Makita XCS01 User manual

GB Cordless Steel Rod Cutter Instruction manual
FCoupe Tige Sans-Fil Manuel d’instructions
ECortadora de Varilla a Batería Manual de instrucciones
XCS01

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ENGLISH (Original instructions)
Explanation of general view
SPECIFICATIONS
• Due to our continuing program 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
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.
1. Red indicator
2. Button
3. Battery cartridge
4. Star marking
5. Switch Lock
6. Switch trigger
7. Side A
8. Side B
9. Protector
10. Hold Bolt
11. Rebar
12. Blades
13. More than 200 mm
14. Air Hole
15. Hex Wrench
16. Return Valve
17. Blade A (Thicker Blade)
18. Blade B (Thicker Blade)
19. Bolt (Longer)
20. Bolt (Shorter)
21. Washer
22. Bar Holder
23. Cutter Rod
24. Blade A on Bar Holder
25. Blade B on Cutter Rod
26. Spare Blades
27. Limit mark
28. Rear cover
29. Screws
30. Arm
31. Spring
32. Recessed part
33. Carbon brush cap
34. Hole
Model XCS01
Max. Cutting Capacity (Dia.mm)
3/4" (#6)
Grade 40 - Grade 60
Grade 40: Tensile Strength 490 N / mm270,000 PSI
Grade 60: Tensile Strength 620 N / mm290,000 PSI
Cutting speed 6.5 seconds
Overall length 412 mm (16-1/5")
Net weight 10.6 kg (23.4 lbs)
Rated voltage D.C. 18 V

6
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.
CORDLESS STEEL ROD CUTTER
SAFETY WARNINGS
1. Hold the tool securely while it is in use. If the tool is
not held securely, you may be injured.
2. Keep your hands and face away from the moving
parts. They may cause an injury.
3. Release the Switch trigger immediately to stop
operation when the tool is out of order or makes
an abnormal sound during use. Have it inspected
and repaired by an authorized service center.
Failure to do so may result in damage or injury.
4. If you drop or strike the tool, check carefully that
the body is not damaged, cracked, or deformed.
Any such damage could cause injury.
5. This tool is an electro-hydraulic tool. The oil
reservoir was filled before delivery. Do not add oil
unless the tool operates abnormally.
6. Metal cutting blades have sharp edges. Handle
them carefully to avoid being cut.
7. Damaged, deformed or cracked blades may cause
serious accidents as well as impair operation.
Replace with new genuine blades immediately.

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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.
Symbols
The followings show the symbols used for tool.
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. 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°C (122°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 a damaged battery.
10. Follow your local regulations relating to disposal
of battery.
SAVE THESE INSTRUCTIONS.
CAUTION Only use genuine Makita lithium-ion
batteries. Use of non-genuine Makita batteries, or
batteries that have been altered, may result in the battery
bursting causing fires, personal injury and damage.
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°C - 40°C (50°F - 104°F). Let a hot
battery cartridge cool down before charging it.
4. Charge the battery cartridge once in every six
months if you do not use it for a long period of
time.
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
(Fig. 1)
CAUTION:
• Always switch off the tool before installing or removing
of the battery cartridge.
•Hold the tool and the battery cartridge firmly when
installing or removing battery cartridge. Failure to
hold the tool and the battery cartridge firmly may cause
them to slip off your hands and result in damage to the
tool and battery cartridge and a personal injury.
To remove the battery cartridge, slide it from the tool while
sliding the button on the front of the cartridge.
To install the battery cartridge, align the tongue on the
battery cartridge with the groove in the housing and slip it
into place. Insert it all the way until it locks in place with a
little click. If you can see the red indicator on the upper
side of the button, it is not locked completely.
CAUTION:
• Always install the battery cartridge fully until the red
indicator cannot be seen. If not, it may accidentally fall
out of the tool, causing injury to you or someone
around you.
• Do not install the battery cartridge forcibly. If the
cartridge does not slide in easily, it is not being inserted
correctly.
Battery protection system (Lithium-ion
battery with star marking) (Fig. 2)
Lithium-ion batteries with a star marking are equipped
with a protection system. This system automatically cuts
off power to the tool to extend battery life.
The tool will automatically stop during operation if the tool
and/or battery are placed under one of the following
conditions:
• Overloaded:
The tool is operated in a manner that causes it to
draw an abnormally high current.
In this situation, release the switch trigger on the tool
and stop the application that caused the tool to
become overloaded. Then pull the switch trigger
again to restart.
................... volts
................... direct current

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If the tool does not start, the battery is overheated. In
this situation, let the battery cool before pulling the
switch trigger again.
• Low battery voltage:
The remaining battery capacity is too low and the tool
will not operate. In this situation, remove and
recharge the battery.
Use of non-genuine Makita batteries, or batteries that
have been altered, will void the Makita warranty for the
Makita tool and charger.
OPERATING PROCEDURE
Read, understand and follow all safety instructions and
operating procedures. If you do not understand the
instructions, or if conditions are not correct for proper
operation, do not operate this tool. Consult your
supervisor or other responsible person.
WARNING:
• Before the Battery is inserted into the tool, pull and
release the switch trigger to ensure that it returns when
released.
The motor is on when the switch trigger is pulled and off
when the switch trigger is released.
Switch Lock Operation (Fig. 3)
• Push in the Switch Lock on side A. The Switch is un-
locked and the Trigger can be operated.
• Push in the Switch Lock on side B. The Switch is
locked and the Trigger cannot be operated.
CAUTION:
• The switch trigger should be locked at all times when
not in use.
WARNING:
• Before operation, confirm that the position of the
operator, relative to the tool, and the surrounding area
is safe for operation. Put on safety glasses and wear
protective clothing.
• Refer to the tool specifications in this manual and do
not cut rebar of size or hardness that exceeds the
cutting capacity of the tool.
• Do not cut material other than rebar. Please ask the
manufacturer if you want to cut other materials.
WARNING:
• Replace damaged (chipped, broken, cracked) or
deformed blades immediately. The blade will not cut
true and may fracture or break causing serious
personal injury.
Cutting Procedure
WARNING
•Never use the tool without the protector in place.
Failure to do so can cause serious personal injury.
(Fig. 4)
1. Position the rebar to be cut between the blades.
(Fig. 5)
Adjust the Hold Bolt according to the diameter of the
rebar to be cut so that the rebar is at 90 degrees to the
blades. The Hold Bolt supports the rebar and keeps it
perpendicular to the blades when cutting. (Fig. 6)
WARNING
• When cutting rebar, adjust the Hold Bolt according to
the diameter of the rebar to be cut so that the rebar is
at 90 degrees to the blades. Without this adjustment,
the cut piece may fly off and cause serious injury to the
operator or bystanders. Never fail to check the position
of the operator relative to the tool and confirm the
safety of the operator and surrounding area.
2. Position the rebar to be cut so that it is fully between
the blades. (Fig. 7)
WARNING
• If the rebar to be cut is not positioned fully between the
blades, the blades will be damaged; the rebar will be
ejected violently and may cause serious personal
injury.
WARNING
• Do not cut rebar when the piece to be cut off is less
than 200 mm in length. Cutting shorter length may
cause the rebar to fly off during cut and may result in
serious personal injury. (Fig. 8)
WARNING
• Do not cut rebar when it is not properly supported by
the Hold Bolt. When cutting, hold the rebar on the Hold
Bolt side. (Fig. 9) If not, the cut piece may fly off and
cause serious injury to the operator or bystanders.
3. Push in the Switch Lock on Side A. The switch is
unlocked and the trigger can be operated.
4. Press the switch trigger to start cutting operation. The
Cutter Rod will move forward to cut the rebar. Keep
the Switch depressed until the Cutter Rod stops at the
end of its stroke.
5. Release the switch trigger when the cut is completed
and the Cutter Rod has reached the end of its stroke.
The Cutter Rod will then return automatically to its
starting position. The Cutter Rod will not return if the
stroke is not completed. Similarly the Cutter Rod will
not be able to move forward again until after it returns
completely to its starting position. Press the switch to
start the next cut, only after the Cutter Rod completely
returns to its starting position and stops.
WARNING
• When cutting rebar of a high tensile strength the cut
piece may fly off and cause serious injury to the
operator. Wear safety glasses and confirm that the
surrounding area is safe before starting operation.
(Fig. 10)
WARNING
• Keep your hands and face away from the blades, the
moving parts and the cutting area, during operation.
Remove the Battery from the tool immediately after
use.
NOTE:
• Keep the air hole in the end of the Bar Holder clear of
dirt and debris. The air hole controls the internal
pressure and should not be obstructed. (Fig. 11)
Rotating Function of Motor (Fig. 12)
The Motor Body can be rotated through 360 degrees, in
either direction, during operation. This feature is
particularly useful when working in awkward or narrow
areas as it allows the operator to position the tool in the
best position for easy operation.

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Return Valve Operation (Fig. 13)
The function of the Return Valve is to allow the Cutter Rod
to return to the starting position if it is unable complete a
cut or becomes jammed. This will release the oil pressure
and allow the Cutter Rod to return. Retighten the Return
Valve once the Cutter Rod is fully returned and before
starting the next operation.
BLADES REPLACEMENT
PROCEDURE
If the cutting edges of the blades are chipped, cracked,
deformed, or damaged in any way, their cutting ability will
be reduced. Cutting under such conditions may cause
further damage and result in personal injury. The blades
should be replaced as a set immediately if any damage is
found.
WARNING
• When replacing the blades, ensure that the Battery is
removed from the tool to prevent accidental operation.
Ensure that Blade A, on the Bar Holder and Blade B, on
the Cutter Rod are fitted in their correct respective
positions. (Fig. 14)
1. Undo the bolts and the washers that hold Blade A and
Blade B.
2. Remove dirt and clean the surfaces where the new
blades are to be fitted.
3. Fit Blade A to the Bar Holder and Blade B to the Cutter
Rod. Replace bolts and washers and tighten firmly.
WARNING
• The bolts that hold Blade A and Blade B should be
tightened regularly. If the bolts become loose the
Blades may be damaged and may cause personal
injury.
Type of spare blade and detachment
(Fig. 15)
Securing bolts should be firmly tightened.
Confirm periodically that the blade is tightened properly.
Spare blade size Use this table to identify the correct blades for your model.
NOTE:
• Use only genuine Makita blades.
ADDING OIL
This cordless rebar cutter is electro-hydraulic. When
shipped from the factory, it was filled with oil. Do not
attempt to add oil as long as the tool performs well. Over a
period of time the oil level will gradually go down.
Eventually this will cause a noticeable dropping off in
performance. When this happens add oil as follows.
1. Place some rebar between the blades and pull the
switch trigger.
2. Release the switch trigger just before the cut is
completed to stop the tool.
3. Remove the Battery from the tool, so that the Blades
cannot be moved accidentally.
4. Remove the Bolt (SB10x15) which caps the oil filler
hole. Add the oil, being careful not to allow any oil to
spill into the motor.
5. Replace the Bolt (SB10x15) and tighten securely.
6. Reinsert the Battery into the tool and complete the
cutting operation.
7. Repeat the above procedure several times until the oil
level remains correct.
CAUTION
• Only pure hydraulic oil as recommended by Makita &
Company Ltd., should be used in this tool.
Recommended oils include the Makita supplied
hydraulic oil, Super Hyrando #46 (JX Nippon Oil &
Energy Corp.); Shell Tellus Plus #46 (U.S. Shell); or
equivalent spec anti-wear hydraulic oil, ISO Viscosity
Grade 46. Do not use other oils as these may cause
damage to the seals and other internal machine parts.
Model A (Fitted to Bar Holder) B (Fitted to Cutter Rod)
XCS01 (ø3 - ø20) 28 mm×20 mm×11.5 mm (Bolt Size 6 mm)
1-1/8"×13/16"×7/16" (Bolt Size 1/4")
26 mm×20 mm×10 mm (Bolt Size 5 mm)
1"×13/16"×3/8" (Bolt Size 3/16")

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TROUBLE SHOOTING
WARNING:
• Remove battery before working on machine.
NOTE:
• The internal components of the pump and piston area have very close tolerances and are sensitive to damage from
dust, dirt, contamination of the hydraulic fluid or improper handling. The disassembly of the pump housing requires
special tools and training, and should only be attempted by qualified repair personnel that have been properly trained
and have the right tools. The improper servicing of electrical components can lead to conditions that could cause
serious injury. The pump, piston components and all electrical parts should be serviced only by authorized repair shop,
dealer or distributor.
MAINTENANCE
CAUTION:
• Always be sure that the tool is switched off and the
battery cartridge is removed before attempting to
perform inspection or maintenance.
• Never use gasoline, benzine, thinner, alcohol or the
like. Discoloration, deformation or cracks may result.
Replacing carbon brushes (Fig. 16)
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 two screws then remove the
rear cover. (Fig. 17)
Raise the arm part of the spring and then place it in the
recessed part of the housing with a slotted bit screwdriver
of slender shaft or the like. (Fig. 18)
Use pliers to remove the carbon brush caps of the carbon
brushes. Take out the worn carbon brushes, insert the
new ones and replace the carbon brush caps in reverse.
(Fig. 19)
Make sure that the carbon brush caps have fit into the
holes in brush holders securely. (Fig. 20)
PROBLEM CAUSE SOLUTION
Cutter Rod will not
extend.
Insufficient oil Top up oil. (Refer to “Adding Oil”)
Cutter Rod has not returned completely due
to build up of debris between Cutter Rod and
Bar Holder.
Manually push back Cutter Rod.
Remove debris and clean
Cutter Rod has not returned completely due
to damage to the Cutter Rod.
Replace Cutter Rod.
Cutter Rod has not returned completely due
to loose or damaged Blades.
Tighten Blade bolts.
Replace Blades
Cutter Rod has not returned completely due
to weak Return spring.
Replace Return spring.
Insufficient power to cut
rebar.
Insufficient oil. Top up oil. (Refer to “Adding Oil”)
Return Valve not properly seated or seating
damaged.
Clean tip of Return Valve and Seating.
Remove any scratched from seating.
Return Valve, damaged. Replace.
Incorrect clearance between Cylinder and
Piston.
Replace Piston (Note: different size pistons
available)
Check Valve, not properly seated or seating
damaged.
Clean Check Valve and seating.
Replace.
Urethane packing, damaged or broken. Replace.
Oil leaks. Oil leveller Bladder, damaged or broken. Replace.
Cutter Rod/ Bar Holder, O-Ring damaged;
Rod/Bar Holder, surface scratched or
grooved.
Replace Back-Up Ring and O-ring.
Replace Cutter Rod/Bar Holder
Cylinder/Bar Holder, O-Ring damaged Replace O-ring.
Cylinder/Pump Case, Gasket damaged. Replace liner B.
Bar Cutter/Cylinder/Pump Case, flange bolts
loose.
Tighten bolts.
Motor not moving.
Motor slow or erratic.
Voltage incorrect. Charge Battery.
Battery at end of working life. Replace Battery.
DC Motor damaged by over-heating. Replace DC Motor.
DC Motor bearings or gear damaged or
broken.
Replace bearings or gear.