Page 1
Cordless Circular Saw
85
mm
Without Battery or Charger
85
mm
(3-3/8") MODEL 5091D
Vith Battery Cartridge
INSTRUCTION MANUAL
(3-3/8") MODEL 5091DZ 85
mm
(3-3/8") MODEL 5091DWH
mm
85
With Battery Cartridge and Fast Charger
(3-3/8") MODEL 5091DWG
SPECIFICATIONS
Model 5091D
Blade
diameter
85
mm
(3-3/8")
Battery Cartridge 1201 I 1201A Model DC1201 Fast Charger
0 - 24.5
(0
Voltage
12
Cutting depth
900 450
mm
-
15/16")
(0
I
v
No load speed Overall Net
0 - 18" 316 mm 1.9
~
11/16") (12.112") (4.2
Input
60
A.C. only
Hz
I
(RPM)
1,000
D.C.
output
7.2
1
V
-
12
length
V
1
I
Charging time
1
weight
kg
Ibs)
Hr.
Page 2
IMPORTANT
SAFETY INSTRUCTIONS
(For
All
Tools)
WARNING:
WHEN USING ELECTRIC TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE
THE RISK
OF
FIRE, ELECTRIC SHOCK, AND PERSONAL
INJURY, INCLUDING THE FOLLOWING:
READ ALL
1.
KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries.
CONSIDER WORK AREA ENVIRONMENT. Don't use power tools
2.
or wet locations. Keep work area well
Don't use tool
KEEP CHILDREN AWAY. All visitors should be kept away from work area.
3.
Don't let visitors contact tool or extension cord.
STORE IDLE TOOLS. When not in use, tools should be stored
4.
or locked-up place
DON'T FORCE TOOL.
5.
it
was intended.
6.
USE RIGHT TOOL. Don't force small tool or attachment to do the job of a
heavy-duty tool. Don't use tool for purpose not intended; for example, don't
use circular saw for cutting tree limbs or logs.
7.
DRESS PROPERLY. Don't wear loose clothing or jewelry. They can be caught
in
moving parts. Rubber gloves and non-skid footwear are recommended
when working outdoors. Wear protective hair covering to contain long hair.
USE SAFETY GLASSES. Also use face or dust mask if cutting operation is
8.
dusty.
DON'T ABUSE CORD. Never carry tool by cord or yank
9.
receptacle. Keep cord from heat, oil, and sharp edges.
SECURE WORK. Use clamps or a vise to hold work. It's safer than using
IO.
your hand and
11.
DON'T OVERREACH. Keep proper footing and balance at all times.
MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and
12.
safer performance. Follow instructions for lubricating and changing accessories. Inspect tool cords periodically and if damaged, have repaired by authorized service facility. Inspect extension cords periodically and replace
damaged. Keep handles dry, clean, and free from oil and grease.
DISCONNECT TOOLS. When not
13.
ing accessories, such as blades, bits, cutters.
INSTRUCTIONS.
lit.
Don't expose power tools to rain.
in
presence of flammable liquids or gases.
-
out of reach of children.
It
will do the job better and safer at the rate for which
it
frees both hands to operate tool.
in
use, before servicing, and when chang-
in
damp
in
dry, and high
it
to disconnect from
if
2
Page 3
14.
REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to
see that keys and adjusting wrenches are removed from tool before turning
it
on.
15.
AVOID UNINTENTIONAL STARTING. Don't carry tool with finger on switch.
Be sure switch is OFF when plugging in.
16.
OUTDOOR USE EXTENSION CORDS. When tool is used outdoors, use only
so
extension cords intended for use outdoors and
17.
STAY ALERT. Watch what you are doing, use common sense. Don't operate
marked.
tool when you are tired.
18.
CHECK DAMAGED PARTS. Before further use of the tool, a guard or other
part that is damaged should be carefully checked to determine that
operate properly and perform its intended function. Check for alignment of
moving parts, binding of moving parts, breakage of parts, mounting, and any
other conditions that may affect its operation. A guard or other part that
is damaged should be properly repaired or replaced by an authorized service center unless otherwise indicated elsewhere in this instruction manual.
Have defective switches replaced by authorized service center. Don't use
tool
if
switch does not turn
19.
GUARD AGAINST ELECTRIC SHOCK. Prevent
it
on and off.
body
contact
with
grounded
surfaces. For example; pipes, radiators, ranges, refrigerator enclosures.
20.
REPLACEMENT PARTS. When servicing, use only identical replacement parts.
21.
POLARIZED PLUGS. To reduce the risk of electric shock, this equipment has
a polarized plug (one blade is wider than the other). This plug
polarized outlet only one way. If the plug does not
reverse the plug.
the proper outlet. Do not change the plug
If
it
still does not fit, contact a qualified electrician to install
in
any way.
fit
fully
will
in
the outlet,
it
will
fit in a
VOLTAGE WARNING: Before connecting the tool to a power source (receptacle,
outlet, etc.) be sure the voltage supplied is the same as that specified on the
nameplate of the tool. A power source with voltage greater than that specified
for the tool can result
the tool.
If
in
doubt, DO NOT PLUG IN THE TOOL. Using a power source with
in
SERIOUS INJURY to the user
-
as
well as damage to
voltage less than the nameplate rating is harmful to the motor.
3
Page 4
IMPORTANT SAFETY INSTRUCTIONS
FOR
CHARGER
&
BATTERY CARTRIDGE
I.
SAVE THESE INSTRUCTIONS
contains important safety and operating instructions for battery charger.
2.
Before using battery charger, read all instructions and cautionary markings
(1)
on
3.
CAUTION - To reduce risk of injury, charge only MAKITA Battery Cartridge
7000, 7001, 9000, 9001, 9100, 9101, 9101A, 1200, 1201, 1201A, 1210
&
damage.
4.
Do not expose charger to rain or snow.
5.
Use of an attachment not recommended or sold by the battery charger
manufacturer may result
6.
To reduce risk of damage to electric plug and cord,
cord when disconnecting charger.
7.
Make sure cord is located
otherwise subjected to damage or stress.
8.
An extension cord should not be used unless absolutely necessary. Use of
improper extension cord could result
extension cord must be used, make sure:
a. That pins on plug of extension cord are the same number, size, and shape
b.
c. That wire size is at least as large as the one specified in the table below.
battery charger,
1211.
Other types of batteries may burst causing personal injury and
as those of plug on charger;
That extension cord is properly wired and
RECOMMENDED MINIMUM AWG
EXTENSION CORDS FOR BATTERY CHARGERS
I
Lenath of Cord (Feet)
I
AWG Size of Cord
(2)
battery, and
in
a risk of fire, electric shock, or injury to persons.
so
that
TABLE
(3)
product using battery.
pull
it
will
not be stepped on, tripped over, or
in
a risk of fire and electric shock. If
in
good electrical condition; and
1
SIZE
I
25
I
50
I
100 I 150
I
18 I 18
I
18
-
This manual
by plug rather than
FOR
I
I
16
I
9.
Do not operate charger
mediately.
IO.
Do not operate charger if
wise damaged
11.
Do not disassemble charger or battery cartridge; take
serviceman when service or repair is required. Incorrect reassembly may
result
in
12.
To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning. Turning off controls
4
in
any way; take
a risk of electric shock or fire.
with
damaged cord or plug - replace them im-
it
has received a sharp blow, been dropped, or other-
it
to a qualified serviceman.
it
to a qualified
will
not reduce this risk.
Page 5
ADDITIONAL SAFETY RULES
FOR
1.
Do
not charge Battery Cartridge when temperature is BELOW
or ABOVE 4OoC
2.
Do
not attempt to use a step-up transformer, an engine generator or
receptacle.
3.
Do
not allow anything to cover or clog the charger vents.
4.
Always cover the battery terminals
cartridge is not used.
5.
A battery short can cause a large current flow, overheating, possible burns
and even a breakdown.
(1
1
Do
not touch the terminals with any conductive material.
(2)
Avoid storing battery cartridge
as nails, coins, etc.
(3)
Do
not expose battery cartridge to water or rain.
6.
Do
not store the tool and Battery Cartridge
ture may reach or exceed
7.
Do
not incinerate the Battery Cartridge even if
completely worn out. The battery cartridge can explode
CHARGER
(104OF).
35OC
&
BATTERY CARTRIDGE
10°C
with
the battery cover when the battery
in
a container with other metal objects such
in
locations where the tempera-
(95OF).
it
is severely damaged or is
in
a fire.
(5OOF)
DC
power
Page 6
ADDITIONAL SAFETY RULES
1.
Be aware that this tool is always
not have to be plugged into an electrical outlet.
2.
Wear hearing protection.
3.
Keep Guards
In
Place and In Working Order.
Never wedge or tie lower guard open. Check operation of lower guard before
each use. Don't use if lower guard does not close briskly over saw blade.
CAUTION: If saw is dropped, lower guard may be bent, restricting full return.
4.
Do not use blades which are deformed or cracked.
5.
Keep Blades Clean and Sharp.
Sharp blades minimize stalling and kickback.
6.
DANGER: Keep Hands Away From Cutting Area.
Keep hands away from blades. Don't reach underneath work while blade
is rotating. Don't attempt to remove cut material when blade is moving.
CAUTION: Blades coast after turn off.
7.
Support Large Panels.
Large panels must be supported as shown
blade pinching and kickback.
When cutting operation requires the resting of the saw on the work piece,
the saw shall be rested on the larger portion and the smaller piece cut off.
in
an operating condition, because
in
Fig. 1 to minimize the risk of
it
does
To
avoid kickback, do support board
or panel near the cut.
8.
Use Rip Fence.
Fig.
Don't support board or panel away
from the cut.
Always use a fence or straight edge guide when ripping.
9.
Guard Against Kickback.
Kickback occurs when the saw stalls rapidly and is driven back towards the
operator. Release switch immediately if blade binds or saw stalls. Keep blades
in
Fig.
1.
Use
sharp. Support large panels as shown
fence or straight edge
guide when ripping. Don't force tool. Stay alert exercise control. Don't
remove saw from work during a cut while the blade is moving.
6
Fig.
;
Page 7
NEVER
place your hand or fingers
behind the saw. If kickback occurs,
the saw could easily jump backwards
over your hand, possibly causing
severe injury.
I
IO.
Lower Guard. Raise lower guard with the retracting handle.
11.
Adjustments. Before cutting be sure depth and bevel adjustments are tight.
12.
Use Only Correct Blades In Mounting. Don't use blades with incorrect size
holes. Never use defective or incorrect blade washers or bolts.
13.
Avoid Cutting Nails. Inspect for and remove all nails from lumber before
cutting.
14.
Operate with proper hand support
and proper workpiece support.
A
typical illustration
support and workpiece support.
WARN
to prevent
typical hand support
IN
G
:
It
is important to support the workpiece properly and to hold the saw firmly
loss
of
control which could cause personal injury. Fig. 4 illustrates
of
the saw.
of
proper hand
Fig.
Fig.
3
7
Page 8
15.
Place the wider portion of the saw base on that part of the workpiece which
is
solidly supported, not on the section that
As
examples, Fig. 5 illustrates the RIGHT way to cut off the end of a board,
and Fig.
DON'T TRY TO HOLD SHORT
16.
Never attempt to saw
lar saw held upside down
This
lead to serious accidents.
6
the WRONG way. If the workpiece
with
the circu-
in
is
extremely dangerous and can
PIECES
Fig.
a vise.
5
will
fall off when the cut is made.
is
short or small, clamp
BY
HAND!
r------
it
down.
Fig.
1
I
17.
Before setting the tool down after completing a cut, be sure that the lower
(telescoping) guard has closed and the blade has come to a complete stop.
SAVE THESE INSTRUCTIONS.
8
Fig.
Page 9
Installing or removing
0
Always switch off the tool before insertion or removal of the battery cartridge.
0
To
remove the battery cartridge, pull out
set
the
plate on the tool and grasp both
sides of the cartridge while withdrawing
the
battery cartridge
it
Battery cartridge
from the tool.
To insert the battery cartridge, align the
tongue on the battery cartridge with the
groove in the housing and slip
place. Snap the
Be sure to close the
set
plate back into place.
set
plate fully before
it
into
using the tool.
Fig.
Do not use force when inserting the battery cartridge.
If the cartridge does not slide in easily,
it
is
not being inserted correctly.
Charging
Your new battery cartridge
You will need to charge
the fast charger Model DC1201 to charge
the battery cartridge.
*Plug the fast charger into the proper A/C
voltage source. The charging light will
flash in green color.
Insert the battery cartridge
plus and minus terminals on the battery
cartridge are on the same sides
respective markings on the fast charger.
Insert the cartridge fully into the port
When the battery cartridge
red and charging will begin.
is
*When charging
a
tone will sound steadily for about 5 seconds.
completed, the charging light color will change from red to green and
After charging, unplug the charger from the power source. Refer to the table below for
the charging time.
Fast charger
is
not charged.
it
before use. Use
so
that the
as
their
so
that
it
rests on the charger port floor.
is
inserted, the charging light color will change from green to
The
charging light will remain lit steadily during charging.
DC1201
Fig.
I
I
1200
1201 / 1201A
I
Approx.
45
min
I
ADDrOX.
60
min
9
Page 10
CAUTION:
.The fast charger Model DC1201
it
cartridges. Never use
When you charge a new battery cartridge or a battery cartridge which has not been used
for
a
long period of time,
does not indicate
ing
it
completely and recharging a couple of times.
0
If you charge a battery cartridge from a just-operated tool or a battery cartridge which
has been left in
ing light may flash in red color. If this occurs, wait for
the battery cartridge cools. The battery cartridge will cool faster if you remove the
battery cartridge from the fast charger.
0
If the charging light flashes alternately in green and red color and a tone sounds "beep,
beep, beep,
The terminals on the charger or battery cartridge are clogged with dust
cartridge
0
If you wish to charge two battery cartridges, allow
fast charger.
. .
is
worn out or damaged.
for other purposes or for other manufacturer's batteries.
it
a
problem. You can recharge the battery cartridge fully after discharg-
a
location exposed to direct sunlight or heat for a long time,
."
for about
is
specifically designed to charge only
may not accept a full charge. This
a
while. Charging will begin after
20
seconds, a problem exists and charging
15
minutes between chargings on the
Makita
is
a
normal condition and
the
is
not possible.
or
the
battery
charg-
battery
Removing
CAUTION
Always be sure that the tool
installing or removing the blade.
To remove the blade, press the shaft lock
so
the hex wrench to loosen the bolt counter-
clockwise. Then remove the bolt, outer
flange and blade.
or
installing the
:
that the blade cannot revolve and use
saw
blade
is
switched off and the battery cartridge
is
removed before
10
Page 11
To
install the blade, follow the removal
procedure in reverse.
BE SURE TO TIGHTEN THE BOLT
SECURELY.
CAUTION
0
Be sure the blade
0
Use only the Makita hex wrench to install or remove the blade.
:
is
installed with teeth pointing up
at
the front of the tool.
Fig.
1
Hex wrench storage
When not in use, the hex wrench can be
convenient
I
y
stored.
I
Hex
I
Fig.
li
11
Page 12
Adjusting the depth
of
cut
Loosen the screw on the depth guide and move the base up or down. You can read the
depth of cut by aligning the top of the notch in the depth guide with the graduations on
its
right side. (Note : This can be done for
0"
bevel cutting only.) At the desired depth of
cut, secure the base by tightening the screw.
Depth guide
guide
Base
1
CAUTION
0
Use a shallow depth of cut when cutting thin workpiece for cleaner, safer cuts.
0
After adjusting the depth of cut, always tighten the clamp screw securely.
:
Screw
Fig.
13
I
Fig.
14
Bevel cutting
Loosen the screw on the bevel
on the front of the base.
angle
(0"
-
45")
Set
by tilting accordingly,
scale
plate
for the desired
then tighten the clamp screw securely.
Screw Bevel scale plate
CAUTION
:
After adjusting the depth of cut and bevel cutting angle, be sure to tighten the screw.
12
Fig.
l!
Page 13
Sighting
The front of the base
is
notched to provide
two guide edges.
For straight cuts, align the edge with
engraved on
it
with your cutting line
the workpiece.
45'
For
engraved on
bevel cuts, align the edge with
it
with your cutting line.
0'
on
45'
straight
I
cuts
\
'For
Cutting
450
line
bevel
Fig.
For
Switch action
To
prevent the trigger from being acciden-
tally pulled,
To
start the tool, slide the lock-off lever
a
lock-off lever
is
provided.
Lock-off
lever
in the direction of the arrow and pull the
trigger.
CAUTION
Before inserting the battery cartridge into the tool, always check to
Release
:
the trigger to stop.
I
see
that the switch
Fig.
trigger actuates properly and returns to the "OFF" position when released.
Operation
Hold the tool firmly. Set the base plate on
the workpiece to be cut without the blade
making any contact. Then turn the tool on
and wait until the blade attains full speed.
Now simply move the tool forward over
the workpiece surface, keeping
advancing smoothly until the sawing
completed. To
get
clean cuts, keep your
sawing line straight and your speed of
advance uniform.
it
flat and
is
I
Base
Fig.
CAUTION:
0
Always gently keep the tool moving straight ahead when cutting. Forcing or twisting the
tool will result in overheating of the motor and dangerous kickback, possibly causing
severe injury.
0
If the tool
tool to rest for
is
operated continuously until the battery cartridge has discharged, allow the
15
minutes before proceeding with a fresh battery.
11
J
17
18
13
Page 14
Guide rule
The handy guide rule allows you to do
extra-accurate straight cuts. Simply slide
the guide rule up snugly against the side of
the workpiece and secure
with the clamp screw on the front of the
base. It also makes repeated cuts of uniform width possible.
it
in position
\A
Clamp
screw
1
Fig. 1
MAINTENANCE
CAUTION
Always be sure that the tool
attempting ot perform inspection or maintenance.
To maintain product SAFETY and RELlABl LITY, repairs, maintenance or adjustment
should be performed by Makita Authorized or Factory Service Centers, always using
Makita replacement parts.
:
is
switched off and the battery cartridge
is
removed before
14
Page 15
OPTIONAL ACCESSORIES
The accessories listed in this manual are available at an extra cost from your Makita distributor or Makita factory
service center. Service centers are listed on the warranty card packed with your
tool.
CAUTION
These accessories or attachments are recommended for use with your Makita tool specified in
manual. The use
The accessories or attachments should be used only in the proper and intended manner.
0
Hex
Part
0
Fast charger
Model DC1201
Part
0
Battery cover
Part
:
wrench
No.
783202.0
No.
113126-0
No.
414938-7
of
any other accessories or attachments might present a risk of injury to persons.
Battery cartridge 1200
Part
No.
192271 -4
0
High
capacity battery 1201
Part
No.
192296-8
0
Power display battery (High cap.) 1201A
Part
No.
192407-5
6
0
Tungsten carbide tipped saw blade
For wood
Part
No,
Diameter
(mm)
792623-5 85 (3-3/8”)
Hole diameter
(mm) teeth
15 (19/32”) 20
No.
this
0
Combination saw blade
For rip and cross-cut work.
Has fewer teeth than
crosscut blade for
faster cutting.
Plywood saw blade
For smooth splinter-free
cutting of plywood and
other thin laminates.
Part
No,
721003-8
Part
No,
792299-8
Diameter Hole diameter
(mm) (mm) teeth
No.
85 (3-3/8”) 15 (19/32“) 50
Diameter Hole diameter No.
(mm)
(mm) teeth
85 (3-3/8”) 15 (19/32”) 50
15
Page 16
85
mm
(3-3/8")
CORDLESS CIRCULAR
Model
5091D
SAW
Mar,-30-'95
US
16
Note: The switch and other part configurations
may differ from country to country.
Page 17
MODEL 5091 D
'E
:ED
OESCRIPTION
'2
ED
DESCRIPTION
Mar
-
30
-'95
US
bwaME
11
21
31
41
51
61
76
81
91
10
11
12
13
14
15
16
17
16
19
20
21
22
23
24
25
Note: The switch and other part specifications may differ
Hex
Socket
Outer Flange 28
Inner Flange 28
Retaining Ring
Salety
Flat Washer 30
Tapping Screw 4x18
Bearing Box
Tension Spring
1
Makita Label
Blade Case
1
Tapping Screw 4x18
1
1
Housing Set (With Item
Compression Spring 7
1
1
Pin
5
1
Plane Bearing 4
1
Gear Complete
Thin Washer 4
1
1
Plane Bearing
1
Woodruff Key
1
Retaining Ring
1
Helical Gear 33
1
Flat Washer
1
Ball Bearing 606LB
1
Spindle
Head Bolt MSx12
S
Cover
6
4
3
S
6
-
28
36)
-
68
-
8
from
country
MA!aNE
26
27
26
29
30
31
32
33
341
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
to
country.
1
Stop
Ring
1
Hex. Nut M5
3
Tapping Screw 4x18
1
Ball Bearing
1
Switch
1
Lock
on
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
Lever
Compression Spring 4
DC Motor 12
Motor Housing
Name Plate
Housing
Set
High Capacity Battery 1201
Set
Plate
Battery Holder
Switch Lever
Tapping Screw 4x18
Screw M5x10
Spring Washer 5
Flat Washer 5
Base
Screw M5x10
Spring Pin 4
Flat Washer 5
Spring Washer 5
Screw M5x10
E
-
4
6000VV
V
(With Item 13)
-
40
17
Page 18
Recycling the Battery
The
only
way to dispose
to recycle it. The law prohibits any other
method
To
recycle the battery:
1.
Remove the battery from the
2.
a). Take the battery
of
disposal.
to
your nearest Makita Factory Service Center
or
b). Take the battery
Distributor that has been designated as a Makita battery recycling location.
Call your nearest Makita Service Center or Distributor
that provides Makita battery recycling. See your local Yellow Pages under
“Tools-Electric’
to
your nearest Makita Authorized Service Center or
:
tool.
of
a Makita battery
is
to
determine the location
I
Ni-Cd
I
MAKITA
Every Makita
be free of defects from workmanship and materials for the period of ONE YEAR from the date of
original purchase. Should any trouble develop during this one-year period, return the COMPLETE
tool,
the trouble is caused by defective workmanship or material, Makita will repair
replace) without charge.
This Warranty does not apply where:
a
repairs have been made or attempted by others:
a
repairs are required because of normal wear and tear:
a
The
e
alterations have been made
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES FROM THE SALE OR USE OF THE PRODUCT. THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THE TERM OF THIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,”
AFTER THE ONE-YEAR TERM OF THIS WARRANTY.
This Warranty gives you specific legal rights, and you may also have other rights which vary from
state
damages,
limitation on how long an implied warranty lasts,
tool
freight prepaid,
tool
has been abused, misused or improperly maintained;
to
state. Some states do not allow the exclusion or limitation of incidental or consequential
so
the above limitation
Makita Corporation
2650
LIMITED
is thoroughly inspected and tested before leaving the factory. It is warranted
to
one of Makita’s Factory or Authorized Service Centers. If inspection shows
to
Gainesville Hwy., Buford, GA
ONE
Warranty
the
tool.
or
exclusion may not apply
88401
so
2
YEAR WARRANTY
Policy
(or
to
the above limitation may not apply
-
061
you. Some states do not allow
of
America
30518
at our option,
to
you.
PRINTED
to
IN
USA
1995-9-4D
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