Makita BCS550Z Handbuch

PRODUCT

P 1 /13

Specification

Standard equipment

Optional accessories

Note: The standard equipment for the tool shown above may differ by country.

TCT saw blade 136mm (5-3/8") 30T ............................... 1

Hex wrench ....................................................................... 1

Safety goggle .................................................................... 1

Plastic carrying case.......................................................... 1

Model No.

Description

CONCEPT AND MAIN APPLICATIONS

BCS550

Cordless Metal Cutter 136mm (5-3/8")

Model BCS550 is a MAKSTAR Cordless Metal Cutting Saw,

featuring compact and lightweight design for high maneuverability

and easy handling.

The items listed below in "Standard Equipment" also come with the above items.

H2 L1 L2

Continuous Rating (W)

Voltage (V) Cycle (Hz) Input Output Max. Output (W)

3,600

Li-ion

3.0

approx. 22 min. with DC18RA

136 (5-3/8)

51 (2)

Yes

2.4 (5.3)

North American countries: 15.88 (5/8)

Other countries: 20 (13/16)

370

Current (A)

No load speed: rpm= min.-1

Battery

Cell

Capacity: Ah

Charging time

Size of blade:

mm (")

Max. cutting

capacities: mm (")

Net weight*: kg (lbs)

*with Battery BL1830

Diameter

at 0

degree

at 45 degrees

at 50

degrees

Electric brake

Hole diameter

Fast charger DC18RA

Charger DC24SA

Charger DC24SC

Li-ion battery BL1830

Screw M5x20

Compression spring 6

136mm (5-3/8") TCT saw blade 30T

136mm (5-3/8") TCT saw blade 50T

Rip fence (Guide rule)

TECHNICAL INFORMATION

Dimensions: mm (")

Width (W1)

Height (H1)

Length (L1) 348(13-3/4)

180 (7-1/8)

201 (7-7/8)

Height (H2) 145 (5-3/4)

Base Size: mm (")

Width (W2)

Length (L2) 200 (7-7/8)

106 (4-3/16)

This product is available in the following variations.

BCS550

BCS550Z

BL1830DC18RA

NoNo

Model No. type quantity

Charger

No All countries

Yes

Plastic

carrying case Offered to

BCS550RF

North America

All countries except

North America

BCS550RFE 2

Battery

P 2 /13

[2] LUBRICATION

[1] NECESSARY REPAIRING TOOLS

CAUTION: Remove the battery, SAW BLADE from the machine for safety

before repair/ maintenance !

Repair

1R027

1R028

1R031

1R032

1R037

1R356 Bearing plate 10mm (for arbor press)

Bearing setting pipe 18-10.2

Bearing setting pipe 20-12.2

Bearing setting pipe 28-20.2

Bearing setting plate 8.2

Bearing setting plate 20.2

Bearing extractor (2 pcs)

Bearing extractor

1R263

1R269

1R278 Round bar for arbor 4-50

1R281 Round bar for arbor 7-50

Retaining ring S and R pliers Removing/installing Retaining ring

Removing/installing Bearing retainer 14-23

Removing Ball bearing 604ZZ

Removing Ball bearing 604ZZ and 696ZZ

Removing Ball bearing 604ZZ

Supporting Gear shaft when assembling Helical gear 35,

Ball bearing 6900ZZ and Helical gear 15 to Gear shaft

Supporting Bearing box section when removing Helical gear 23,

Sleeve 10, and Ball bearing 6900ZZ from Spindle

Removing Bearing box section

Assembling Helical gear 35 to Gear shaft

Assembling Ball bearing 6900ZZ and Helical gear 15 to Gear shaft

Removing Helical gear 35, Ball bearing 6900ZZ and Helical gear 15

from Gear shaft

Removing Helical gear 15 and Ball bearing 6900ZZ

1R291

Wrench for bearing retainer1R316

Code No. Description Use for

Fig. 1

(viewed from the opposite side)

Handle R

Thickness ring

3g to the gear room for Helical gear 23 and Helical gear 15

Surface that contacts Safety cover complete

3g to the gear room located on the opposite side for Helical gear 35

and Pinion gear of Armature shaft

Helical gear 23

Item No.

Description Portion to lubricate Lubricant

Apply the following grease to protect parts and product from unusual abrasion:

Makita grease N. No.2 to the following portions designated with the black triangle

Machine oil to the following portions designated with the gray triangle

Safety cover complete

Helical gear 35

Helical gear 15

P 3 /13

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Base

Repair

Sleeve 4

Tapping screw 4x25

Rubber sleeve 6

Pipe 6

Base

Hex lock nut M5-8

Pan head screw M5

Flat head square neck bolt M6x75

Hex nut M6

Stop ring E-8

Flat washer 6

For easy removal of Hex nut M6, loosen Hex nut M6

using Lever 40 as a wrench before removing Lever 40.

Lever 40

Fig. 2 Fig. 3

Fig. 4 Fig. 5

1) Remove Blade cover (transparent part) by unscrewing Tapping screw 4x12. (Fig. 2)

2) Remove Rubber sleeve 6 and Sleeve 4 by unscrewing Tapping screw 4x25. (Fig. 3)

3) Remove the following 5 parts from Flat head square neck bolt M6x75: Stop ring E-8, Lever 40, Hex nut M6,

Flat washer 6, Pipe 6. Swivel Safety cover and pull off the bolt. Remove Pan head screw M5 while fixing

Hex nut M5-8 with Wrench 8. (Fig. 4) Base can now be separated from the machine. (Fig. 5)

Tapping screw 4x12

Blade cover

(transparent)

DISASSEMBLING

Handle and Motor housing

viewed from Motor housing side

Safety cover comp.

P 4 /13

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Base (cont.)

[3] -2. Safety Cover Complete and Bearing Box Section

Repair

1) Do the reverse of the disassembling steps.

2) After assembling Base to the machine, adjust the following portion for smooth adjustment of cut depth:

A. Pan head screw M5 in the hinge portion of Base

Must be tightened so that the machine can move along

Depth guide smoothly without rattling. (Figs. 4 and 5)

B. Lever 40

Must be installed so that it can be locked at an angle of

between 0 and 30 degrees from the centerline towards

Switch side when the cut depth is set to the maximum.

(Fig. 6)

1) Remove Blade cover and Rubber sleeve. (Figs. 2 and 3)

2) By removing Retaining ring WR-26 with 1R291, the following parts can be removed (Fig. 7):

two Spacers (one on the outside and the other on the inside of Safety cover), Safety cover complete,

Tension spring 3, Thickness ring

Note 1: Safety cover complete can be separated from Blade case by unhooking the end of Tension spring 3 from

Blade case.

Note 2: Two Spacers may fall off when Safety cover complete is separated from Blade case.

Be careful not to lose them.

3) By unscrewing two M5x16 Countersunk head screws, Bearing box section can be removed by hand. (Fig. 8)

If cannot be removed by hand, lever off using a pair of 1R263 as illustrated in Fig. 8A.

Note: It is recommended to use cordless impact driver for removing the screws because threadlocker is applied to them.

Fig. 7 Fig. 8

DISASSEMBLING

Retaining ring WR-26

Spacer

Thickness ring

Safety cover complete

Countersunk head

screw M5x16

Bearing box section

ASSEMBLING

Fig. 6

Lever 40

Depth guide

Base centerline of Handle

30 degrees

Tension spring 3

Blade case

Fig. 8A

1R263

Bearing box section

P 5 /13

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Safety Cover Complete and Bearing Box Section (cont.)

Repair

Fig. 11

Fig. 12

1R031

Helical gear 23

Spindle

Fig. 10

1R291

Retaining ring S-10

Fig. 9

1R269

Ball bearing 696ZZ

Bearing box section

Spindle

4) Remove Ball bearing 696ZZ from Bearing box section with 1R269. (Fig. 9)

5) Remove Retaining ring S-10 with 1R291. (Fig. 10)

6) Remove Spindle by following the steps below (Fig. 11):

1. Put Bearing box section on 1R031 with Helical gear 23 side up.

2. Remove Helical gear 23 and Sleeve 10 by pressing the end face of

Spindle using arbor press.

3. Apply 1R281 to the end face of Spindle, and press it using arbor press.

Spindle can now be removed from Bearing box section.

Important: Ball bearing 6900DDW in Bearing box section will always

be damaged in these steps.

Do not forget to replace with new one.

7) Attach a pair of 1R041 to vise. Fix Bearing box section in vise.

Remove Bearing retainer 14-23 from Bearing box by turning counter-

clockwise with 1R316. Damaged Ball bearing 6900DDW can now be

removed. (Fig. 12)

1R041

Vise

O ring 26

Bearing retainer

14-23 Ball bearing 6900DDW,

damaged in the previous step

Sleeve 10

1R281

DISASSEMBLING

1R316

Bearing box

Bearing box section

Fit these pins in the groove

of Bearing retainer 14-23.

P 6 /13

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Safety Cover Complete and Bearing Box Section (cont.)

Repair

Spacer

Safety cover complete Spacers assembled correctly

to Safety cover complete

Blade side

Tension spring 3

Gear housing side

Fig. 15

Fig. 13 Fig. 14

Thickness ring

Apply machine oil to the outer surface of

Thickness ring for smooth movement of

Safety cover complete.

Bearing box section

1) Assemble Bearing box section by doing the reverse of the disassembling steps, and install it on the machine.

(Fig.8on page 4)

Note: Before assembling Helical gear 23 to Spindle, make sure that O ring 26 is installed on Bearing box

as illustrated to right in Fig. 12 on page 5.

2) Assemble Safety cover complete to the machine.

Note 1: Be sure to assemble two Spacers to Safety cover complete as illustrated in Fig. 13.

Note 2: Do not forget to assemble Thickness ring to Bearing box. (Fig. 14)

Note 3: When linking Safety cover complete to Blade case with Tension spring 3, hook each end of Tension spring 3

as illustrated in Fig. 15.

ASSEMBLING

Blade case

Safety cover complete

Hook this end of Tension spring 3 through

the hole in Blade case from Blade side.

Hook this end of Tension spring 3 through the hole

in Safety cover complete from gear housing side.

P 7 /13

Repair

1R278

1R356

(2 pcs)

Helical gear 15

Helical gear 35

Ball bearing 6900ZZ

Ball bearing

6900ZZ

Gear shaft

Tapping screw 4x18 (8 pcs)

Handle L

1) Remove Handle L from Handle R by unscrewing eight 4x18 Tapping screws. Remove the assembly of Gear housing

and Motor section from Handle R by unscrewing three 4x35 Tapping screws. (Fig. 16)

2) Remove Gear unit from Handle R. (Fig. 17)

3) Remove Ball bearing 604ZZ from Gear unit by following the steps below:

1. Move Ball bearing 604ZZ so as to provide a space between Helical gear 35 and

Ball bearing 604ZZ for inserting 1R356. (Fig. 18)

2. Insert 1R356 (2 pcs) into the space provided in the previous step.

Apply 1R278 to the end face of Gear shaft. By pressing 1R278 using arbor press,

Ball bearing 604ZZ can be removed from Gear unit. (Fig. 19)

4) Set Gear unit on 1R037 with the side of Helical gear 15 up. Apply 1R281 to the

end face of Gear shaft. By pressing 1R281 using arbor press, Gear shaft can be

removed form Gear unit. (Fig. 20)

Handle R

1R281

1R037

Handle R, viewed from

Motor section side

Gear unit

Tapping screw 4x35 (3 pcs)

Gear housing

Motor section

Fig. 16

Fig. 17

Fig. 18 Fig. 19 Fig. 20

Ball bearing 604ZZ

[3] DISASSEMBLY/ASSEMBLY

[3] -3. Gear Unit (that engages with Armature)

1R269

DISASSEMBLING

P 8 /13

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -3. Gear Unit (that engages with Armature) (cont.)

1R032

Arbor press

1R028

1) Assemble Helical gear 35 to Gear shaft by following the steps below (Fig. 21):

1. Put Gear shaft on 1R032 with the smaller diameter end of Gear shaft in the center hole of 1R032.

2. Insert Helical gear 35 through Gear shaft.

3. Apply 1R028 to Helical gear 35.

4. Press down 1R028 with arbor press.

2) Assemble Ball bearing 6900ZZ to Gear shaft by following the steps below (Fig. 22):

1. Put the unit you have assembled in the step 1) on 1R032.

2. Insert Ball bearing 6900ZZ through Gear shaft.

3. Apply 1R027 to Ball bearing 6900ZZ.

4. Press down 1R027 with arbor press.

3) Assemble Helical gear 15 to Gear shaft by following the steps below (Fig. 23):

1. Put the unit you have assembled in the step 2) on 1R032.

2. Insert Helical gear 15 through Gear shaft.

3. Apply 1R027 to Helical gear 15.

4. Press down 1R027 with arbor press.

4) Assemble Ball bearing 604ZZ to Gear shaft by following the steps below (Fig. 24):

1. Put the unit you have assembled in the step 3) on Ball bearing 604ZZ.

2. Press down the unit with arbor press.

Helical gear 35

Gear shaft

Note: Be sure to press down 1R028

until it stops so that Helical gear 35

contacts the flanged portion of Gear

shaft.

Note: Be sure to press down 1R027

until it stops so that Ball bearing

6900ZZ contacts the raised center of

Helical gear 35.

Note: Be sure to press down 1R027

until it stops so that Helical gear 15

contacts the stepped portion of Gear

shaft.

Arbor press

Helical gear 35

flanged portion

of Gear shaft

1R032

1R027

Helical gear 35

Ball Bearing

6900ZZ

raised center of

Helical gear 35

Ball Bearing

6900ZZ

Helical gear 15

stepped portion

of Helical gear 35

Arbor press

1R032

1R027

Helical gear 35

Ball Bearing

6900ZZ

Helical gear 15

Ball bearing

604ZZ

Completion of Gear unit

Helical gear 15

Helical gear 35

Ball bearing 6900ZZ

Ball bearing 604ZZ

Fig. 21 Fig. 22 Fig. 23

Fig. 24

ASSEMBLING

Arbor press

P 9 /13

[3] DISASSEMBLY/ASSEMBLY

[3] -4. Armature

1) Remove Motor section and Gear housing from Handle R as illustrated in Fig. 16 on page 7.

2) Remove Carbon brush then Gear housing and Shaft lock. (Fig. 25)

3) Separate Housing R from Housing L by unscrewing four 4x18 Tapping screws.

Take out Motor assembly consisting of Armature, Yoke unit and End bell complete. (Fig. 26)

4) Pull off Armature from Endbell complete throughYoke unit. (Fig. 27)

Fig. 25 Fig. 26 Fig. 27

Brush holder cap

Carbon brush

Gear housing

Shaft lock

Compression

spring 6

Tapping screw 4x18 (4 pcs)

Housing R

Motor assembly

Housing L

Armature

Yoke unit

Endbell

complete

ASSEMBLING

DISASSEMBLING

Your fingers can be pinched

and injured.

[Wrong][Correct] [Wrong][Correct]

Fig. 28 Fig. 29

1) Put Armature through Yoke unit.

Note 1. Yoke unit is not reversible when assembled to Armature. Be sure to assemble so that the notch in Yoke unit is

positioned on the drive-end of Armature as illustrated to left in Fig. 28. If assembled wrong, Motor assembly cannot

be assembled to Housing L.

Note 2. Because Armature is pulled strongly towards Yoke unit by the magent force of Yoke unit;

1. Be sure to hold the gear portion of Armature as illustrated to left in Fig. 29. Do not hold the Armature core

as illustrated to right or your fingers will be pinched between Yoke unit and the fan of Armature.

2. Be careful not to damage the copper wire of Armature.

notch

Repair

P 10/13

[3] DISASSEMBLY/ASSEMBLY

[3] -4. Armature (cont.)

[3] -5. Lock Off Lever and Switch Lever

2) Install Endbell complete on the commutator end of Armature. (Fig. 30)

3) Assemble Motor assembly (consisting of Armature, Yoke unit and Endbell complete) to Housing L. (Fig. 31)

4) Do the reverse of disassembling steps. (Figs. 25 and 26)

Note: Make sure that Shaft lock is set in place before assembling Gear housing to Motor section.

Fit the two ribs on the inside surface

of Housing L in the notch in Yoke unit

when installing Motor assembly to

Housing L.

notch

Yoke unit

Fig. 30 Fig. 31

Fig. 32

Housing L

Lock off lever

Switch lever Switch lever

Compression spring 4

Assemble Lock off lever and Switch lever to Handle L. (Fig. 32)

Note: The same Compression spring 4 is used for Lock off lever and Switch lever.

Compression spring 4

Handle L

Compression spring 4

Insert Compression spring 4 over the boss

on the back of Lock off lever until it stops.

Insert Compression spring 4 over the boss

on the back of Switch lever until it stops.

Switch

Repair

ASSEMBLING

Brush holder of Endbell

notch

For easy assembling, it is recommended

to align the center line of Brush holder

with that of notch in Yoke unit in this step.

two ribs

Lock off lever

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