Makita 5091DWG User manual

Cordless Circular Saw
Blade
diameter
85 mm (3-3/8") MODEL 5091DZ 85 mm (3-3/8") MODEL 5091DWH
85
mm (3-3/8") MODEL 5091DWG
Without Battery or Charger
85 mm (3-3/8") MODEL 5091D With Battery Cartridge and Fast Charger
No load speed Overall Net
Cutting depth
900 450
(RPM) 1 length 1 weight
Vith Battery Cartridge
INSTRUCTION MANUAL
85 mm
(3-3/8")
SPECIFICATIONS
0 - 24.5 mm 0 - 18" 316 mm 1.9 kg
(0 - 15/16") (0 ~ 11/16") (12.112") (4.2 Ibs)
1,000
Model 5091D
Battery Cartridge 1201 I 1201A Model DC1201 Fast Charger
12 v
Voltage I Input I output I Charging time
A.C. only
60 Hz D.C. 7.2 V - 12 V 1 Hr.

IMPORTANT
SAFETY INSTRUCTIONS
(For All Tools)
WARNING: WHEN USING ELECTRICTOOLS, BASICSAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWEDTO REDUCE
THE RISK
OF FIRE, ELECTRIC SHOCK, AND PERSONAL
INJURY, INCLUDING THE FOLLOWING:
READ ALL INSTRUCTIONS.
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
13.
2
KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries.
CONSIDER WORK AREA ENVIRONMENT. Don't use power tools
in damp
or wet locations. Keep work area well
lit. Don't expose power toolstorain.
Don't use tool
in presence of flammable liquids or gases.
KEEP CHILDREN AWAY. All visitors should be kept away from work area.
Don't let visitors contact tool or extension cord.
STORE IDLETOOLS. Whennotinuse, tools should bestored
in dry, and high
or locked-up place
- out of reach of children.
DON'T FORCETOOL.
It will do thejob better and safer attheratefor which
it was intended.
USE RIGHT TOOL. Don't force small tool or attachment todo the job of a
heavy-dutytool. Don't usetoolfor purpose notintended; for example, don't
use circular saw for cutting tree limbs or logs.
DRESS PROPERLY. Don't wear loose clothing orjewelry. They canbecaught
in moving parts. Rubber gloves and non-skid footwear are recommended
when workingoutdoors. Wear protective hair covering tocontain longhair.
USESAFETY GLASSES. Also use face or dust mask if cutting operation is
dusty.
DON'T ABUSE CORD. Nevercarry tool by cord or yank
it todisconnect from
receptacle. Keep cord from heat, oil, and sharp edges.
SECURE WORK. Use clamps or a vise to hold work. It's safer than using
your hand and
it frees both hands to operate tool.
DON'T OVERREACH. Keep proper footing and balance at all times.
MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and
safer performance. Follow instructions for lubricating and changing acces-
sories. Inspect toolcords periodicallyandifdamaged, haverepairedbyautho-
rized service facility. Inspect extension cords periodically and replace
if
damaged. Keep handles dry, clean, and free from oil and grease.
DISCONNECTTOOLS. When not
in use, before servicing, and whenchang-
ing accessories, such as blades, bits, cutters.

14. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to
see that keysand adjusting wrenches are removed from tool before turning
it on.
15. AVOID UNINTENTIONALSTARTING. Don't carry toolwithfinger onswitch.
Be sure switch is OFF when plugging in.
16. OUTDOORUSEEXTENSIONCORDS. When toolisusedoutdoors, use only
extension cords intended for use outdoors and
so marked.
17. STAY ALERT. Watch what you are doing, use commonsense. Don't operate
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
it will
operate properly and perform itsintended function. Check for alignment of
moving parts, bindingof moving parts, breakageof 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 serv-
ice center unlessotherwise indicated elsewhere inthis instructionmanual.
Have defective switches replaced by authorized service center. Don't use
tool
if switch does not turn it on and off.
19. GUARDAGAINST ELECTRIC SHOCK. Prevent body contact with grounded
surfaces. For example; pipes, radiators, ranges, refrigerator enclosures.
20. REPLACEMENTPARTS. When servicing, useonly identicalreplacementparts.
21. POLARIZEDPLUGS. To reduce the risk of electric shock, thisequipment has
a polarized plug (one blade is wider than the other). This plug
will fit in a
polarized outlet only one way. If the plug does not
fit fully in the outlet,
reversethe plug.
If it stilldoes notfit, contactaqualified electrician toinstall
the proper outlet. Do not change the plug
in any way.
VOLTAGE WARNING: Before connecting thetooltoa 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 in SERIOUS INJURYtothe user - as well as damage to
the tool.
If in doubt, DO NOT PLUG INTHE TOOL. Using a power source with
voltage less than the nameplate rating is harmful to the motor.
3

IMPORTANT SAFETY INSTRUCTIONS
FOR CHARGER &
BATTERY CARTRIDGE
I. SAVE THESE INSTRUCTIONS - This manual
contains important safety and operating instructions for battery charger.
2. Before using battery charger, read all instructions and cautionary markings
on
(1) battery charger, (2) battery, and (3) product using battery.
3. CAUTION - To reduce risk of injury, charge only MAKITA Battery Cartridge
7000,7001,9000,9001,9100,9101,9101A,1200,1201, 1201A,1210
& 1211. Other types of batteries may burst causing personal injury and
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
in a risk of fire, electric shock, or injurytopersons.
6. To reduce risk of damage toelectric plug and cord, pull by plug rather than
cord when disconnecting charger.
7. Make sure cord is located so that it will not be stepped on, tripped over, or
otherwise subjected to damage or stress.
8. An extension cord should not be used unless absolutely necessary. Use of
improper extension cord could result
in a risk of fire and electric shock. If
extension cord must be used, make sure:
a. That pinsonplugofextensioncordarethe samenumber, size, andshape
b. That extension cordisproperlywired and in goodelectricalcondition; and
c. That wire size isat leastas large as the one specified inthetable below.
TABLE
1
RECOMMENDED MINIMUM AWG SIZE FOR
EXTENSIONCORDS FOR BATTERY CHARGERS
as those of plug on charger;
I Lenath of Cord (Feet) I 25 I 50 I 100 I 150 I
I AWG Size of Cord I 18 I 18 I 18 I 16 I
9. Do not operate charger with damaged cord or plug - replace them im-
mediately.
IO. Donot operatecharger if it hasreceiveda sharpblow, beendropped, or other-
wise damaged
in any way; take it to a qualified serviceman.
11. Do not disassemble charger or battery cartridge; take it to a qualified
serviceman when service or repair is required. Incorrect reassembly may
result
in a risk of electric shock or fire.
12. To reducerisk of electricshock, unplugcharger fromoutlet before attempt-
ingany maintenanceor cleaning.Turningoff controls
will notreducethis risk.
4

ADDITIONAL SAFETY RULES
FOR CHARGER & BATTERY CARTRIDGE
1. Do not charge Battery Cartridge when temperature is BELOW 10°C (5OOF)
2. Do notattempt touseastep-uptransformer, anengine generator or DC power
or ABOVE 4OoC
(104OF).
receptacle.
3. Do not allow anything to cover or clog the charger vents.
4. Always cover the batteryterminals with the battery cover when the battery
5. A battery short can cause a large current flow, overheating, possible burns
cartridge is not used.
and even a breakdown.
(1 1 Do not touch the terminals with any conductive material.
(2) Avoid storing battery cartridge in acontainer withother metalobjects such
(3) Do not expose battery cartridge to water or rain.
ture may reach or exceed
35OC (95OF).
completely worn out. The battery cartridge can explode in a fire.
as nails, coins, etc.
6. Do not store the tool and Battery Cartridge in locations where the tempera-
7. Do not incinerate the Battery Cartridge even if it is severely damaged or is

ADDITIONAL SAFETY RULES
1. Be aware that this tool isalways in an operating condition, because it does
2. Wear hearing protection.
3. Keep Guards In Place and In Working Order.
not have to be plugged into an electrical outlet.
Never wedge or tie lower guardopen. Check operation of lower guardbefore
each use. Don't use if lower guard does not close briskly over saw blade.
CAUTION: Ifsaw isdropped, lower guard may bebent, restrictingfullreturn.
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.
Large panels must be supported as shown
in Fig. 1 to minimize the risk of
blade pinching and kickback.
When cutting operation requires the resting of the saw onthe work piece,
the saw shall be rested on the larger portion and the smaller piece cut off.
7. Support Large Panels.
To avoid kickback, do support board
or panel near the cut.
Fig.
Don't support board or panel away
from the cut.
Fig. ;
8. Use Rip Fence.
9. Guard Against Kickback.
Always use a fence or straight edge guide when ripping.
Kickbackoccurs when the saw stalls rapidlyand isdriven backtowards the
operator. Releaseswitchimmediatelyifblade bindsor saw stalls. Keepblades
sharp. Support large panels as shown
in Fig. 1. Use 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

NEVER place your hand or fingers
behind the saw. If kickback occurs,
the saw couldeasilyjump backwards
over your hand, possibly causing
severe injury.
I
Fig. 3
IO. Lower Guard. Raise lower guard with the retracting handle.
11. Adjustments. Before cuttingbe sure depth and bevel adjustments aretight.
12. Use Only Correct BladesIn 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 of proper hand
support and workpiece support.
Fig.
WARN IN G :
It is important tosupport the workpiece properly andtoholdthe saw firmly
toprevent
loss of control whichcould cause personalinjury. Fig. 4 illustrates
typical hand support
of the saw.
7

15. Place the wider portionof thesaw baseonthat partof the workpiece which
is solidly supported, notonthe sectionthat will falloff whenthecut ismade.
As examples, Fig. 5 illustrates the RIGHT way tocut off theend of a board,
andFig.
6 theWRONG way. Iftheworkpiece is shortor small, clamp it down.
DON'T TRY TO HOLD SHORT
PIECES BY HAND!
Fig. 5
Fig. 1
r------
16. Neverattempt tosaw with thecircu-
lar saw held upside down
in a vise.
This
is extremelydangerousandcan
lead to serious accidents.
I
Fig.
17. Beforesetting the tool downafter completinga cut, be sure that the lower
(telescoping)guard hasclosed and the bladehas come toa complete stop.
SAVE THESE INSTRUCTIONS.
8

Installing or removing the battery cartridge
0 Always switch off the tool before insertion or removal of the battery cartridge.
0 To remove the battery cartridge, pull out
the
set plate on the tool and grasp both
sides of the cartridge while withdrawing
it
from the tool.
To insert the battery cartridge, align the
tongue on the battery cartridge with the
groove in the housing and slip
it into
place. Snap the
set plate back intoplace.
Be sure to close the
set plate fully before
usingthe tool.
Batterycartridge
Fig.
Do not use force when inserting the battery cartridge.
Ifthe cartridge does not slide in easily,
it is not being insertedcorrectly.
Charging
Your new battery cartridge is not charged.
You will need tocharge
it before use. Use
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 so that the
plus and minus terminals on the battery
cartridge are on the same sides
as their
respective markings on the fast charger.
Insert the cartridge fully into the port
so that it rests on the charger port floor.
When the battery cartridge is inserted, the charging light color will change from green to
red and chargingwill begin.
The charging light will remain lit steadily during charging.
*When charging
is completed, the charging light color will change from red to green and
a tone will soundsteadily for about 5 seconds.
After charging, unplug the charger from the power source. Refer to the table below for
the chargingtime.
Fig.
Fast charger DC1201
I 1200 I Approx. 45 min
I 1201 / 1201A I ADDrOX. 60 min
9

CAUTION:
.The fast charger Model DC1201 is specifically designed to charge only Makita battery
cartridges. Never use
it for other purposes or for other manufacturer's batteries.
When you charge a new battery cartridge or a battery cartridge which has not been used
for
a long period of time, it may not accept a full charge. This is a normal condition and
does not indicate
a problem. You can recharge the battery cartridge fully after discharg-
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
a location exposed to direct sunlight or heat for a long time, the charg-
ing light may flash in red color. If this occurs, wait for
a while. Chargingwill begin after
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,
. . ." for about 20 seconds, a problem exists and charging is not possible.
The terminals on the charger or battery cartridge are clogged with dust
or the battery
cartridge
is worn out or damaged.
0 If you wish to charge two battery cartridges,allow 15 minutes betweenchargings on the
fast charger.
Removing or installingthe saw blade
CAUTION :
Always be sure that the tool is switched off and the battery cartridge is removedbefore
installing or removing the blade.
To remove the blade, press the shaft lock
so that the blade cannot revolve and use
the hex wrench to loosenthe boltcounter-
clockwise. Then remove the bolt, outer
flange and blade.
10

To install the blade, follow the removal
procedure in reverse.
BE SURE TO TIGHTEN THE BOLT
SECURELY.
Fig. 1
CAUTION :
0 Be sure the blade is installed with teeth pointing up at the front of the tool.
0 Use only the Makita hex wrench to install or remove the blade.
Hex wrench storage I
When not in use, the hex wrench can be
convenient
I y stored.
Hex
I
Fig. li
11

Adjustingthe depth of cut
Loosenthe screw on the depth guide and move the base up or down. You can readthe
depth of cut by aligning the top of the notch inthe depthguide withthegraduations on
its right side. (Note : This can be donefor 0" bevel cutting only.) At the desireddepthof
cut, secure the base by tighteningthe screw.
guide
Base
1 Screw
I
Fig. 13
CAUTION :
Depth guide
Fig.
14
0 Use a shallow depth of cut when cutting thinworkpiece for cleaner, safer cuts.
0 After adjustingthe depth of cut, always tighten the clamp screw securely.
Bevel cutting
Loosen the screw on the bevel scale plate
onthe front of the base.
Set for thedesired
angle
(0" - 45") by tilting accordingly,
thentighten theclamp screw securely.
Screw Bevel scale plate
Fig.
l!
CAUTION :
After adjustingthe depthof cut and bevel cutting angle, be sure totighten the screw.
12

Sighting
The front of the base
is notched to provide
two guide edges.
For straight cuts, align the edge with
0'
engraved on it with your cutting line on
the workpiece.
For
45' bevel cuts, align the edge with 45'
engraved on it with your cutting line.
I
For straight cuts \ 'For 450 bevel
Cutting line
Fig. 11
Switchaction
To prevent the trigger from being acciden-
tally pulled,
a lock-off lever is provided.
To start the tool, slide the lock-off lever
in the direction of the arrow and pull the
trigger.
Release the trigger to stop.
Lock-off lever
I J
Fig. 17
CAUTION :
Before inserting the battery cartridge into the tool, always check to see that the switch
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
it flat and
advancing smoothly until the sawing
is
completed. To get clean cuts, keep your
sawing line straight and your speed of
advance uniform.
I Base
Fig. 18
CAUTION:
0 Always gently keep the tool moving straight ahead when cutting. Forcingor twisting the
tool will result in overheating of the motor and dangerous kickback, possibly causing
severe injury.
0 If the tool is operated continuously until the battery cartridge has discharged, allow the
tool to rest for
15 minutes before proceedingwith a fresh battery.
13

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
it in position
with the clamp screw on the front of the
base. It also makes repeated cuts of uni-
form width possible.
\A Clamp screw
1
Fig. 1
MAINTENANCE
CAUTION :
Always be sure that the tool is switched off and the battery cartridge is removed before
attempting ot perform inspection or maintenance.
To maintain product SAFETY and RELlABlLITY, repairs, maintenance or adjustment
should be performed by Makita Authorized or Factory Service Centers, always using
Makita replacementparts.
14

OPTIONAL ACCESSORIES
The accessorieslistedinthis manual are available at an extra cost from your Makitadistributoror Makitafactory
servicecenter. Servicecentersare listedon the warranty card packed with your
tool.
CAUTION :
These accessories or attachments are recommended for use with your Makita tool specified in this
manual. The use of any other accessories or attachments might present a risk of injury to persons.
The accessories or attachments should be used only in the proper and intended manner.
Part No, Diameter
(mm)
792623-5 85 (3-3/8”)
0 Hex wrench
Part No. 783202.0
Hole diameter No.
(mm) teeth
15 (19/32”) 20
0 Fast charger
Model DC1201
Part No. 113126-0
Part No,
721003-8
0 Battery cover
Part No. 414938-7
Diameter Hole diameter
No.
(mm) (mm) teeth
85 (3-3/8”) 15 (19/32“) 50
6
Part No,
792299-8
0 Tungsten carbide tipped saw blade
Diameter Hole diameter No.
(mm) (mm) teeth
85 (3-3/8”) 15 (19/32”) 50
For wood
0 Combination saw blade
For ripand cross-cut work.
Has fewer teeth than
crosscut blade for
faster cutting.
Plywood saw blade
For smooth splinter-free
cutting of plywoodand
other thin laminates.
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
15

Mar,-30-'95 US
85 mm (3-3/8")
CORDLESS CIRCULAR
SAW
Model 5091D
Note: The switch and other part configurations
may differ from country to country.
16

MODEL5091D
'E :ED OESCRIPTION
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
Mar
- 30 -'95 US
'2 ED DESCRIPTION
1
1
3
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
bwaME
10
11
12
13
14
15
16
17
16
19
20
21
22
23
24
25
Hex
Socket Head Bolt MSx12
Outer Flange28
Inner Flange 28
RetainingRing
S - 28
Salety Cover
Flat Washer 30
TappingScrew 4x18
Bearing Box
TensionSpring
Makita Label
Blade Case
TappingScrew 4x18
Housing Set (With Item
36)
CompressionSpring 7
Pin 5
Plane Bearing4
Gear Complete
6 - 68
Thin Washer 4
Plane Bearing
4
Woodruff Key 3
Retaining Ring S - 8
HelicalGear 33
FlatWasher
6
Ball Bearing606LB
Spindle
11
21
31
41
51
61
76
81
91
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Stop Ring E - 4
Hex.Nut M5
TappingScrew 4x18
Ball Bearing
6000VV
Switch
Lock
on Lever
CompressionSpring 4
DC Motor 12
V
Motor Housing
Name Plate
Housing
Set (With Item 13)
High CapacityBattery 1201
Set Plate
Battery Holder
Switch Lever
Tapping Screw 4x18
Screw M5x10
SpringWasher 5
FlatWasher 5
Base
Screw M5x10
Spring Pin 4
- 40
FlatWasher 5
Spring Washer 5
Screw M5x10
Note: The switch and other part specifications may differ
from country to country.
17

Recycling the Battery
The only way to dispose of a Makita battery is
to recycle it. The law prohibits any other
method
of disposal.
I Ni-Cd I
To recycle the battery:
1. Remove the battery from the tool.
2. a). Take the battery to your nearest Makita Factory Service Center
or
b). Take the battery to your nearest Makita Authorized Service Center or
Distributor that has been designated as a Makita battery recycling location.
Call your nearest Makita Service Center or Distributor to determine the location
that provides Makita battery recycling. See your local Yellow Pages under
“Tools-Electric’
:
MAKITA LIMITED ONE YEAR WARRANTY
Warranty Policy
Every Makita tool is thoroughly inspectedand tested before leavingthe factory. It is warranted to
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, freight prepaid, to one of Makita’s Factory or Authorized ServiceCenters. If inspection shows
the trouble is caused by defective workmanship or material, Makita will repair
(or at our option,
replace) without charge.
ThisWarranty does not apply where:
a repairs have been made or attemptedby others:
a repairs are required because of normal wear and tear:
a The tool has been abused, misused or improperly maintained;
e alterations have been made to the tool.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTALOR CON-
SEQUENTIAL DAMAGES FROM THE SALE OR USE OF THE PRODUCT. THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THE TERM OFTHIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,”
AFTER THEONE-YEAR TERM OFTHIS WARRANTY.
This Warranty gives you specific legal rights, and you may also have other rights which vary from
state
to state. Some states do not allow the exclusion or limitation of incidental or consequential
damages,
so the above limitation or exclusion may not apply to you. Some states do not allow
limitation on how long an implied warranty lasts,
so the above limitation may not apply to you.
Makita Corporation of America
2650 Gainesville Hwy., Buford, GA 30518
88401 2 - 061
PRINTED IN USA
1995-9-4D