Makita 5044KB User manual

Circular Saw with Dust Collection
DOUBLE
100 mm (4") MODEL 5044KB
Equipped wlth Electric Blade Brake
Blade
diameter
100 mm (4")
INSTRUCTION MANUAL
No load speed Overall length Net weight
Max.
cutting depth (RPM)
27 mm (1-1/16"1 9,000 310 mm (12-3/16"\ 3.1 kg (6.8 Ibs)
SPECIFICATIONS
* Manufacturer reserves the right to change specifications without notice.
* Note: Specifications may differ from country to country.
WARNING: For your personal safety, READ and
UNDERSTAND before using.
SAVE THESE INSTRUCTIONS
FOR FUTURE REFERENCE.

GENERAL SAFETY RULES
(For All Tools)
WARNING! Read and understand all instructions. Failure
tofollow
all instructions listed below, may result in electric
shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
READ ALL INSTRUCTIONS.
WORK AREA
1. Keepyour work area cleanand well lit. Cluttered benchesand dark areas invite
accidents.
2. Do notoperate powertools in explosiveatmospheres, such as in the presence
of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.
3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control.
ELECTRICAL SAFETY
4. Double Insulatedtools are equippedwith apolarizedplug (onebladeiswider
than the other.) This
plug will fit in a polarized outlet only one way. If the
plug does
not fit fully in the outlet, reverse the plug. If it still does not fit,
contact a qualified electrician to install a polarized outlet. Do not change
the plug
in any way. Double insulation H eliminates the need for the three
wire grounded power cord and grounded power supply system.
5. Avoid body contact with groundedsurfaces such as pipes, radiators, ranges
and refrigerators. There is an increased risk of electric shock if your body
is
grounded.
6. Don't expose powertools torain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
7. Donot abuse the cord. Never use the cordto carry the tools or pullthe plug
from an outlet. Keepcordawayfrom heat, oil, sharp edges or movingparts.
Replace damaged cords immediately. Damaged cords increase the risk of
electric shock.
8. Whenoperating apowertooloutside, usean outdoorextension cord marked
"W-A' or "W." These cords are rated for outdoor use and reduce the risk
of electric shock.
PERSONAL SAFETY
9. Stay alert, watch what youaredoing and usecommonsensewhen operating
a power tool. Do not use tool while tired or under the influence of drugs,
alcohol, or medication.
A moment of inattentionwhile operating power tools
may result
in serious personal injury.
IO. Dressproperly. Donotwear looseclothing or jewelry. Contain longhair. Keep
your hair, clothing, andglovesaway frommovingparts. Loose clothes, jewelry
or long hair can be caught in mpving parts.
2

11. Avoid accidental starting. Be sure switch isoff before plugging in. Carrying
tools with your finger onthe switch or plugging intools that havethe switch
on invites accidents.
12. Removeadjusting keys or switchesbefore turning the tool on. A wrench or
a key that is left attachedto a rotating part of the tool may result
in personal
injury.
13. Donotoverreach.Keepproperfootingandbalanceat alltimes. Proper footing
and balance enables better control of the tool in unexpected situations.
14. Use safety equipment. Always wear eye protection. Dust mask, nonskid
safety shoes, hard hat, or hearing protection must be used for appropriate
conditions.
TOOL USE AND CARE
15. Use clamps or other practical way to secure and support the workpiece to
astable platform. Holding the work by hand or against your body is unstable
and may lead to
loss of control.
16. Do notforce tool. Usethe correct toolfor your application. The correct tool
will do the
job better and safer at the rate for which it is designed.
17. Do not use tool if switch does not turn
it on or off. Any tool that cannot
be controlled with the switch is dangerous and must be repaired.
18. Disconnect the plugfrom the power source before making any adjustments,
changing accessories,
or storing the tool. Such preventive safety measures
reduce the risk of starting the tool accidentally.
19. Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
20. Maintain tools with care. Keep cutting tools sharp and clean. Properly
maintainedtools, withsharpcutting edges are less likelytobind and are easier
to control.
21. Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the tools operation. If damaged, have
the tool serviced before using. Many accidents are caused by poorly main-
tained tools.
22. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool, may become hazardous
when used on another tool.
SERVICE
23. Tool service must be performed only by qualified repair personnel. Service
or maintenance performed by unqualified personnel could result in a risk of
injury.
24. When servicinga tool, use only identical replacement parts. Follow instruc-
tions
in the Maintenance section of this manual. Use of unauthorized parts
or failuretofollow Maintenance Instructions may createa risk of electric shock
or injury.
3

Specific Safety Rules
1. DANGER! Keep hands away from cuttingarea and blade. Keep your second
hand on auxiliary handle, or motor housing. If both hands are holding the
saw, they cannot be cut by the blade.
Keep your body positioned to either side of the saw blade, but not in
line
withthe saw blade. KICKBACK could causethe saw tojump backwards. (See
"Causes and Operator'Prevention of Kickback")
Do not reach underneath the work. The guard can not protect you from the
blade below the work. Don't attempt to remove cut material when blade is
moving.
CAUTION: Blades coast after turn off.
2. Check lower guardfor proper closing before each use. Do not operate saw
if lower guard does not move freely and close instantly. Never clamp or tie
the lower guardintothe open position. If saw is accidentallydropped, lower
guard may be bent. Raisethe lower guard with the Retracting Lever and make
sure
it movesfreely anddoes nottouch the bladeor any other part, in all angles
and depths
of cut.
3. Check the operation and condition of the lower guard spring. If the guard
andthe springare notoperating properly, they must beserviced before use.
Lower guard may operate sluggishly due to damaged parts gummy deposits,
or
a buildup of debris.
4. Lower guard should be retracted manually only for special cuts such as
"Pocket Cuts" and "Compound Cuts." Raise lower guardby RetractingLever.
As soon as blade enters the material, lower guard must be released. For all
other sawing, the lower guard should operate automatically.
5. Always observe that the lower guard is covering the blade before placing
saw down on bench or floor. An unprotected, coasting blade will cause the
saw to walk backwards, cutting whatever is in its path. Be aware of the time
it takes for the blade to stop after switch is released.
6. NEVER holdpiece being cut in your handsor across your leg. It is important
to support the work properly to minimize body exposure, blade binding, or
loss of control.
7. Holdtoolby insulatedgrippingsurfaceswhen performing anoperationwhere
the cutting tool may contact hidden wiring or its
own cord. Contact with
a "live" wire will also make exposed metal partsof the tool "live" and shock
the operator.
8. When ripping always use a rip fence or straight edge guide. This improves
the accuracy
of cut and reduces the chance for blade binding.
9. Always use blades with correct size and shape (diamond vs. round) arbor
holes. Blades that do not match the mounting hardware of the saw will run
eccentrically, causing
loss of control.
IO. Never usedamagedor incorrect blade washers or bolts. The blade washers
and bolt were specially designed for your saw, for optimum performanceand
safety or operation.
4

11. Causes and Operator Prevention of Kickback:
Kickback is a sudden reaction to apinched, bound or misalignedsaw blade,
causing an uncontrolled saw to lift up and out of the workpiece toward the
operator.
To avoid kickback, do support board
or panel near the cut.
Whenthebladeispinched or bound tightly by thekerf closingdown, theblade
stalls and themotor reaction drives theunitrapidlyback toward theoperator.
If the blade becomes twisted or misaligned in the cut, the teeth at the back
edge of theblade can dig into the top surface of the wood causing theblade
to climb
out of the kerf and jump back toward operator.
Kickback is the result
of tool misuse and/or incorrect operating procedures
or conditions and canbe avoided by takingproper precautionsas givenbelow.
Maintaina firm grip with bothhands onthe saw andpositionyour bodyand
arm to allow you to resist KICKBACK forces. KICKBACK forces can be
controlled by the operator, if proper precautions are taken.
When blade is binding, or when interrupting a cut for any reason, release
the trigger and holdthe saw motionless
in thematerial until the bladecomes
toa complete stop. Never attempt toremove thesaw fromthework or
pull
the saw backward while the blade is in motion or KICKBACK may occur.
Investigate and takecorrective actions toeliminate the cause of blade binding.
When restarting a saw
in the workpiece, center the saw blade in the kerf
and check that saw teeth are not engaged into the material.
If saw blade
is
binding, it may walk up or KICKBACK from the workpiece as the saw is
restarted.
Support large panels tominimizethe risk
of blade pinchingand KICKBACK.
Large panels tend tosag under their ownweight. Supports must be placed
under the panel on bothsides, near the line
of cut and near the edge of the
panel as shown
in Fig. 1.
To minimizethe risk of blade pinching and kickback. When cutting operation
requires the resting of the saw onthe workpiece, the saw shall be rested on
the larger portion and the smaller piece cut off.
Don't support board or panel away
from the cut.
5

Do not use dull or damaged blade. Unsharpened or improperly set blades
producenarrow kerf causing excessive friction, blade bindingand KICKBACK.
Bladedepthand beveladjusting lockingleversmust betight andsecurebefore
making cut.
If blade adjustment shifts while cutting, it may cause binding
and KICKBACK.
Use extra caution when makinga "Pocket Cut" intoexisting walls or other
blindareas.The protrudingblade may cut objects
that can cause KICKBACK.
NEVER place your hand or fingers
behind the saw. If kickback occurs,
the saw couldeasilyjump backwards
over your hand, possibly causing
severe injury.
Fig. 3
12. Adjustments. Before cuttingbesure depthand beveladjustments aretight.
13. Avoid Cutting Nails. Inspect for and remove all nails from lumber before
cutting.
14. When operating the saw, keep the
cordaway from the cuttingarea and
position
it so that it willnotbecaught
on the workpiece during the cutting
operation.
Operate
with proper hand support,
proper workpiece support, and
supply cord routing away from the
work area.
WARNING:
A typical illustration of proper hand
support, workpiece support, and
supply cord routing.
Fig. 1
It isimportant tosupport the workpiece properly and toholdthe saw firmly
toprevent
loss of control which could causepersonalinjury. Fig. 4 illustrates
typical hand support of the saw.
6

15. Placethe wider portionof the saw base'onthat partof the workpiece which
issolidly supported, notonthe sectionthat
will falloffwhenthecut is made.
As examples, Fig.
5 illustratesthe RIGHTway tocut off the end of a board,
and Fig.
6 theWRONG way. Ifthe workpiece isshort or small, clamp it down.
DON'T TRY
TO HOLD SHORT PLACES BY HAND!
~
Fig. !
Fig.
16. Neverattempt tosaw with the circu
lar saw held upside down
in a vise.
Thisisextremelydangerous andcan
lead to serious accidents.
I
"
17. Before setting the tooldown after completinga cut, be sure that the lower
(telescoping)guard has closedand the blade has come toa complete stop.
7

SYMBOLS
The followings show the symbols usedfor tool.
................................. volts
................................. amperes
................................. herts
................................. kilograms
................................. hours
................................. minutes
................................. seconds
................................. alternating current
................................. direct current
................................. no loadspeed
................................. alternating or direct current
................................. Class II Construction
................................. splash-proof construction
................................. watertight construction
................................ revolutionsor reciprocation per minute
@ ................................. number of blow
8

FUNCTIONAL DESCRIPTION
Hex wrench storage
When not in use, store the hex wrench as
shown in the figure to keep it from being
lost.
Adjusting depthof cut
Loosenthe depth adjustinglever and move
the base up or down. At the desireddepth
of cut, secure the base by tightening the
lever.
CAUTIO N:
I
I
Depth adjusting lever
Useashallowdepth of cut when cutting thin workpieces for cleaner, safer cuts.
Sighting
When cutting, align the right side of notch
in the front
of the base with your cutting
lineon the workpiece.
I I
9

Dust collection
This tool is equipped with the dust box to
collect dust and cut chips. When the dust
box is about two thirds full, empty the dust
box of its contents. Press the lever and
open the dust cap. Tip the rear
of the tool
downtoempty the dust box.
Cleaner cutting operations can be per-
formed by connecting this tool to Makita
vacuum cleaner Model
432. Remove the
rubbercap from the dust cap and connect
the hose
of vacuum cleaner to the dust
cap.
Switchaction
CAUTION:
Beforeplugging in the tool, always check to see that the switch trigger actuates properly
andreturnsto the
"OFF" positionwhen released.
To prevent the switch trigger from being
I
accidentally pulled, a lock-off button is pro-
vided.
To start the tool, press the lock-off button
and pull the switch trigger. Release the
switch triggerto stop.
Switchtrigger Lock-off button
10

ASSEMBLY
Removing or installing saw blade
CAUTION:
*Always be sure that the tool is switched off and unpluggedbefore removingor installing
the blade.
*Use only the Makitahex wrench providedto installor removethe blade. Failure to do
so
may result in overtightening or insufficient tightening of the bolt. This could cause an
injury.
.Always makesure that the directionof the arrow on the surface
of the blade matches the
directionof the arrow onthe safety guard(safetycover)when installingthe blade.
To remove the blade, first remove the
thumb screw which secures the dust box,
then removethe dust box.
Press the shaft lock
so that the blade
cannot revolve and loosen the hex socket
headbolt with the hex wrench by turning it
counterclockwise.
Then remove the hex socket head bolt,
outer flange and blade.
To installthe blade, follow the removalpro-
cedures in reverse. Install the cup washer,
inner flange, saw blade, outer flange and
hex socket head bolt on the spindle in that
order. BE SURE TO TIGHTEN THE HEX
SOCKET HEAD BOLTSECURELY.
After installing the blade, install the dust
box andtighten the thumb screw to secure
the dust box.
1
I
Hex socket head bolt
11

OPERATION
CAUTION:
Be sure to move the tool forward in
a straight line and gently. Forcing and exerting pres-
sure or allowingthe blade
to bend, pinch or twist inthe cut can cause overheating of the
motorand dangerous kickback
of the tool.
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.
Nowsimply movethe tool forwardover 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.
CAUTION:
When usingdiamondwheels, alwaysfollow the followinginstructions.
*Check the wheel carefully for cracks
or damage before operation. Crackedor damaged
@Do not use water.Water may get intothe motor,causingan electric shock hazard.
*If the cutting action
of the diamond wheel begins to diminish, use an old discarded
coarse grit bench grinder wheel or concrete block
to dress the diamond wheel. To do
this, tightly securethe bench grinder wheel or concrete block and cut in it.
wheels will cause
a serious injury to operator.
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 positionwith
the thumb screw on the front
of the base.
It also makes repeated cuts of uniform
width possible.
12

MAINTENANCE
CAUTION:
Always besure that the
tool is switched off and unpluggedbefore attempting to perform
inspectionor maintenance.
Replacingcarbon brushes I
Remove and check the carbon brushes
regularly.Replacewhen they wear down
to
the limit mark. Keep the carbon brushes
clean and free to slip in the holders. Both
carbon brushes should be replaced
at
Limit mark
the same time. Use only identical carbon
brushes.
Use a screwdriver to remove the brush
holder caps. Take out the worn carbon
brushes, insert the new ones and secure
the brushholder caps.
\
To maintainproduct SAFETY and RELIABILITY, repairs,any other maintenance or adjust-
ment shouldbeperformed by MakitaAuthorized or FactoryService Centers, always using
Makitareplacementparts.
13

OPTIONAL ACCESSORIES
The accessories listed in this manual are available at an extra cost from your Makita distributor or
Makita factory servicecenter. Service centers are listed onthe 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.
Guide rule
Part No. 165240-8
Carbide-tippedsaw blade
Faster, smoother, longer sawing without blade
sharpening.
Cuts wood, drywall, plastics, hard
wood, etc.
Hex wrench 5
Part No. 703203-8
part No. I Dizzy 1 Hole diameter
No.
(mm) I teeth
A-90439 I lOO(4") 1 15.88 (5/8") I 16
14

Mur.-4-'99 US
100 mm (4")
Model 5044KB
CIRCULAR SAW with Dust Collection
1
68
Note: The switch and other part configurations
may differ from country to country.
15

MACHiNE
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cap
Dust Cap Complcle
Earth Plale
Dust Box L
Tapping Screw 4x18
DUSI Box R
Makita Label
Hex Socket Head Boll M6x40
Lever 54
Hex Nut M6
Ring Spring 12
Switch
Dust Cover
Name Plate
Tapping Screw 4x18
Pan Head Screw M5x45
Cord Guard 8- 90
Cord
Strain Relief
Tapping Screw 4x18
Carbon Brwh
Brush Holder Cap
Motor Housing Complele
Flat Washer 6
Handle Cover
S"PPOl1 Complete
Field
Tapping Screw 5x55
8"ttle Plate
Ball Bearing 608DDW
Insulated Washer
ARMATURE ASSEMBLY
Wth Item 32. 33 & 351
Ball Beering 6000DDW
Pipe 9
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-
Helical Gear 17
Stop Ring E-4
Shaft Lock
CompressionSpring 5
Gear Housing Complete
Rubber Sleeve 6
Ball Beating 607LB
Helical Gear 47
mng 12
Bearing Retainer 22-33
Ball Bearing 6201DDW
Spindle
Bearing Box Complete
Countersunk Head Screw M5x16
Thickness Ring
Tension
Spring 4
Safety cover
Pen HeadScrew M4x12
Cover Guide
Dm1 Cover
Retaining Ring 5-32
Cup Washer 12
Inner Flange 34
Outer Flange 34
Hex Socket Head Bolt M6x20
Depth Guide
Cap Square Boll M6x90
Pan Head Screw M4x12
Hex Socket Head Bolt M6x8
Hex Lock Nut M5-8
Screw M6x20
CompressionSpring 7
Pan Head Screw M5
Base
Note The switch and other part specitication~ may dafter from country IO country.
r-
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I
MAKlTALIMITEDONE YEAR WARRANTY
Warranty Policy
Every Makita tool IS thoroughly inspectedand testedbefore leaving the factory. It is warranted 10
be free of defect$ from workmanship and materials for the period of ONE YEAR from the dale of
original purchase. Should any trouble develop during this one-yearperiod. return the COMPLETE
1001. freight prepaid. to one of Makita'r Factory or Authorized Service Centers. If inspection shows
the trouble is caused by defective wvarkmanshio or material. Mskita dII reoair (or at our ootion.
replace)without charge.
This Warranty does not apply where:
repairshave beenmade or attempted by others:
repairs are required because of normal wear and lear
The fool has beenabused,misusedor improperly maintained;
alleralions have been made to the 1001.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES FROM THE SALE OR USEOF THE PRODUCT. THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THETERM OF THIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF "MERCHANTABILITY" AND "FITNESS FOR A SPECIFIC PURPOSE."
AFTER THEONE-YEAR TERM OF THIS WARRANTY.
This Warranty gives you specific legal rights, and you may also have other rights which vaiy from
state to state. Some stale^ do not allow the exclusion or limitation of incidental or consequential
damages. $0 the above limitation or exclusion may not apply to you. Some states do no1 allow
limitation on how long an implied warranty Iasls. so the abovelimitation may not apply to you.
Ma ki ta Corporation
3-11 -8, Sumiyoshi-cho,
Anjo, Aichi
446-8502 Japan
884203 - 064
PRINTED INJAPAN
1999 - 3 - N