Makita DSC191 User Manual

GB Cordless Steel Rod Cutter Instruction manual

F Coupe Tige Sans-Fil Manuel d’instructions

E Cortadora de Varilla a Batería Manual de instrucciones

DSC191

910

11 12

13 14

15 16

17 18

19 20

ENGLISH (Original instructions)

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

Explanation of general view

SPECIFICATIONS

Model DSC191

Max. Cutting Capacity (Dia.mm)

Grade 40 - Grade 60 Grade 40: Tensile Strength 490 N / mm Grade 60: Tensile Strength 620 N / mm

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

• 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

70,000 PSI

90,000 PSI

19 mm (3/4")

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

9. If operating a power tool in a damp location is

extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

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.

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.

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.

................... volts

................... direct current

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.

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.

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.

Spare blade size Use this table to identify the correct blades for your model.

Model A (Fitted to Bar Holder) B (Fitted to Cutter Rod)

DSC191 (ø3 - ø20)

NOTE:

• Use only genuine Makita blades.

28 mm×20 mm×11.5 mm (Bolt Size 6 mm)

1-1/8"×13/16"×7/16" (Bolt Size 1/4")

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.

26 mm×20 mm×10 mm (Bolt Size 5 mm)

1"×13/16"×3/8" (Bolt Size 3/16")

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.

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