Makita BSS500Z Manual

PRODUCT
P1 /14
Specification
Standard equipment
Optional accessories
Note: The standard equipment for the tool shown above may differ by country.
Model No.
Description
CONCEPT AND MAIN APPLICATIONS
BSS500, BSS501
Cordless Circular Saw 136mm (5-3/8")
Models BSS500 and BSS501 have been added to the lineup of
MAKSTAR Cordless Circular 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.
H1 H2
L1 L2
W1
W2
3,600
136 (5-3/8)
51 (2)
35 (1-3/8)
Yes
2.5 (5.5)* 2.6 (5.7)**
North American countries: 15.88 (5/8)
Other countries: 20 (13/16)
No load speed: rpm= min.-1
Battery
Size of blade:
mm (")
Max. cutting
capacities: mm (")
Net weight: kg (lbs)
*with Battery BL1430 **with Battery BL1830
Diameter
at 0 degree
at 45 degrees
Electric brake
Hole diameter
TECHNICAL INFORMATION
Dimensions: mm (")
Width (W1)
Height (H1)
Length (L1) 359 (14-1/8) 364 (14-3/8)
BSS500 BSS501
183 (7-1/4)
201 (7-7/8)
Height (H2) 145 (5-3/4)
Base Size: mm (")
Width (W2)
Length (L2) 213 (8-3/8)
109 (4-1/4)
These products are available in the following variations.
BSS500
BSS500
BSS500Z
BL1430DC18RA
NoNo
Model No. type quantity Charger
No All countries
Yes
Plastic
carrying case Offered to
No
BSS500RF
North America
All countries except
North America
1
BSS500RFE 2
Battery
BSS501
BSS501
BSS501Z
BL1830DC18RA
NoNo No All countries
Yes
No
BSS501RF
North America
All countries except
North America
1
BSS501RFE 2
(The image illustrated above is Model BSS500.)
TCT Saw blade 136mm, 16T ............................ 1
Hex wrench 5 ..................................................... 1
Guide rule .......................................................... 1
Dust nozzle (for European countries only) ....... 1
Li-ion battery BL1430 (for BSS500)
Li-ion battery BL1830 (for BSS501)
TCT Saw blade for wood 136mm, 16T
Dust nozzle
Fast charger DC18RA
Charger DC18SC
Charger DC24SA (for North America only)
Charger DC24SC (for all countries except North America)
Cell
Voltage: V
Capacity: Ah
Li-ion
1814.4
BSS501BSS500
3.0
Model
Specifications

P 2 /14
[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
adjustment for accuracy of 90 degree/45 degree cut
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
1R003 Retaining Ring S Pliers ST-2N Removing Retaining ring WR-26
Removing Retaining ring WR-26
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
1R212 Tip for Retaining ring pliers
90 degree set square1R208
Code No. Description Use for
[2] LUBRICATION
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
Fig. 1
(viewed from the opposite side)
19
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
51
Helical gear 23
19
Item No.
Description Portion to lubricate Lubricant
19
51
Safety cover complete
Helical gear 35
Helical gear 15

P 3 /14
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Base
Repair
DISASSEMBLING
Base is joined to Motor section and Saw section with the following screws and nuts:
*at Hinge portion: Pan head screw M5, Hex lock nut M5-8
*at Depth guide portion: Flat head square neck bolt M6x75, Hex nut M6
Remove them in the order of Fig. 2, 3, 4.
Base
Pan head screw M5
Flat head square
neck bolt M6x75
Fig. 4
Pipe 6
Hex lock nut M5-8
Remove Hex lock nut M5-8 from Pan head
screw M5.
Pan head screw M5
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
Handle and Motor housing
viewed from Motor housing side
Safety cover
Fig. 3
Flat head square neck bolt M6x75
Tapping screw 4x25
Safety cover
Sleeve 4
Rubber sleeve 6
Fig. 2
Turn Safety cover in the direction of the arrow
to obtain enough space for you to remove
Rubber sleeve 6.
Keeping Safety cover in the position,
remove Sleeve 4 and Rubber sleeve 6 from Blade case
by unscrewing Tapping screw 4x25.

P 4 /14
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Base (cont.)
Repair
ASSEMBLING
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. (Fig. 3 and 4)
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. 5)
Also do Adjustment for Accuracy of 90 degree and
45 degree Cut. (See page 11 for details.)
Fig. 5
30 degrees
Center line of Handle
Lever 40
Depth guide
Base
[3] -2. Safety Cover Complete and Bearing Box Section
Fig. 6
Retaining ring WR-26
Flat washer 26
Safety cover
Thickness ring
1R212
Blade case
Tension spring 4
Fig. 7
Fig. 7A
Countersunk head
screw M5x16
Bearing box
1R263
1R263
Bearing box section
1) Remove Rubber sleeve. (Fig. 2)
2) By removing Retaining ring WR-26 with 1R212, the following parts can be removed (Fig. 6):
Flat washer 26, Safety cover, Tension spring 4, Thickness ring.
Note : Safety cover complete can be separated from Blade case by unhooking the end of Tension spring 4 from
Blade case.
3) By unscrewing two M5x16 Countersunk head screws, Bearing box section can be removed by hand. (Fig. 7)
If cannot be removed by hand, lever off using a pair of 1R263 as illustrated in Fig. 7A.
Note: It is recommended to use cordless impact driver for removing the screws because threadlocker is
applied to them.
DISASSEMBLING

P 5 /14
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Safety Cover Complete and Bearing Box Section (cont.)
Repair
Fig. 9
1R291
Retaining ring S-10
Fig. 8
1R269
Ball bearing 696ZZ
Bearing box section
4) Remove Ball bearing 696ZZ from Bearing box section with 1R269. (Fig. 8)
5) Remove Retaining ring S-10 with 1R291. (Fig. 9)
6) Remove Spindle by doing the steps below (Fig. 10):
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. 11)
Fig. 10
Fig. 11
1R031
Helical gear 23
Helical gear 23
Spindle
Spindle
Sleeve 10
1R281
Bearing box section
1R041
Vise
O ring 26
Bearing retainer
14-23 Ball bearing 6900DDW,
damaged in the previous step
1R316
Bearing box
Fit these pins in the groove
of Bearing retainer 14-23.
DISASSEMBLING

P 6/14
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Safety Cover Complete and Bearing Box Section
Repair
1) Assemble Bearing box section by doing the reverse of the disassembling steps, and install it on the machine.
(Fig.7on 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. 11 on page 5.
2) Assemble Safety cover complete to the machine.
Note 1: Do not forget to assemble Thickness ring to Bearing box, before assembling Safety cover. (Fig. 12)
Note 2: When linking Safety cover complete to Blade case with Tension spring 4, hook each end of Tension spring 4.
as illustrated in Fig. 13.
Fig. 12
Apply machine oil to the outer surface of
Thickness ring for smooth movement of
Safety cover complete.
Bearing box
section
Blade side
Tension spring 3
Gear
housing side
Fig. 13
Blade case
Safety cover
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 from gear
housing side.
Thickness
ring
[3] -3. Gear Unit [that engages with Armature]
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. 14)
Handle R
Tapping screw 4x35 (3 pcs)
Gear housing
Motor section
Fig. 14
DISASSEMBLING
ASSEMBLING

P 7/14
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Gear Unit [that engages with Armature] (cont.)
Repair
1R278
1R356 (2 pcs)
Helical gear 15
Helical gear 15
Helical gear 35
Helical gear 35
Ball bearing 6900ZZ
Ball bearing
6900ZZ
Gear shaft
2) Remove Gear unit from Handle R. (Fig. 15)
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. 16)
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. 17)
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. 18)
1R281
1R037
Handle R, viewed from
Motor section side
Gear unit
Fig. 15
Fig. 16 Fig. 17 Fig. 18
Ball bearing 604ZZ
Ball bearing 604ZZ
1R269
DISASSEMBLING

P 8/14
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. 19):
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. 20):
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. 21):
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. 22):
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
Fig. 19 Fig. 20 Fig. 21
ASSEMBLING
Ball bearing
604ZZ
Completion of Gear unit
Helical gear 15
Helical gear 35
Ball bearing 6900ZZ
Ball bearing 604ZZ
Fig. 22
Arbor press

P 9/14
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Armature
1) Remove Motor section and Gear housing from Handle R as illustrated in Fig. 14 on page 6.
2) Remove Carbon brush then Gear housing and Shaft lock. (Fig. 23)
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. 24)
4) Pull off Armature from Endbell complete through Yoke unit. (Fig. 25)
Fig. 23 Fig. 24 Fig. 25
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. 26 Fig. 27
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. 26. If assembled wrong, Motor assembly cannot
be assembled to Housing L.
Note 2. Because Armature is pulled strongly towards Yoke unit by the magnet force ofYoke unit;
1. Be sure to hold the gear portion of Armature as illustrated to left in Fig. 27. 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
notch
Repair

P 10/14
[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. 28)
3) Assemble Motor assembly (consisting of Armature, Yoke unit and Endbell complete) to Housing L. (Fig. 29)
4) Do the reverse of disassembling steps. (Figs. 23 and 24)
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. 28 Fig. 29
Fig. 30
Housing L
Lock off lever
Switch lever Switch lever
Compression spring 4
Assemble Lock off lever and Switch lever to Handle L. (Fig. 30)
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

P 11/14
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Adjustment for Accuracy of 90 degree and 45 degree Cut
Repair
For 90 degree cut For 45 degree cut
Fig. 31
As illustrated in Fig. 31, do the adjustment using Triangular rule (or 1R208) and hex wrench 2.5.
Inner flange side Motor housing side
triangular rule
hex wrench 2.5
Turn the M5x8 Hex socket head set screw
located on the Motor housing side.
Saw blade
Base
Inner flange side Motor housing side
Base
Saw blade
triangular rule
hex wrench 2.5
Turn the M5x8 Hex socket head set screw
located on the Inner flange side.

Circuit diagram
P 12/14
Power supply
circuit
Switch
Endbell
complete
Terminal
Independent switch for LED
Connector of
Power supply circuit
Connector of LED
(integral part of
Power supply circuit)
LED circuit
Fig. D-1
Protective tube
Color index of lead wires' sheath
Black
White
Red

P 13/14
Wiring diagram
[Blade case viewed from Handle R side]
Lead wire holder
Protective tube
Fix Protective tube that covers LED lead wires
with Lead wire holder on Blade case.
Pull out LED lead wires from the hole in Blade case
as illustrated below.
Connector
Connector
LED circuit
Fig. D-2
[1] Wiring of LED Lead Wire on Blade Case
Route as illustrated in Figs. D-2,D-3.
Fig. D-3
opening
Handle R
Blade case
[2] Wiring Lead Wires of Endbell Complete in/on Motor Section
through hole
Pull out from this through hole.
Endbell complete
Fig. D-4 Fig. D-5
groove
Housing L Housing R Housing L
1) Route on the inside of Housing L as illustrated in Fig. D-4.
Note: Assemble Housing R to Housing L after completion of wiring on the inside of Housing L.
2) Route on the front of Housing R as illustrated in Fig. D-5.
Note: Assemble Gear housing to Motor section after completion of wiring on the front of Housing R.
Lead wire holder
Fix Lead wires with
these Lead wire holders.
Lead wire holder
through hole
[Motor section viewed from front]
Fix with Lead wire holder.Route through this groove.

P 14/14
Wiring diagram
Fig. D-6
[3] Wiring in Handle
Route Lead wires as illustrated in Fig. D-6.
Power supply circuit
Power supply circuit
Handle R
Switch
Flag connector
Terminal
Flag connector and Terminal
wire connecting portion
Handle R
Assemble Power supply circuit to Handle R
with Lead wire (white) on Handle R side.
Lead wire (white)
Terminal
Pole mark
The Flag connector has to be so connected that
the wire connecting portions are positioned
on the side of pole marks of Terminal.
Fix Lead wires with these Lead wire holders.
Independent switch
for LED
Fix Lead wires with these Lead wire holders.