Makita Makstar BSS610 Manual

Models No.
Description
PRODUCT
TECHNICAL INFORMATION
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
P 1 / 7
Model BSS610 has been developed as our first cordless circular saw that is
powered by 18V/3.0Ah Li-ion battery.
Main features are:
Powerful 360W maximum output, yet still with the extra-lightweight and
compact design achieved by using Lithium-ion battery as power unit
Smooth and powerful cutting at the high rotational speed of 3,700 rpm
delivered from enhanced motor
Easy to trace cutting line with:
a) LED job light
b) Built-in blow-off nozzle that directs sawdust away from cutting line Dimensions: mm (")
Width (W)
Height 1 (H1)
Length (L) 347 (13-5/8)
202 (8)
228 (9)
Height 2 (H2) 166 (6-1/2)
Note: The standard equipment for the tool shown above may differ from country to country.
BSS610
Cordless Circular Saw 165mm (6-1/2")
W
H1
H2
L
TCT Saw blade 165mm (6-1/2") .................................. 1 pc
Hex wrench 5 ................................................................ 1 pc
Guide rule ..................................................................... 1 pc
Dust nozzle ( exclusively for European countries) ....... 1 pc
Plastic carrying case .................................................... 1 pc
Charger DC18SC
Charger DC24SA
Charger DC24SC
TCT Saw blade 165mm (6-1/2")
Li-ion battery BL1830
*Offered as Model BSS610 to USA, Canada, Mexico, and Panama
Battery
Size of blade:
mm (")
Electric brake
Max cutting capacities:
mm (")
Canada, USA,
Mexico, Panama
Diameter
Hole
diameter
The others
at 45
at 50
No load speed: min-1=rpm
Cell
Voltage: V
Capacity: Ah
Li-ion
18
3.0
Yes
Net weight*: kg (lbs)
*Includes battery BL1830
3.2 (7.1)
15.88 (5/8)
20 (13/16)
40 (1-9/16)
at 0 57 (2-1/4)
36 (1-7/16)
3,700
165 (6-1/2)
Max output (W) 360
BSS610SFE*
BSS610SF BL1830
No
DC18SC
No
Model No. type quantity Charger
Yes
Blade
Yes
No
Plastic
carrying case
2
1
BSS610Z No
Battery
This new product will be available in the following variations.

P 2 / 7
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
Makita Part 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 helical gear 52
Adjusting the right angle of saw blade to base plate
Holding bearing box, when removing helical gear 52
Bearing extractor
Bearing extractor
Removing / Mounting retaining ring
Adjust the saw blade's angle of 45 degree to base plate
Removing / Mounting bearing retainer
Descriptions Purpose
Item No. Parts item Portion to be lubricated
Helical gear 52
Bearing box
31 Blade case
Amount
Gear room 6g
[3] Replacing Base complete
Fig. 2 Fig. 3
1. Loosen M5x6 Hex socket head set screw for fixing Depth guide to Base complete. See Fig.2.
Loosen Lever 40 and remove Shoulder pin 6-7 for connecting Depth guide and Base complete.
2. Remove the following parts as shown in Fig.3. 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.
Stop ring E-8
Shoulder pin 6-7
Cap square
neck bolt M6x20
Hex socket head
set screw M5x6
Lever 30
Flat washer 6
Angular guide
Hex nut M6
Hex wrench
Base complete
Lever 40
Hex. wrench
M5x6 Hex socket set screw Shoulder pin 6-7
CAUTION: Remove Saw blade, Inner flange 40, Outer flange 40, Hex socket head bolt and
Battery cartridge from the machine for safety before repair/ maintenance !

P 3 / 7
Fig.5
DISASSEMBLING
[4] Assembling Lock Off Lever and Switch Lever
[5] Disassembling/Asssembling Safety Cover and Bearing Box (Gear Section)
Fig.4
Fig.7Fig.6
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.4.
2. Put their assembled parts into places as illustrated in Fig.5 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.6.
2. Remove retaining ring S-34 with No.1R003 "Retaining pliers ST-2N". Safety cover can be separated from the machine
as illustrated in Fig.7.
3. Remove Bearing box by unscrewing two M5x16 countersunk head screws as shown in Fig.8. If it is difficult to remove
the Bearing box by hand, lever it up with 1R263 "Bearing extractor" as shown in Fig.9.
Housing L
Rubber ring 6 Safety cover Safety cover
Retaining ring S-34
Countersunk
head screw M6
Fig. 8 Fig. 9
1R263 Bearing extractor
Bearing box
Countersunk head
screw M5x16
Repair

P 4 / 7
Repair
ASSEMBLING
1. Check that O ring 39 is fit in a groove of Bearing box and Thickness ring is put on
Bearing box as illustrated in Fig.10.
2. Fix the Gear section to the machine as Fig.8 of page 3.
3. Hook one end of Tension spring 3 into a hole of Safety cover as mentioned in Fug.11.
4. Install safety cover in place while hooking the other end of Torsion spring 3 into a hole
of Blade case set.
5. Fix Rubber ring 6 and M6 countersank head screw to Blade case complete.
1. Remove Ball bearing 606ZZ using 1R269 "Bearing extractor".
2. Remove Retaining ring S-12 using 1R291 "Retaining S & R pliers".
3. File the outsides of two spikes of 1R340 "Bearing retainer wrench" 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.12.
4. Put Bearing box on 1R232 "Pipe 30", and push the step of Spindle at its small end side using 1R026 "Bearing
setting pipe 16-8.2" and Arbor press to align the step of Spindle with the surface of Spur gear 52 as illustrated in
Fig.13.
5. Separate Spur gear 52 from Spindle using Arbor press.
6. Remove Ball bearing 6001DDW using 1R269 "Bearing extractor".
Fig.11
Fig.10
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.12
Bearing box
O ring 39
Notches of
Bearing
retainer 19-29
Bearing retainer wrench
(1R340)
Spikes of Bearing
retainer wrench
[6] Replacing Spur Gear 52, Ball Bearing 606ZZ and Ball Bearing 6001DDW
Thickness ring
Fig. 13
1R232
Pipe 30
1R026
Bearing Setting
Pipe 16-8.2
Step pf
Spindle
Spur gear 52
Arbor press
Small
end of
Spindle

P 5 / 7
Repair
Fig. 14
1. Remove carbon brushes.
2. See Fig.14. Loosen two 4x12 Tapping screws bind CT to remove Light cover from Blade case.
3. Disconnect the connector of power supply circuit from that of LED circuit.
4. Refer to Fig.15. After separating Stop ring E-8, Lever 40, Hex nut M6 and Flat washer from M6x90 Flat head screw,
loosen three M5x40 pan head screws.
5. Pull Armature out of Motor housing.
6. Remove Ball bearings of the Armature.
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.
[7] Replacing Armature
[8] Adjusting for accuracy of 90 and 45 cut
Tapping screw
CT4x12
Light cover
Connector of
power supply
circuit
Connector of
LED circuit
Fig. 15
Pan head screw M5x40Motor housing
Blade case
Flat washer 6
Flat head square
neck bolt M6x90
Hex nut M6
Lever 40
Stop ring
E-8
DISASSEMBLING
ASSEMBLING
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.
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
Fig.17
Saw blade Saw blade

Circuit diagram
Wiring diagram
P 6 / 7
Color index of lead wires' sheath
Black
White
Red
Micro switch
(The component of
power supply circuit)
Power supply circuit
Insulated
connector
Terminal
Brush holder
Connector
of power circuit
Connector
of LED circuit
LED circuit
Lead unit
ON-OFF
switch
Handle Section
Motor Housing
Blade
Case
Blade Case
View from inner flange side
Polyolefin tube
LED
Put polyolefin tube into the groove of connector box.
Connector box
Lead wire holder
Put the following electrical
parts in the connector box.
Put the lead wire of
power supply circuit
into lead wire holder.
Connector
Connector
* Connector and lead wire
of LED
* Connector and lead wire
of power supply circuit

Wiring diagram
P 7 / 7
Handle and Motor Housing
Brush
holder
Terminal
Lead unit
Lead wire holder
Lead wire
holder
Lead wire holder
Power supply circuit
Micro switch
See Fig.S.
Main switch
Censormatic chip
The hole for
flat head square
neck bolt M6x90
Brush
holder
Lead wire holder
Put censormatic chip
into place at front handle
if it is used.
Pass the lead wires of power
supply circuit through this hole
to the blade case section.
Lead wires (black and red) of
brush holders have to be expanded
near these lead holders to avoid
the lead wires' contacts with M6x90
flat head square neck bolt .
The lead wires should not be pinched. Bending the terminals of Micro switch are
acceptable when the lead wires of micro switch are apt to be pinched by walls of
Motor housing and Handle cover. See below for the detail.
This receptacle should be connected
to Terminal so as to face the lock
button for the Battery.
Battery's
lock button
Battery
These lead wires
are apt to be pinched.
These lead wires are not pinched.
Terminal Wall of Handle cover
Inflected
terminals
Micro switch
Power supply
circuit
Wiring of Micro Switch
WrongWrong Wrong