Makita HS301D User manual

CONCEPT AND MAIN APPLICATIONS
We have launched a new 10.8V (12V max*1) platform. The new platform has
been developed based on the current one, and features newly developed slide
Li-ion battery instead of stick one; use of the new battery provides stable
contact between battery and tool and the same ergonomic handle as LXT series
models to obtain more satisfaction from professional users.
Its main features and benefits are:
• Cutting efficiency is higher than the current model HS300D
• Ergonomically designed handle with soft grip
• Battery protection circuit
PRODUCT
P 1/ 17
December 2015
Model No.
Description 85mm (3-3/8") Cordless Circular Saw
ECHNICAL INFORMATION
T
HS301D
Battery
Specification Model
Energy capacity: Wh
Voltage: V
Capacity: Ah
Cell Li-ion
50, 70, 130 with DC10WC
22, 30, 60 with DC10SA
10.8
HS301D
85 (3-3/8)
Blade size: mm (")
1.5, 2.0, 4.0
No load speed: min-ı= rpm
Bevel capacity: degree
1,500
0 - 45
17, 22, 44
25.5 (1)
16.5 (5/8)
Cutting capacity:
mm (")
at 0°
at 45°
Weight according to
EPTA-Procedure 01/2003*4: kg (lbs)
1.6 (3.5)*2
1.8 (3.9)*3
YesSoft grip
Yes
Yes (on the battery)
Blower function
Battery fuel gauge
Type Slide
Charging time: min
*4 With TCT saw blade 85mm (3-3/8") and Dust nozzle
Specification
Standard equipment
Optional accessories
*5 Battery / Charger / Plastic carrying case are not supplied with “Z” model.
*6 Supplied with the same quantity of extra Battery.
Note: The standard equipment may vary by country or model variation.
L
H
W
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 313 (12-3/8)*2
331 (13)*3
170 (6-11/16)
155 (6-1/8)
160Max output: W
Diameter
Hole diameter 15 (9/16)
TCT saw blade 85mm (3-3/8")
Hex wrench
Dust nozzle
Battery*5
Battery cover*6
Charger*5
Plastic carrying case*5
Guide rule (Rip fence)
Dust nozzle
Saw blades
Battery BL1015 (BL1016*1)
Battery BL1020B (BL1021B*1)
Battery BL1040B (BL1041B*1)
Charger DC10SA (DC10SB*1)
Charger DC10WC (DC10WD*1)
*2 With BL1015 / BL1020B
*3 With BL1040B
*1 For Asia, Central and South America, Australia and North America
OFFICIAL USE
for ASC & Sales Shop

P 2 / 17
Repair
[1] NECESSARY REPAIRING TOOLS
Code No. Description Use for
1R003 removing Retaining ring WR-26
1R027 press fitting Ball bearing 606ZZ
1R028
1R033
1R035
1R037
1R041
1R164
1R212
1R269
1R278
1R282
1R283
RETAINING RING PLIERS ST-2N
BEARING SETTING PIPE 18-10.2
BEARING SETTING PIPE 20-12.2
BEARING SETTING PLATE 10.2
BEARING SETTING PLATE 15.2
BEARING SETTING PLATE 20.2
VISE PLATE
RING SPRING SETTING TOOL A
TIP FOR RETAINING RING PLIERS
BEARING EXTRACTOR
ROUND BAR FOR ARBOR 4-50
ROUND BAR FOR ARBOR 8-50
ROUND BAR FOR ARBOR 9-50
1R356 BEARING PLATE 10MM
1R361 BEARING RETAINER TIGHTEN' TOOL
press fitting Helical gear 28
removing Helical gear 28
removing Helical gear 47
protecting Bearing box from crack
removing Spindle, Helical gear 28
together with 1R003
removing Ball bearing 606ZZ
removing Helical gear 47, Ball bearing 606ZZ
removing Helical gear 28
removing Spindle, Helical gear 28
removing Ball bearing 604ZZ
disassembling / assembling Bearing retainer 14-23
press fitting Helical gear 47 and Helical gear 28
[2] LUBRICATION
Fig. 1
Item No. Description
Handle set R A: Portion in Gear room where Helical gear 47 (26) rotates
B: Hole for Spindle in Gear room
a little
3 g
1 g
(23c) O ring 19 which is a component parts
of Gear housing (23)
Gear housing
Amount
Symbol of
lubricant
Portion to lubricate
Apply Makita grease FA. No.2 to the parts designated with black triangle.
(17)
(17)
(23)
(23)
(26)
(23c)
Makita grease FA. No.2
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Index
A
B
[1] NECESSARY REPAIRING TOOLS
[2] LUBRICATION
[3]-1 Tightening torque for Screws
[3]-2. Base
[3]-3. Lock off lever, Switch lever
[3]-4. Safety cover
[3]-5. Helical gear 47, Helical gear 9B,
Ball bearing 606ZZ, Ball bearing 604ZZ
[3]-6. Helical gear 28, Ball bearing 6900DDW
[3]-7. DC Motor
* Circuit diagram
* Wiring diagram
Wiring to DC Motor, Wiring in Motor housing
* Wiring of Controller unit
* Wiring in Handle set R
P 2
P 3
P 3-4
P 5
P 6-8
P 9-13
P 13
P 14
P 15
P 16
P 17

P 3 / 17
Repair
[3]-1 Tightening torque for Screws
[3]-2 Base
Screw or Bolt
Fig. 2
M5 Pan head screw
Bearing retainer 14-23
M5x16 counter sunk
head screw fastening Bearing retainer (34) to Handle set R (17)
fastening through hinge of Handle set R (17) to
M5-8 Hex nut (49)
fixing Ball bearing 6900DDW (32) in Bearing box (34)
(48)
(31)
(36)
No.
Tightening
torque (N.m)
Q’ty
1
2
1
12 ~ 16
2.4 ~ 3.5
1.3 ~ 1.8
Use for
(34)
(36)
(45)
(54)
(55)
(56) (57)
(53)
(46)
(47)
(48)
Screwdriver
(49)
DISASSEMBLING
(32)
1. Unscrew M5x10 Thumb screw (45).
Remove Spring washer 5 (46)
and Flat washer 5 (47).
2. Unscrew M5 Pan head screw (48)
while blocking M5-8 Hex nut (49)
with Wrench 8.
3. Disassembled as drawn.
(31)
(17)
(48)
(49)
Stop ring E-3
Base
Pin 5
[3] DISASSEMBLY/ASSEMBLY
Fig. 3
(58)
(59)
(52)
(51)
(50) M5x10 Thumb screw
(51) Spring washer 5
(52) Flat washer 5
(53) Depth guide
(54) Pin 4
(55) Stop ring E-3
(56) Pin 5
(57) Angular guide
(58) Stop ring E-3
(59) Base
(50)
Wrench 8

P 4 / 17
Repair
[3]-2 Base
(16) : 6 pcs.
(7)
(53)
< Note >
Assemble Depth guide (53) to the outside
of Base (59).
ASSEMBLING
[3]-3 Lock off lever, Switch lever
DISASSEMBLING
ASSEMBLING
1. Unscrewing six 4x18 Tapping
screws (16), separate Handle set L (7)
from Handle set R (17).
1. Assemble Compression spring 4 (14)
to Lock off lever (9).
Assemble Compression spring 4 (8)
to Switch lever (15).
<Note>
Compression spring 4 (14) and
Compression spring 4 (8) are the same.
2. Disassemble Lock off lever (9),
Switch (11) and Switch lever (15)
from Handle set R (17).
2. Assemble Lock off lever (9) and
Switch lever (15) to the Handle set (R)
as shown.
[3] DISASSEMBLY/ASSEMBLY
Fig. 4
Fig. 5
Fig. 5A
(59)
(11)
Assemble the component parts to Base.
(9)
(15)
(17)
(15)
(9)
(8)
(14)
(15)
(9)
(8)
(14)

P 5 / 17
Repair
[3]-4 Safety cover
ASSEMBLING
DISASSEMBLING
1. Remove Retaining ring WR-26 (41) using 1R003 with 1R212.
Remove Flat washer 26 (40).
2. Release Tension spring 4 (38) from
Safety cover (39).
[3] DISASSEMBLY/ASSEMBLY
Fig. 7
Fig. 8
Fig. 6
(39)
(38)
(39)
(40)
(41)
1R003
1R212
(38)
1. Set the hook of Tension spring 4 (38) to Safety cover (39) as drawn.
2. After setting Safety cover (39) to the machine, assemble Flat washer 26 (40).
And then, secure Safety cover (39) with Retaining ring WR-26 (41).
Gear
housing
side
Blade side
(39)
(40)
(41)
1R003
1R212
(38)

P 6 / 17
Repair
[3]-5 Helical gear 47, Helical gear 9B, Ball bearing 606ZZ Ball bearing 604ZZ
DISASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
Fig. 10
Fig. 11
Fig. 9
(2)
2. Unscrewing three 4x30 Tapping screws (2),
separate Motor housing set (1), (3) and Gear
housing complete (23).
Remove Duct (19) by unscrewing one
4x18 Tapping screw (18).
(18)
(19)
3. Striking Handle set R (17),
remove Helical gear 47 (26)
section consisted of Ball
bearing 604ZZ (25), Ball
bearing 606ZZ (27) and
Helical gear 9B (28).
(16) : 6 pcs.
(7)
1. Unscrewing six 4x18 Tapping
screws (16), separate Handle set L (7)
from Handle set R (17).
(17)
(1)
(3)
(23)
(17)
(26)
(25)
(27)
Plastic hammer
(28)
(26)

P 7 / 17
Repair
[3]-5 Helical gear 47, Helical gear 9B, Ball bearing 606ZZ Ball bearing 604ZZ
DISASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
Fig. 13
Fig. 12
Fig. 12A
4A. <Note> When replacing Helical gear 47 (26), remove Helical gear 9B (28) as follows, but without removing
Ball bearing 604ZZ (25), because Helical gear 9B (28) may be deformed.
4. When replacing Ball bearing 604ZZ (25),
hold it with a pair of 1R356 by inserting
them into the gap between Helical
gear 47 (26) and Ball bearing
604ZZ (25).
Set them on Arbor press.
Applying 1R278 to Helical
gear 9B (28), press with Arbor
press.
5. Disassemble Ball bearing 606ZZ (27)
from Helical gear 9B (28) with 1R269.
(1R356)
1R269
(28)
1R278
1R356
1R356
4A-1. Supporting Helical gear 47 (26) with 1R037, press Ball bearing 604ZZ (25) with Arbor press.
So, Ball bearing 604ZZ (25) is attached firmly to Helical gear 47 (26).
4A-2. Applying 1R278 to Helical gear 9B (28), press with Arbor press.
So, Ball bearing 604ZZ (25) is separated from Helical gear 47 (26)
1R356
1R356
(26)
(25)
(26) (25) 1R278
(28)
1R037
(27)
(28)

P 8 / 17
Repair
[3]-5 Helical gear 47, Helical gear 9B, Ball bearing 606ZZ Ball bearing 604ZZ
ASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
Fig. 16
Fig. 14
Fig. 15
5. Assemble Duct (19) to Gear housing complete.
And then mount Motor housing set to
Gear housing complete (23).
1R027
(27)
(28)
(26)
1R028
1. Press fit Ball bearing 606ZZ (27) to
Helical gear 9B (28) with 1R027.
2. Press fit Helical gear 47 (26)
to Helical gear 9B (28) with
1R028.
(25)
(23)
3. Press fit Ball bearing
604ZZ (25) to Helical gear
9B (28) with Arbor press.
4. Assemble Helical gear 47 (26)
section to handle set R (17).
And then, mount Gear housing
complete (23) to Housing set
R (17).
(28)
(19) (23)
Helical gear 47 (26) section (17)
(26)
(28)

P 9 / 17
Repair
[3]-6 Helical gear 28, Ball bearing 6900DDW
DISASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
Fig. 19
Fig. 17
Fig. 18
6. Put Helical gear 28 (30) on 1R035.
Applying 1R282 to Spindle (35),
press with Arbor press. So, Spindle (35)
can be separated from Helical gear 28 (30).
(36)
(33)
3. Remove Bearing box (34) from
Handle set R (17) by unscrewing
two M5x16 Countersunk head
screw (36).
4. Remove O ring 26 (33).
< Note >
M5x16 Counter sunk head screw is
adhesive. Use Cordless impact driver
for removing.
5. Put Bearing box (34) on 1R164.
Applying 1R283 to Spindle (35),
press it with Arbor press.
(34)
1. Remove Retaining ring WR-26 (41) using 1R003 to which 1R212 is attached.
And then, remove Flat washer 26 (40). See Fig. 6.
2. Release Compression spring 4 (38) from Safety cover (39).
Safety cover can be disassembled from the machine. See Fig. 6.
(34)
(17)
1R283
1R164
(34)
(35)
(35)
1R282
1R035
(30)
(35)
(35)

P 10 / 17
Repair
[3]-6 Helical gear 28, Ball bearing 6900DDW
DISASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
Fig. 22
Fig. 20
Fig. 21
10. Now, Bearing box section can be
disassembled as drawn.
(30) Helical gear 28
(35) Spindle
(31) Bearing retainer 14-23
(32) Ball bearing 6900DDW
(33) O ring 26
(34) Bearing box
(36) M5x16 Counter sunk head
screw
(37) Thickness ring
7. Protecting Bearing box (34) with
1R041, set it as drawn.
8. Remove Bearing retainer (35) with
1R361 by turning counterclockwise.
9. Pass Spindle (35) through Ball
bearing 6900DDW (32),
standing it on Worktable.
And press Bearing box (34)
toward worktable.
So, Ball bearing 6900DDW (32)
is removed from Bearing box (34)
stuck to Spindle (35).
1R041
1R041
1R361
1R361
(35)
(32)
(35)
(34)
(36)
(34)
(37)
(33)
(32)
(31)
(35)
(30)
(32) (34)
(35)
(34)

P 11 / 17
Repair
[3]-6 Helical gear 28, Ball bearing 6900DDW
ASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
Fig. 25
Fig. 23
Fig. 24
4. Support Spindle (35) with 1R033.
Passing Helical gear 28 (30) through
Spindle (35), put 1R028 on Helical
gear 28 (30). And press fit it by
pressing 1R028 with Arbor press.
5. Support Bearing box (34) with 1R164.
Using 1R028, press fit the entire of
Spindle section to Bearing box (34).
1. Put Ball bearing 6900DDW (32) into Bearing box (34).
2. Put Bearing retainer 14-23 (31) on Ball bearing 6900DDW (32).
No need to tighten Bearing retainer 14-23 (31) firmly.
1R041
1R041
1R361
1R361
(31)
(33)
(34)
(31)
(32)
3. Tighten Bearing retainer (31) with
1R361 turning clockwise.
1R033
1R028
(30)
(35)
1R028
1R164
(30)
(34)
(35)

P 12 / 17
Repair
[3]-6 Helical gear 28, Ball bearing 6900DDW
ASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
Fig. 26
Fig. 27
6. Do not forget to mount O ring 26 (33) to
Bearing box (34) at the illustrated portion.
7. Do not forget to mount Thickness ring (37)
to Bearing box (34) at the illustrated portion.
8. Tighten Bearing box (34) with two M5x12 Countersunk head screws (36).
(33)
(37)
(36)
(34)
Apply Loctite 272 to the thread.
Adhesive
(34)
Loctite 272
Adhesive
Loctite 272

P 13 / 17
Repair
[3]-6 Helical gear 28, Ball bearing 6900DDW
ASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
Fig. 28
Fig. 29
Fig. 30
(2)
(6)
1. Unscrewing six 4x18 Tapping
screws (6), disassemble Handle
set L (17).
2. Unscrewing three 4x30 Tapping
screws (2), disassemble Motor
housing set (1) (3).
1. Unscrewing four 4x18 Tapping
screws (4), disassemble Motor
housing set (1) (3).
2. Now, DC motor (19) can be
replaced.
(19)
(1)
(3)
(17)
(3)
(1)
(4)
[3]-7 DC Motor
DISASSEMBLING

Circuit diagram
P 14 / 17
White
Yellow
DC Motor
Red point mark
Fig. D-1
Controller
Line filter (if used)
Line filter (if used)
Controller unit
Terminal
Flag receptacle
with lock
(#250, t=0.8mm)
Flag receptacle with lock (#250, t=0.8mm)
Flag receptacle
without lock
(#187, t=0.5mm)
Straight receptacle
with lock
(#250, t=0.8mm)
Switch
Color index of lead wires' sheath
Black
Red
COM
NO
＋
－
T
16 AWG*
16 AWG*
16 AWG*
16 AWG*
Flag receptacle
with lock
(#187, t=0.8mm)
16 AWG*
22 AWG*
* AWG: American Wire Gauge
Switch circuit
COM NO

Wiring diagram
P 15 / 17
Red point mark
Flag receptacle
Connect Flag receptacles to DC Motor (20)
as follows.
* Connect receptacle with red lead wire
to the Motor terminal designated with
red point mark.
* Connect terminals so that the lead wires
are guided to Motor housing L (1) side
as illustrated.
Fig. D-2
Fig. D-3
Rib A
Lead wire
holder
(1)
(1)
(20)
Put lead wires to this
lead wire holder.
Put Line filter between
Rib A and Rib B if it is used.
Put Lead wires to
this groove.
Line filter
Rib B
Wiring to DC Motor
Wiring in Motor housing
Put DC Motor to Motor housing L (1) so that
the lead wires can be easily guided to the
bottom of Motor housing L.
Put lead wires deeply to
the space between the
following ribs.
* Rib for Ball bearing set
and
* Rib of the rear side of
Motor housing L
Red mark

Wiring diagram
P 16 / 17
Put Controller (10) to Handle set R (17)
as follows.
* Facing its three lead wire side (white),
(yellow), (black) to the bottom of Handle
set R (17)
* Facing its two lead wire side (red), (black)
for connecting to DC motor, to Handle
set L side
Two Lead wires (red), (black) connected to DC Motor
Three Lead wires (white), (yellow), (black)
connected to Switch and Terminal
The following lead wires has
to be put in this portion.
* Lead wire (black) for
connecting to DC Motor
* Lead wire (black) for
connecting to Terminal
Fig. D-4
(10)
Put the following lead wires between Boss A and Boss B.
* Controller’s lead wire (white) for connecting to Switch
* Controller’s lead wire (yellow) for connecting to Terminal
* Controller’s lead wire (red) for connecting to DC Motor
< Note> Lead wire (red) for connecting to DC Motor has to
be put on the other lead wires (white), (yellow).
Boss A Boss B
to DC Motor
to Switch
to Terminal
Wiring of Controller Unit
(17)
(10)

Wiring diagram
P 17 / 17
Fig. D-4
(10)
(17)
Put Line filter to this space if it is used.
Flag receptacle has to be so connected that the lead wire can
be guided to Handle set R (17) side.
(11)
Flag receptacle
Terminal
Wiring in Handle set R
Lead wire
(white)
(11)
tape
Do not put any lead wires
on these ribs.
Do not put any lead
wires on this rib.
Do not put any lead
wires on these ribs.
Put controller’s lead wires to this groove.
The lead wires bundled with tape have to be put on the lead wire
(white) between Line filter and Switch (11).