickness of
the workpiece. Less than a full tooth of the blade
teeth should be visible below the workpiece.
4. Never hold piece being cut in your hands or
across your leg. Secure the workpiece to a
stable platform. It is important to support the
work properly to minimize body exposure, blade
binding, or loss of control.
5. Hold power tool by insulated gripping
surfaces when performing an operation where
the cutting tool may contact hidden wiring.
Contact with a "live" wire will also make exposed
metal parts of the power tool "live" and shock the
operator.
6. When ripping always use a rip fence or
straight edge guide. This improves the accuracy
of cut and reduces the chance for blade binding.
7. Always use blades with correct size and shape
(diamond versus round) of arbour holes.
Blades that do not match the mounting hardware
of the tool will run eccentrically, causing loss of
control.
8. Never use damaged or incorrect blade
washers or bolts. The blade washers and bolt
were specially designed for your tool, for optimum
performance and safety of operation.
9. Causes and operator prevention of kickback;
−Kickback is a sudden reaction to a pinched,
bound or misaligned blade, causing an
uncontrolled tool to lift up and out of the
workpiece toward the operator.
−When the blade is pinched or bound tightly by
the kerf closing down, the blade stalls and the
motor reaction drives the unit rapidly back
toward the operator.
−If the blade becomes twisted or misaligned in
the cut, the teeth at the back edge of the
blade can dig into the top surface of the
workpiece causing the blade to climb out of
the kerf and jump back toward the operator.
Kickback is the result of tool misuse and/or
incorrect operating procedures or conditions and
can be avoided by taking proper precautions as
given below.
• Maintain a firm grip with both hands on the
tool and position your arms to resist
kickback forces. Position your body to
either side of the blade, but not in line with
the blade. Kickback could cause the tool to
jump backwards, but kickback forces can be
controlled by the operator, if proper
precautions are taken.
• When blade is binding, or when
interrupting a cut for any reason, release
the trigger and hold the tool motionless in
the material until the blade comes to a
complete stop. Never attempt to remove
the tool from the work or pull the tool

5
backward while the blade is in motion or
KICKBACK may occur. Investigate and take
corrective actions to eliminate the cause of
blade binding.
• When restarting a tool in the workpiece,
center the blade in the kerf and check that
blade teeth are not engaged into the
material. If blade is binding, it may walk up
or kickback from the workpiece as the tool is
restarted.
• Support large panels to minimise the risk
of blade pinching and kickback. Large
panels tend to sag under their own weight.
Supports must be placed under the panel on
both sides, near the line of cut and near the
edge of the panel.
• Do not use dull or damaged blades.
Unsharpened or improperly set blades
produce narrow kerf causing excessive friction,
blade binding and kickback.
• Blade depth and bevel adjusting locking
levers must be tight and secure before
making cut. If blade adjustment shifts while
cutting, it may cause binding and kickback.
• Use extra caution when making a "plunge
cut" into existing walls or other blind areas.
The protruding blade may cut objects that can
cause kickback. For plunge cuts, retract lower
guard using retracting handle.
10. Check lower guard for proper closing before
each use. Do not operate the tool if lower
guard does not move freely and close instantly.
Never clamp or tie the lower guard into the
open position. If tool is accidentally dropped,
lower guard may be bent. Raise the lower guard
with the retracting lever and make sure it moves
freely and does not touch the blade or any other
part, in all angles and depths of cut.
To check lower guard, open lower guard by hand,
then release and watch guard closure. Also check
to see that retracting handle does not touch tool
housing. Leaving blade exposed is VERY
DANGEROUS and can lead to serious personal
injury.
11. Check the operation and condition of the lower
guard spring. If the guard and the spring are
not operating properly, they must be serviced
before use. Lower guard may operate sluggishly
due to damaged parts, gummy deposits, or a
buildup of debris.
12. Lower guard should be retracted manually
only for special cuts such as "plunge cuts"
and "compound cuts." Raise lower guard by
retracting handle and as soon as blade enters
the material, the lower guard must be released.
For all other sawing, the lower guard should
operate automatically.
13. Always observe that the lower guard is
covering the blade before placing tool down
on bench or floor. An unprotected, coasting
blade will cause the tool to walk backwards,
cutting whatever is in its path. Be aware of the
time it takes for the blade to stop after switch is
released.
14. Do not stop the blades by lateral pressure on
the blade.
15. DANGER:
Do not attempt to remove cut material when
blade is moving.
CAUTION: Blades coast after turn off.
16. Place the wider portion of the tool base on that
part of the workpiece which is solidly
supported, not on the section that will fall off
when the cut is made.
17. Never attempt to make a cut with the tool held
upside down in a vise. This is extremely
dangerous and can lead to serious accidents.
18. Wear safety goggles and hearing protection
during operation.
19. Always use blades recommended in this
manual. Do not use any abrasive wheels.
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.
ENC007-4
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.

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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. 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.
6. Do not store the tool and battery cartridge in
locations where the temperature may reach or
exceed 50 ﾟC (122 ﾟF).
7. 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.
8. Be careful not to drop or strike battery.
9. Do not use dropped or struck battery.
SAVE THESE INSTRUCTIONS.
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.
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
3
007523
• Always switch off the tool before insertion or
removal of the battery cartridge.
• To remove the battery cartridge, withdraw it from
the tool while sliding the button on the side of the
cartridge.
• To insert the battery cartridge, align the tongue on
the battery cartridge with the groove in the housing
and slip it into place. Always insert it all the way
until it locks in place with a little click. If you can
see the red part on the upper side of the button, it
is not locked completely. Insert it fully until the red
part cannot be seen. If not, it may accidentally fall
out of the tool, causing injury to you or someone
around you.
• Do not use force when inserting the battery
cartridge. If the cartridge does not slide in easily, it
is not being inserted correctly.
Adjusting depth of cut
1
007524
CAUTION:
• After adjusting the depth of cut, always tighten the
lever securely.
Loosen the lever on the side of the rear handle and
move the base up or down. At the desired depth of cut,
secure the base by tightening the lever.
1. Lever
1. Red part
2. Button
3. Battery cartridge

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For cleaner, safer cuts, set cut depth so that no more
than one blade tooth projects below workpiece. Using
proper cut depth helps to reduce potential for dangerous
KICKBACKS which can cause personal injury.
Sighting
2
1
3
007525
When cutting, align the A position on the front of the
base with your cutting line on the workpiece.
Switch action
12
007526
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.
• Do not pull the switch trigger hard without pressing
the lock-off lever. This can cause switch breakage.
To prevent the switch trigger from being accidentally
pulled, a lock-off lever is provided. To start the tool,
press the lock-off lever and pull the switch trigger.
Release the switch trigger to stop.
WARNING:
• For your safety, this tool is equipped with lock-off
lever which prevents the tool from unintended
starting. NEVER use the tool if it runs when you
simply pull the switch trigger without pressing the
lock-off lever. Return tool a MAKITA service center
for proper repairs BEFORE further usage.
• NEVER tape down or defeat purpose and function
of lock-off lever.
Lighting the lamp
1
007527
CAUTION:
• Do not look in the light or see the source of light
directly.
Only to turn on the light, pull the switch trigger without
pressing the lock-off lever. To turn on the light and run
the tool, press the lock-off lever and pull the switch
trigger with the lock-off lever being pressed.
NOTE:
• Use a cotton stick to wipe the dirt off the lens of
lamp. Be careful not to scratch the lens of lamp, or
it may lower the illumination.
• Do not use gasoline, thinner or the like to clean the
lens of lamp. Using such substances will damage
the lens.
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.
Removing or installing blade
2
1
007528
CAUTION:
• Be sure the blade is installed with teeth pointing up
at the front of the tool.
• Use only the Makita wrench to install or remove the
blade.
1. Shaft lock
2. Hex wrench
1. Lamp
1. Switch trigger
2. Lock-off lever
1. A position
2. Cutting line
3. Base

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To remove the blade, press the shaft lock so that the
blade cannot revolve and use the wrench to loosen the
hex bolt counterclockwise. Then remove the hex bolt,
outer flange and blade.
To install the blade, follow the removal procedure in
reverse. BE SURE TO TIGHTEN THE HEX BOLT
CLOCKWISE SECURELY.
1
2
3
4
5
007529
When changing blade, make sure to also clean upper
and lower blade guards of accumulated chips and
particles. Such efforts do not, however, replace the need
to check lower guard operation before each use.
Hex wrench storage
1
007530
When not in use, store the hex wrench as shown in the
figure to keep it from being lost.
OPERATION
CAUTION:
• Always insert the battery cartridge all the way until
it locks in place. If you can see the red part on the
upper side of the button, it is not locked completely.
Insert it fully until the red part cannot be seen. If not,
it may accidentally fall out of the tool, causing injury
to you or someone around you.
• Be sure to move the tool forward in a straight line
gently. Forcing or twisting the tool will result in
overheating the motor and dangerous kickback,
possibly causing severe injury.
• 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.
• Never twist or force the tool in the cut. This may
cause motor overload and/or a dangerous
kickback, resulting in serious injury to the operator.
• Always wear eye protection or goggle before
operation.
1
2
3
007531
Hold the tool firmly. The tool is provided with both a front
grip and rear handle. Use both to best grasp the tool. If
both hands are holding the tool, they cannot be cut by
the blade. Set the base on the workpiece to be cut
without the blade making any contact. Then turn the tool
on and wait until the blade attains full speed. Now simply
move the tool forward over the workpiece surface,
keeping it flat and advancing smoothly until the cutting is
completed.
To get clean cuts, keep your cutting line straight and
your speed of advance uniform. If the cut fails to properly
follow your intended cut line, do not attempt to turn or
force the tool back to the cut line. Doing so may bind the
blade and lead to dangerous kickback and possible
serious injury. Release switch, wait for blade to stop and
then withdraw tool. Realign tool on new cut line, and
start cut again. Attempt to avoid positioning which
exposes operator to chips and particles being ejected
from the tool. Use eye protection to help avoid injury.
The sight grooves in the base makes it easy to check the
distance between the front edge of the blade and the
workpiece whenever the blade is set to the maximum
depth of cut.
2
1
3
007534
CAUTION:
• Do not use a deformed or cracked blade. Replace
it with a new one.
• Do not stack materials when cutting them.
1. Cutting line
2. Base
3. Sight grooves
1. Front grip
2. Rear handle
3. Base
1. Hex wrench
1. Hex bolt
2. Outer flange
3. Saw blade
4. Inner flange
5. Cup washer

9
• Do not cut hardened steel, stainless steel, wood,
plastics, concrete, tile, etc. Cut only mild steel
and aluminum.
• Do not touch the blade, workpiece or cutting chips
with your bare hand immediately after cutting, they
may be extremely hot and could burn your skin.
• Always use the blades appropriate for your job.
The use of inappropriate blades may cause a poor
cutting performance and/or present a risk of
personal injury.
Rip fence (guide rule) (Accessory)
1
2
007532
The handy rip fence allows you to do extra-accurate
straight cuts. Simply slide the rip fence up snugly against
the side of the workpiece and secure it in position with
the screw on the front of the base. It also makes
repeated cuts of uniform width possible.
MAINTENANCE
CAUTION:
• Always be sure that the tool is switched off and the
battery cartridge is removed before attempting to
perform inspection or maintenance.
Inspecting blade
• Check the blade carefully for cracks or damage
before and after each use. Replace a cracked or
damaged blade immediately.
• Continuing to use a dull blade may cause a
dangerous kickback and/or motor overload.
Replace with a new blade as soon as it no longer
cuts effectively.
• Blades for metal cutter cannot be re-sharpened.
Replacing carbon brushes
1
001145
Remove and check the carbon brushes regularly.
Replace when they wear down to the limit mark. Keep
the carbon brushes clean and free to slip in the holders.
Both carbon brushes should be replaced at the same
time. Use only identical carbon brushes.
Use a screwdriver to remove the brush holder caps.
Take out the worn carbon brushes, insert the new ones
and secure the brush holder caps.
1
2
007533
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.
• Carbide-tipped blades
• Rip fence (Guide rule)
• Thumb screw M5 x 20
• Compression spring 6
• Hex wrench 5
• Safety goggle
• Various type of Makita genuine batteries and
chargers
1. Brush holder
cap
2. Screwdriver
1. Limit mark
1. Clamping screw
2. Rip fence (Guide
rule)

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Makita Corporation Anjo, Aichi, Japan
884688B228