Makita BSS611 Manual

PRODUCT
T
ECHNICAL INFORMATION
P 1/ 6
Models No.
Description
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
BSS611
Cordless Circular Saw 165mm (6-1/2")
TCT Saw blade 165mm (6-1/2") ................................... 1
Hex wrench 5 ................................................................. 1
Guide rule ...................................................................... 1
Dust nozzle (for European countries only) .................... 1
Plastic carrying case ...................................................... 1
TCT Saw blade 165mm (6-1/2")
Li-ion battery BL1830
*Offered as Model BSS610 to North America
Battery
Size of blade:
mm (")
Max cutting capacities:
mm (")
North America
Diameter
Hole
diameter Other countries
at 45 degrees
at 50 degrees
No load speed: min-1=rpm
Cell
Voltage: V
Capacity: Ah
Li-ion
18
3.0
Net weight [with battery BL1830]: kg (lbs) 3.1 (6.9)
15.88 (5/8)
20 (13/16)
40 (1-9/16)
at 0 degree 57 (2-1/4)
36 (1-7/16)
3,700
165 (6-1/2)
Max output (W) 360
BSS611RFE* BL1830
No
DC18RA
No
Model No. type quantity Charger
Yes
Blade
Yes
No
Plastic
carrying case
2
BSS611Z No
Battery
This product is available in the following variations.
Dimensions: mm (")
Width (W1)
Height (H1)
Length (L1) 347 (13-5/8)
202 (8)
228 (9)
Height (H2) 166 (6-1/2)
Base Size: mm (")
Width (W2)
Length (L2) 250 (9-7/8)
122 (4-13/16)
H1H2
L1
L2
W1 W2
Note: The standard equipment for the tool shown above may differ by country.
Fast charger DC18RA
Battery charger DC24SA (for North America only)
Battery charger DC24SC (for all countries except North America)
Model BSS611 has been developed as a cost-competitive
sister tool of Model BSS610.
Features the same lightweight design, portability and high
performance as BSS610 although the following functions
have been removed: LED Job light, Positive stop at 45 degrees,
Blower function, Electric brake.

P 2/ 6
Repair
[2] LUBRICATION
Put Makita grease N. No.1 into the gear room indicated by the black triangle to protect parts and product from unusual
abrasion. See Fig.1.
Fig.1
[1] NECESSARY REPAIRING TOOLS
Code No.
1R003 Retaining ring pliers ST-2N
1R026 Bearing setting pipe 16-8.2
1R208 90 degree set square
1R232 Pipe 30
1R263 Bearing extractor
1R269 Bearing extractor
1R291 Retaining S & R pliers
Triangular rule
1R340 Bearing retainer wrench
Removing / Mounting Retaining ring
Removing Spur gear 52
Setting Saw blade at 90 degrees to Base plate
Holding Bearing box when removing Spur gear 52
Removing Bearing box
Removing Ball bearings
Removing / Mounting Retaining ring
Adjusting Saw blade to Base complete at 45 degrees
Removing / Mounting Bearing retainer
Descriptions Use for
Item No. Descriptions Portion to lubricate
Spur gear 52
Bearing box
31
31
Blade case
Amount
Gear room 6g
60
60
Depth guide Contact surface with Flat washer 6
Contact surface with Head portion of M6x90 Flat head screw a little
[3] Replacing Base complete
Fig. 2 Fig. 3
1. Loosen M5x6 Hex socket head set screw for fixing Depth guide to Base complete. (Fig.2)
Loosen Lever 40 and remove Flat washer 7 and Shoulder pin 6-7 for connecting Depth guide and Base complete. (Fig.3)
Base complete
Hex. wrench
M5x6 Hex socket
set screw
M5x6 Hex socket
set screw
Shoulder pin 6-7
CAUTION: Remove Saw blade, Inner flange, Outer flange, Hex socket head bolt and
Battery cartridge from the machine for safety before repair/ maintenance !
Flat washer 7
Depth guide

P 3/ 6
Fig.6
DISASSEMBLING
[4] Assembling Lock Off Lever and Switch Lever
[3] Replacing Base complete (cont.)
[5] Disassembling/Asssembling Safety Cover and Bearing Box
Fig.5
Fig.8Fig.7
Compression spring 4
Compression spring 4
Switch lever
Switch lever
Lock off lever
Boss
Boss
Lock off lever
Rib
Rib
Switch
1. Compression spring 4 for Lock off lever and Compression spring 4 for switch lever are the same.
Insert the bosses of Lock off lever and Switch lever into the compression springs 4 as illustrated in Fig.5.
2. Put their assembled parts into places as illustrated in Fig.6 so that the Compression springs 4 can perform well between
the bosses and the Ribs of Housing L.
1. Remove Rubber ring 6 together with M6 countersunk head screw as illustrated in Fig.7.
2. Remove retaining ring S-34 with No.1R003. Safety cover can be separated from the machine as illustrated in Fig.8.
3. Remove Bearing box by unscrewing two M5x16 countersunk head screws as shown in Fig.9. If it is difficult to remove
the Bearing box by hand, lever it up with 1R263 as shown in Fig.10.
Housing L
Rubber ring 6 Safety cover Safety cover
Retaining ring
(EXT) S-34
Countersunk
head screw M6
Fig.9 Fig.10
1R263 Bearing extractor
Bearing box
M5x16 Countersunk
head screw (2 pcs.)
Repair
Fig. 4
Stop ring E-8
Shoulder pin 6-7
M6x20 Cap square neck bolt
M5x6 Hex socket
head set screw
Lever 30
Flat washer 6
Angular guide
M6 Hex nut
Hex wrench
2. Remove the following parts as shown in Fig.4.
Base complete can be separated from the machine.
A) Shoulder pin 6-7 for connecting Angular guide and
Base complete
B) Stop ring E-8, M6 Hex nut, Flat washer 6 and M6x20
Cap square neck bolt for securing Lever 30
3. Reuse the above parts (for example, Mx6 Hex socket
head screws) to replace the current base complete by
the new one.
Note: M6 Hex nut in Lever 30 is not interchangeable with
M6 Hex nut in Lever 40.
The former has left handed threads, the latter has
right handed threads.

ASSEMBLING
1. Check that O ring 39 is fit in a groove of Bearing box and Thickness ring is put on
Bearing box. (Fig.11)
2. Fix the Gear section to the machine as illustrated in Fig.9.
Note: When reuse M5x16 countersunk head screws, be sure to apply the given adhesive
(i.e., ThreeBond 1321B/ 1342 and Loctite 242) to the threads.
3. Hook one end of Tension spring 3 into a hole of Safety cover as mentioned in Fig.12.
4. Install Safety cover in place while hooking the other end of Torsion spring 3 into a hole
of Blade case complete.
5. Fix Rubber ring 6 and M6 countersank head screw to Blade case complete.
1. Remove Ball bearing 606ZZ using 1R269.
2. Remove Retaining ring S-12 using 1R291.
3. File the outsides of two spikes of 1R340 to match the spikes into the notches of Bearing retainer 19-29. Turn Bearing
retainer wrench counterclockwise to remove Bearing retainer 19-29 from Bearing box. Refer to Fig.13.
4. Put Bearing box on 1R232, and push the step of Spindle at its small end side using 1R026 and Arbor press to align
the step of Spindle with the surface of Spur gear 52 as illustrated in Fig.14.
5. Separate Spur gear 52 from Spindle using Arbor press.
6. Remove Ball bearing 6001DDW using 1R269.
Fig.12
Fig.11
Inner flange side
Bearing box side
Hook Torsion spring 3 into the hole of Safety cover
from Bearing box side.
Do not hook Torsion spring 3
from Inner flange side.
Inner flange side
Bearing box side
Inner flange side
Bearing box side
Wrong
Correct
Safety cover
Torsion spring 3
Fig.13
Bearing box
O ring 39
Notches of
Bearing
retainer 19-29
1R340
Spikes of Bearing
retainer wrench
[6] Replacing Spur Gear 52, Ball Bearing 606ZZ and Ball Bearing 6001DDW
Thickness ring
Fig. 14
1R232
1R026
Step pf Spindle Spur gear 52
Arbor press
Small end of
Spindle
P 4/ 6
Repair
[5] Disassembling/Asssembling Safety Cover and Bearing Box (cont.)

1. Remove Carbon brushes.
2. After separating Stop ring E-8, Lever 40, M6 Hex
nut and Flat washer from M6x90 Flat head screw,
loosen three M5x40 pan head screws. (Fig.15)
5. Pull Armature out of Motor housing.
6. Remove Ball bearings of the Armature.
Note: 1) When passing Armature through York unit, Armature is attracted to the magnet of Yoke unit.
Therefore, pay attention not to scratch Armature coils. Do not pinch your fingers between Fan of Armature and
Yoke unit.
2) When fixing Motor housing to Blade case complete, be sure to mount Motor housing transversely to Blade case
complete to prevent Baffle plate from being dropped out of Motor housing. (Fig. 15).
[7] Replacing Armature Fig. 15
M5x40 Pan head screwMotor housingBaffle plate
Armature
Blade case
complete
Flat washer 6
Flat head square
neck bolt M6x90
M6 Hex nut
Lever 40
Stop ring
E-8
DISASSEMBLING
ASSEMBLING
[8] Adjusting for accuracy of 90 and 45 cut
For 90 For 45
Fig.16
As illustrated in Fig.16, use Triangular rule and hex wrench 2.5 to set the desired angle.
Adjust the fastening torque of M5 thrust head screw in order to prevent backlash when doing cutting depth adjustment.
See Fig.17.
Adjust the locked position of Lever 40 within 30 degrees from horizontal line as illustrated in Fig.18.
Adjust the locked position of Lever 30 within 20 degrees to right and left from vertical line as illustrated in Fig. 19.
Inner flange side Motor housing side Inner flange side Motor housing side
Triangular
rule Triangular
rule
Hex
wrench
2.5
Hex
wrench 2.5
Turn M5x8 Hex socket
head set screw at inner flange side.
Turn M5x8 Hex socket
head set screw at motor housing side
Thrust head
screw M5
Base complete
Blade case complete
Fig.17
Fig.18 Fig.19
Saw blade
(Horizontal line)
Lever 40 for
cutting depth adjustment
(Vertical line)
Saw blade
P 5/ 6
Repair
Lever 30
for cutting
angle adjustment

Circuit diagram
Wiring diagram
P 6/ 6
Color index of lead wires' sheath
Black
White
Red
DC motor
Pass the lead wires for Brush
holders through this hole.
Switch
Terminal
Lead wire holder
Switch
Terminal
Lead wire holder
Brush holder
Brush holder
Pass the lead wires for Brush
holders through this hole.
Route Receptacles for Terminal
as illustrated.