Makita 5090D User manual

Cordless Circular Saw
Blade
diameter
85"
(3 3/8")
Models 5090D, 5090DW
85" (3 ,I1)
With Fast Charger
Cuttingdepth No loadspeed Overall Net
90" 45"
(RPM) length weight
0-22" 2-18"
1,000 313 mm 1.8 kg.
(0 - 55/64") (5/64 - 45/64') (12 3/8") (4 Ibs.)
INSTRUCTION MANUAL
9.6 V
SPECIFICATIONS
1 Hr. A.C. only 50 Hz - 60 Hz. D.C. 7.2 V - 9.6 V
I I I I I
Battery Cartridge 9000 I ModelDC9700A Fast Charger
Voltage 1 Charginatime I Input I Output

I M PORTANT
SAFETY INSTRUCTIONS
FOR ALL TOOLS
WARNING: When usingelectrictools, basic safety precautions
should always befollowedto reducethe riskof fire,
electric shock, and personal injury,includingthe
following:
-
1.
2.
3.
4.
5.
6.
7.
0.
9.
10.
11.
12.
13.
14.
15.
Keepwork area clean. Clutteredareas andbenches inviteinjuries.
Considerwork area environment. Do not use power tools indamp or wet
locations. Keepwork areawell lit.
Do not expose power tools to rain. Do not
use
tool in presenceof flammableliquids or gases.
Keepchildrenaway. All visitorsshouldbe kept away from work area. Do not
letvisitors contact
tool or extensioncord.
Store idletools. When not in use, tools should be locked-up or storedina dry,
highplace
- out of reachof children.
Do notforce tool. It will do the job betterand safer at the rate for which it was
intended.
Usecorrect tool. Do notforce small tool or attachment to do the job of a
heavy-dutytool.
Do notuse toolfor purpose not intended.
Dress appropriately. Do notwear loose clothing or jewelry. It can be caught
in movingparts. Rubberglovesand non-skidfootwear are recommended when
working outdoors. Wear protectivehair coveringto containlong hair.
Usesafety glasses. Also use face or dust mask if cuttingoperationis dusty.
Do notabuse cord. Never carry tool by cord or yank it to disconnect from
receptacle. Keepcordfrom heat,oil, and sharp edges.
Secure workpiece. Useclamps or a vise to hold work. It is saferthan using
your hand; it also leavesbothhands free to operate tool.
Do not over-reach. Keep properfootingand balance at all times.
Maintaintools with care. Keep tools sharp and clean for betterandsafer
performance. Followinstructionsfor lubricatingandchanging accessories.
Inspect
tool cords periodicallyand, if damaged, have repairedby authorized
servicefacility. Inspectextensioncords periodicallyand replace
if damaged.
Keep handles
dry, clean,andfree from oil andgrease.
Disconnecttools when not in use,beforeservicing, and when changing
accessories,such as blades,bits, and cutters.
Removeadjustingkeys and wrenches. Check to ensure that keys and
adjustingwrenchesare removed from
tool before turningthe tool on.
Avoid unintentionalstarting. Do not carry plugged-intoolwith finger on
switch. Be sure switchis
OFF when pluggingin.
2

16. Outdoor useextensioncords. When tool is used outdoors, use only
extensioncords intendedfor outdoor use and
so marked.
17. Stay alert. Watch what you are doing. Do not operatetool when you are tired.
18. Checkdamagedparts. Beforefurther use of thetool, a guardor other part
that isdamagedshould be carefullychecked to determine that it
will operate
properlyand performits intendedfunction. Check for alignment of moving
parts, bindingof movingparts,breakage of parts,mounting, and any other
conditionsthat may affecttool operation.
A guard or other part that is
damagedshould be properlyrepaired or replaced by an authorizedservice
center unlessotherwiseindicatedelsewhere in this instructionmanual.
Defectiveswitchesshouldbe replacedby an authorizedservice center. Do not
usetool
if the switch does not turnthe tool on and off.
19. Guardagainst electric shock. Prevent body contact with grounded surfaces,
for example: pipes, radiators,ranges, refrigerator enclosures.
20. Replacementparts. When servicing,use only identicalreplacement part.
VOLTAGEWARNING: Beforeconnecting the toolto a power source (receptacle
outlet, etc.) be sure the voltagesuppliedisthe same as that specifiedon the
nameplateof the tool.
A power source with voltage greater than that specifiedfor
the toolcan result in SERIOUS INJURYto the user-as well as damage to the tool.
If indoubt, DO NOT PLUG INTHE TOOL. Usinga power source with voltage less
thanthe nameplateratingis harmful to the motor.
IMPORTANT SAFETY INSTRUCTIONS
FOR BAlTERY
1. Always Cover the BatteryTerminals with the battery cover when the
batterycartridge is not in use.
2. Do not short the Battery Cartridge:
i. Do nottouch the terminalswith any conductive material.
ii. Avoid storing batterycartridgein a container with other metal objects
such as nails,coins, etc.
iii. Do notexpose batterycartridgeto water or rain. A battery short can
causea largecurrentflow, overheating, possible burns, and even a
breakdown.
3. Do not store the tool and BatteryCartridge in locations where the
temperaturemay reachor exceed50°C
(122°F).
4. Do not incineratethe BatteryCartridge even if it is severely damaged or
completelyworn out.The battery cartridgecanexplodein afire.
3

I M PO RTANT SAFETY I NSTRUCTIONS continued
FOR BATTERY AND CHARGER
1. Before using battery charger, readall instructionsand cautionary
markings on:
i. batterycharger
ii. battery
iii. productusing battery.
2. To reducerisk of injury,charge only MAKITA Battery 7000,9000, or 9100.
Other types of batteriesmay burstcausingpersonalinjury anddamage.
3. Do notdisassemblecharger or battery cartridge; take itto a qualified
servicemanwhen service
or repairis required. Incorrectreassembly may
result in a risk of electricshock or fire.
Do not charge Battery Cartridge when temperature is BELOW 10°C (50°F)
orABOVE 40°C (104OF).
4.
FOR CHARGER
1. SAVETHESE INSTRUCTIONS-This manual containsimportant safety and
operating instructionsfor batterycharger.
2. Donotexposecharger torainor snow.
3. Use attachment recommended or soldonly bythe battery charger
manufacturer. Use of any other attachment may resultin a risk of fire, electric
shock, or injuryto persons.
4. Do not operate charger if it hasreceiveda sharp blow, beendropped, or
otherwisedamagedin any way; take itto a qualifiedserviceman.
5. To reduce risk of electricshock, unplug charger from outletbefore
attemptingany maintenance orcleaning. Turning off controlswill not
reducethis risk.
6. Do not attempt to usea step-up transformer, an engine generator, or a
DC powerreceptacle.
7. Do not allow anythingtocover or clog the charger vents.
4
SAVE THESE INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS continued
Lengthof Cord (Feet)
AWG Sizeof Cord
FOR CORD
25 50 100
150
18 18 18 16
1.
To reducerisk of damage to electric plugandcord, pull by plugratherthan
by cordwhen disconnectingcharger.
2. Makesure cord is located so that itwill not be stepped on, trippedover, or
otherwisesubjectedto damage or stress.
3. An extensioncordshould not be usedunlessabsolutelynecessary.
Use of improperextensioncordcould resultin a risk of fire andelectricshock.
If extensioncord mustbe used, make sure that:
i. Pinson plug of extensioncordare the same number, size, andshape
as those
of plugon charger.
ii. Extensioncord is properlywiredand ingoodelectricalcondition.
iii. Wire size isat least as largeasthe one specifiedinthe table below.
RECOMMENDED MINIMUM AWG SIZE FOR
EXTENSIONCORDS FOR BATTERYCHARGERS
FOR CORD AND CHARGER
1. Do not operatechargerwith damagedcord or damaged plug - replace
them immediately.
SAVE THESE INSTRUCTIONS
5

IMPORTANT SAFETY INSTRUCTIONS continued
FOR USE OF SAW
1.
2.
3.
4.
5.
6.
Beawarethat this tool is always in anoperating condition because it does
nothaveto be plugged intoan electricaloutlet.
KeepGuards
In Placeand In WorkingOrder. Never wedge or tie lower
guardopen. Check operationof lower guard before each use.
Do notuse if
lowerguarddoes notclose brisklyover saw blade.
CAUTION:
If saw is dropped, lower guard may be bent,restrictingfull return.
Keep BladesClean and Sharp. Sharp blades minimize stallingand kickback.
DANGER: Keep HandsAway FromCutting Area.
Keephandsaway from blades.
Do not reach underneath work while blade is
rotating. Do not attemptto remove cut materialwhile blade is moving.
CAUTION: Bladescoast after turn
off.
Support Large Panels.
Largepanels must be
supportedas shown in Fig.
1
to minimizethe riskof blade
pinchingand kickback.
Whencutting operation requires
the restingof the saw on the
work piece,the saw should be
rested onthe larger portion
andthe smaller piececut off.
To avoid kickback, do support board
or panel near
the cut.
Fig. 1
Don't support board or panel away
from the cut.
Fig. 2
Use Rip Fence. Always use a fence or straightedge guide when ripping.
6

7.
8.
9.
10.
11.
12.
Guard Against Kickback. Kickback occurs when the saw stalls rapidly andis
driven back towardsthe operator. Releaseswitchimmediately
if bladebinds or
saw stalls. Keepbladessharp. Support large panels as shown in Fig. 1. Use
fence or straightedge guide when ripping.
Do not force tool. Stay alert
exercisecontrol.
Do not remove saw from work duringa cut while the blade is
moving.
NEVER placeyour handor
fingers behindthe saw.
If
kickbackoccurs, the saw could
easilyjump backwardsover
your hand, possiblycausing
severe injury (see Fig.
3).
Fig. 3
LowerGuard. Raiselowerguardwith the retractinghandle.
Adjustments.
Beforecutting be sure depthand beveladjustmentsare
tight.
Use Only Correct BladesIn Mounting. Do not use blades with incorrect size
holes. Neveruse defectiveor incorrect blade washers or bolts.
Avoid Cutting Nails. Inspectfor, and remove, all nailsfrom lumber before
cutting.
I
Operate with proper hand
support and properworkpiece
support
(see Fig. 4).
I
A typical illustration of proper hand
support and
workpiece support.
Fig. 4
WARNING:
It is important to supportthe workpiece properlyand to holdthe saw firmly to
prevent loss of controlwhichcouldcause personalinjury.Fig. 4 illustrates
typical handsupport of the saw.
7

SAFETY INSTRUCTIONSFOR USE OF SAW continued -
13. Placethe wider portionof the saw baseonthat part of theworkpiece
which issolidly supported, not onthe sectionthat will fall
off when the
cut ismade.
If the workpiece isshort or small, clamp it down.
DON’T TRY TO HOLD SHORT PIECES BY HAND!
Fig.
5 illustratesthe CORRECT
way
to cut off the end of a board. Fig.
6 illustratesthe WRONG way
to cut off the end of a board.
Fig.
5 Fig. 6
14. Neverattempttosaw with the
circular saw held upsidedown in
a vise. This isextremely
dangerousand can lead
to serious
accidents.
Fig.
7
15.
Beforesetting the tooldown after completingacut, besurethat the
lower (telescoping)guard has closedandthe bladehascome to a
completestop.
SAVE THESE INSTRUCTIONS
8

BATTERY
CAUTION: Always switch off the tool beforeinsertion or removalof the batterycartridge.
Readthe Safety Instructionsfor battery on pages
3 and 4.
Installingor Removingthe Battery
To
1
2
To
1
2
removethe battery cartridge:
. Pullout the set plateon the tool
. Grasp bothsides of the cartridge
while withdrawingit from the barrel.
insert the battery cartridge:
. Align the tongue of the battery
cartridgewiththe groove inthe
housing.
. Slipthe cartridge into place.
3. Snapthe set plate backintoplace. Be sure to closethe set platefully before
usingthe
tool.
CAUTION: Do not use forcewhen insertingthe battery cartridge.
If the cartridgedoesnotslide ineasily,it isnot beinginsertedcorrectly.
Chargingthe Battery
CAUTION: YOUR NEW BATTERY CARTRIDGEIS NOTCHARGED.
YOU WILL NEEDTO CHARGE IT BEFORE USE.
ReadSafety instructionson page 4 beforecharging battery.
To chargethe battery:
1. Plugthe fast charger intoyour
powersource.
2. Insertthe batterycartridge so that
the plus
(+) and minus (-) terminals
on the batterycartridgeare on the
same sides as their respective
markingson the fast charger.
3. Insertthe cartridgefully intothe port
so that it restson the charger port
floor.
4. Pressthe start button (red).
The charging light will come on and charging will begin.
(If the charginglightdoes not come on, see
NOTE on page 10).
5. When the charging lightgoes out after about one hour, you may remove the
fully chargedbatterycartridge.
6.
After charging, unplugthe charger from the power source. Charging continued
9

BATTERY continued
Chargingthe Battery continued
NOTE: Ifthe charging light does notcome on:
i. Pressthe Reset button(yellow)
ii.Then pressthe Start button(red).
If the charginglightgoes out within 10 seconds even after pressingthe
ResetbuttonandStart buttona coupleof times, the battery cartridgeis
dead. (CAUTION:Wait for more than
5 seconds afterthe charginglight
goes out beforepressingthe Reset buttonagain).
Replacethe batterycartridgewith a new one.
CAUTION
Do not keepthe buttonpressedinwith tape, etc. or the circuit will not function
properly. Also, a malfunctionof the charger may result possiblycausing
overheating,etc.
If you try to chargea cartridgefrom a just-operated tool, sometimes the
charging light will not come on.
If this occurs, let the cartridgecool off for a
while,then re-insertit andtry to charge it once more.
If you wish to chargetwo batterycartridges,allow 15 minutes between
chargingson the fast charger.
Recyclingthe Battery
The
to recycleit. The law prohibitsany other
way to dispose of a Makita battery is
method
of disposal.
I Ni-Cd I
-
To recyclethe battery:
1. Removethe batteryfrom the tool.
2. a). Take the battery to your nearest MakitaFactory Service Center
b). Take the battery
to your nearest Makita Authorized Service Centeror
Distributorthat has been designatedas a Makita batteryrecyclinglocation.
Callyour nearest Makita Service Centeror Distributor to determine the
location thatprovides Makita battery recycling. Seeyour local YellowPages
under "Tools
- Electric. "
OR
10

SAW BLADE
CAUTION: Always be sure that the tool is switched off and the battery cartridge
is removedbefore installing or removingthe blade.
Use onlythe Makitahex wrench to removeand installthe blade.
RemovingSaw Blade
To removethe blade:
1. Pressthe bladestopper pin and
insert it throughthe hole inthe
blade
so that the bladecannot
revolve.
2. Use the hex wrench to loosenthe
bolt.
3. Remove the bolt,flange, and
blade.
InstallingSaw Blade
To install the blade:
1. Placethe blade over the spindle,
With teeth pointinaup at the front
of the tool.
2. Placethe flange over the blade.
3. Insertbolt into bladeandflange.
4. Pressthe bladestopperpin and
insert itthroughthe hole in the
blade
so that the bladecannot
revolve.
I I
5. Usethe hex wrench to tightenthe bolt, flange, and blade in place.
BE SURE TO TIGHTENTHE BOLT SECURELY.
Hex Wrench Storage
When not in use, the hex wrench can
be convenientlystored.
11

CUlTlNG ADJUSTMENTS
CAUTION: Remove battery before makingany cutting adjustments.
Useonly the Makitahex wrench to loosen the bolts.
Adjusting Depth
of cut
To adjust depth of cut:
1. Usingthe hex wrench, loosenthe
bolt (A) on the depth guide.
2. Move the base up or down.
3. At the desireddepthof cut, secure
the base by tighteningthe bolt (A).
Bevel Cutting
For bevelcutting:
1.
Usingthe hexwrench, loosenthe
bolt
(A) on the depth guide.
2. Loosenthe bolt (6) on the bevel
scale plate.
3. Set the desiredangle (OD - 45")
bytiltingaccordingly.
4. Tightenbolts (A) and (B) securely.
CAUTION: After adjustingdepth of cut and bevelcuttingangle, be sure to tightenthe
bolts (A) and
(6) securely.
Sighting
For straight cuts:
1. Align the edge of the base with
your cutting line onthe workpiece.
For 45O bevelcuts:
1.
Align the notchinthe front of the
basewith your cutting lineon the
workpiece.
12

0 P E RAT1 0 N
CAUTION: ReadSafety Instructionson pages 6,7, and 8 before operatingsaw.
SwitchAction
NOTE: To preventthe triggerfrom
beingpulledaccidentally,
a lock-off lever isprovidedas
a safetyfeature.
1. Slidethe lock-offlever in the
directionof the arrow
2. Pullthe trigger switch.
To start the tool:
To stop the tool:
1. Releasethe trigger switch.
Operatingthe Tool
CAUTION: Beforeinsertingthe battery cartridge into the tool, always check to see
that the triggerswitchactuates properly and returns to the
"OFF" position
when released.
To a
1.
2.
3.
4.
,peratethe tool:
Holdthe tool firmly.
Set the base plateon the
workpiece
to be cutwithoutthe
memakinaanv contact.
Turnthe tool on andwait untilthe
bladeattains full SDeed.
Then movethe tool forwardover
the workpiecesurface, keepingit
flat andadvancingsmoothly until
the sawing iscompleted.
Base I
I
Tip:
CAUTION:
If you use the tool continuously untilthe battery has discharged, allow
the toolto resetfor
15 minutes before proceeding with afresh battery.
To make a cleancut, keep your sawing line straight and keep your speed
0;
advanceconstant.
13

MAINTENANCE
CAUTION: Always be sure that the tool is switched off and the battery cartridge
removedbeforeattempting to perform inspectionor maintenance.
To maintainproduct SAFETY and RELIABILITY, repairs,carbon brush inspection
and replacement, or any other maintenanceand adjustmentshould be performed
byMakita Authorizedor Factory ServiceCenters, always using Makita replacement
parts.
OPTIONALACCESSORIES
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 packedwith your
tool.
CAUTION: These accessoriesor attachmentsare recommendedfor usewith your Makitatool
specified
in this manual. The use of any other accessoriesor attachments might
present a
risk of injury to persons. These accessoriesor attachmentsshould be
usedonlv
in the DroDer and intendedmanner.
Hex Wrench
part no. 783202-0 Battery Holster Battery Cover Holsterholds extra
battery
part no. 823033-3C part
no. 414938-7
BatteryCartridge
9OOO Fast Charger
part no. 632007-4
Model DC9700A
part no. 113103-2
Charger12Vfor car
Model DC9112
part no.
1 13110-5
CombinationSaw Blade
For ripand
cross-cut work.
Hasfewer teeth than
cross-cut blade for
faster
cutting.
Plywood Saw Blade
For smooth splinter-free
cutting of plywoodand
other laminates.
14

Sept - 25 - '87 EN
CORDLESS CIRCULAR SAW
Model5090D
85 mm (33/8'')
Note: The switchand otherpartconfigurations
maydiffer
from country to country.
15

CORDLESS CIRCULAR SAW PART DESCRIPTION
Item
No.
1
3
5
8
9
10
11
12
13
14
15
16
17
18
19
20
-
Qty.
Used
1
1
1
I
3
I
1
1
1
1
5
1
1
1
1
1
-
Description
HousingSet (with item 5)
Set Plate
HousingSet (with item 1)
TensionSpring
5
Pan HeadScrew M4x14(withWasher)
BladeCase
Gear
PlaneBearing
5
Leaf Spring
Name Plate
Pan HeadScrew M4x25(withWasher)
Switch
DC Motor9.6V
PlaneBearing4
GearComplete 11-67
Plane Bearing4
Item
No.
21
22
23
24
25
26
27
28
29
30
31
32
41
42
43
44
Qty. Description
Used
1
1
1
1
1
1
3
1
1
1
1
I
1
1
1
1
Pin
5
Compression Spring6
Stop Ring E-4
Safety Cover
Outer Flange28
Hex.Socket HeadBolt M5x12
Countersunk HeadScrew M5x16
Flat Washer
5
Hex Socket HeadBolt M5x10
Base
Flat Washer
5
Hex. Socket HeadBolt M5x10
Lock
Off Lever
Switch Lever
Compression Spring 3
BatteryHolder
MAKITA LIMITED ONE YEAR WARRANTY
WARRANTY POLICY
'
EveryMakita tool isthoroughlyinspectedandtestedbeforeleavingthe factory. It iswarranted to
be free of defectsfromworkmanship and materialsfor the period
of ONE YEAR fromthe date of
originalpurchase.Shouldany troubledevelop during this one-yearperiod, returnthe
COMPLETE
tool, freight prepaid, to one of Makita's Factory or authorizedService Centers. If
inspectionshows the trouble iscausedby defective workmanshipor material,Makita will repair
(or at our option, replace) without charge.
This Warrantydoes notapplywhere:
repairshave been madeor attemptedby others,
repairsare requiredbecause of normal wear and tear,
the tool has been abused, misusedor improperly maintained,
alterationshave beenmade to the tool.
INNO EVENTSHALL MAKITA BE LIABLEFOR ANY INDIRECT,INCIDENTAL OR
CONSEQUENTIALDAMAGESFROMTHE SALE OR USEOF THE PRODUCT. THIS
DISCLAIMERAPPLIES BOTH DURINGAND AFTER THE TERM OF THIS WARRANTY.
MAKITA DISCLAIMSLIABILITY FOR ANY IMPLIEDWARRANTIES,INCLUDINGIMPLIED
WARRANTIES
OF "MERCHANTABILITY"AND "FITNESS FOR A SPECIFICPURPOSE,"
This Warranty gives you specificlegalrights,and you may also have other rightswhich vary lrom
state
to state. Some states do notallow the exclusionor limitationof incidentalor consequential
damages,
so the above limitationor exclusionmay notapply to you. Some statesdo notallow
limitationon how longan impliedwarranty lasts,
so the above limitationmay not apply to you.
AFTER THE ONE-YEARTERM
OF THISWARRANTY.
Makita Corporation of America
2650 Gainesville Hwy
Buford, GA 3051 8
A00205A6
MCNRevised4-93
PRINTED IN USA
1995-7-4D