Makita 5092D User manual

Cordless Circular Saw
Blade
diameter
85 mm (3-3/8”) MODEL 5092D
85 mm (3-3/8”) MODEL 5092DW
With Fast Charger
weight
Cutting depth
No load speed Overall
(RPM) length
9ou 45”
INSTRUCTION MANUAL
Battery Cartridge 1210
Uses 12 V
/ 9.6V Battery
Model DC1290 Fast Charger
SPEC IF I CAT1 0 N S
Model 5092D
Voltaae IrlDUt Output
I Charsina time
I I I 1
379 mm 2.0 kg
1,000
I (14-15/16”) I (4.4 Ibs)
85 mm I yo- 24.5 mm 0 18”
(3-318”) 15/16”) ~ (0--11/16”) I
12 v I AC only 50Hz 60Hr 1 DC 96V. 12V 1 1 Hr
Optional: Battery cartridge
9000 (9.6 V)
* Manufacturer reserves the right to change specifications without notice.
WARNING: For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS
FOR FUTURE REFERENCE.
Note: Specifications may differ from country to country.

I M PORTANT
SAFETY INSTRUCTIONS
(For All Tools)
WARNING: WHEN USINGELECTRICTOOLS, BASICSAFETY
PRECAUTIONSSHOULD 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 tools torain.
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. When not
in use, tools shouldbestored in dry, and high
or locked-up place
- out of reach of children.
DON'T FORCETOOL.
It will dothejob better and safer at theratefor which
it was intended.
USE RIGHT TOOL. Don't force small tool or attachment to do thejob of a
heavy-duty tool. Don't usetoolfor purpose notintended; for example, don't
use circular saw for cutting tree limbs or logs.
DRESSPROPERLY. Don't wear looseclothing 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
dusty.
DON'T ABUSE CORD. Never carry 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.
MAINTAINTOOLS WITH CARE. Keep tools sharp and clean for better and
safer performance. Follow instructionsfor lubricating and changing acces-
sories. Inspecttoolcords periodically and
if damaged, have repaired by autho-
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 when chang-
ing accessories, such as blades, bits, cutters.

14. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to
see that keys and adjusting wrenches are removedfromtool beforeturning
it on.
15. AVOID UNINTENTIONAL STARTING. Don't carrytool with finger onswitch.
Be sure switch is OFF when plugging in.
16. OUTDOOR USE EXTENSION CORDS. Whentool is usedoutdoors, use only
extension cords intended for use outdoors and so marked.
17. STAY ALERT. Watch what you are doing, use common sense. 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 properlyand perform its intendedfunction. Check for alignment of
movingparts, bindingof movingparts, 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 serv-
ice center unless otherwise indicatedelsewhere
in this instruction manual.
Have defective switches replaced by authorized service center. Don't use
tool if switch does not turn it on and off.
19. GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded
surfaces. For example; pipes, radiators, ranges, refrigerator enclosures.
20. REPLACEMENTPARTS. Whenservicing, 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 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, contact a qualified electriciantoinstall
the proper outlet. Do not change the plug
in any way.
VOLTAGE WARNING: Beforeconnectingthe tool toa 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 INJURY tothe user - as well as damage to
the tool. If in doubt, DO NOT PLUG IN THE 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
Length of Cord (Feet)
AWG Size of Cord
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 reducerisk of injury, charge only MAKITA Battery Cartridge
9000,9100, 1200 & 1210. 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
manufacturermay result ina risk of fire, electric shock, or injury topersons.
6. To reduce risk of damage to electric 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 pinsonplugof extension cordare the same number, size, and shape
b. That extension cord isproperly wiredand ingoodelectrical condition; and
c. That wire size is at least as large as the one specified
in the table below.
TABLE 1
RECOMMENDED MINIMUM AWG SIZE FOR
EXTENSION CORDS FOR BATTERY CHARGERS
as those of plug on charger;
25 50
100 150
18 18
18 16
9.
Do not operate charger with damaged cord or plug - replace them im-
mediately.
IO. Donotoperate charger if it has receiveda sharpblow, been dropped, 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 electric shock, unplugcharger from outlet beforeattempt-
ingany maintenance or cleaning. Turningoff controls will not reducethis risk.
4

ADDITIONAL SAFETY RULES
FOR CHARGER
& BATTERY CARTRIDGE
1. Do not charge Battery Cartridge when temperature is BELOW 10°C (50°F)
2. Do not attempttouse a step-uptransformer, an engine generator or DC power
3. Do not allow anything to cover or clog the charger vents.
4. Always cover the battery terminals with the battery cover when the battery
5.
A battery short can ca.use a large current flow, overheating, possible burns
or ABOVE 4OoC (104°F).
receptacle.
cartridge is not used.
and even a breakdown.
(1) Do not touch the terminals with any conductive material.
(2) Avoid storingbatterycartridge in a container with other metalobjectssuch
(3) Do not expose battery cartridge to water or rain.
ture may reach or exceed 35°C (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
5

ADDITIONAL SAFETY RULES
FOR CORDLESS CIRCULAR SAW
1. Be aware that this tool is always inan 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.
Neverwedge 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, restrictingfull 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.
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 on the work piece,
the saw shall be rested onthe larger portion and the smaller piece cut off.
7. Support Large Panels.
To avoid kickback, do support board
or Dane1 near
the cut. Don't support board or panel away
I from the cut.
Fig. 1 Fig. :
8. Use Rip Fence.
9. Guard Against Kickback.
Always use a fence or straight edge guide when ripping.
Kickback occurs whenthe saw stalls rapidly and is driven backtowards the
operator.Releaseswitch immediately
if blade bindsor saw stalls. Keep blades
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 could easilyjumpbackwards
over your hand, possibly causing
severe injury.
Fig. 3
IO. Lower Guard. Raise lower guard with the retracting handle.
11. Adjustments. Beforecuttingbe sure depthand beveladjustments 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.
I
Fig. L
WARNING :
A typical illustration of proper hand
support and workpiece support.
It is importanttosupport the workpiece properly and toholdthe saw firmly
to prevent
loss of control which could cause personal injury. Fig. 4 illustrates
typical hand support of the saw.
7

15. Place the wider portionof the saw base on that partof the workpiece which
issolidly supported, notonthe section that
will fall off when the cut ismade.
As examples, Fig.
5 illustratesthe RIGHT way tocut off the end of a board,
and Fig.
6 the WRONG way. Ifthe workpiece isshort or small, clamp it down.
DON'T TRY TO
HOLD SHORT PIECES BY HAND!
Fig. 6
Fig.
16. Never attempttosaw with the circu-
lar saw held upside down
in a vise.
This is extremely dangerous and can
lead to serious accidents.
Fig. 7
17. Before setting the tooldown after completinga cut, be sure that the lower
(telescoping)guard has closed and the blade has cometoa complete stop.
SAVE THESE INSTRUCTIONS.
8

Installing or removingthe battery cartridge
0 Always switch off the tool before insertionor removalof the battery cartridge.
1200 / 1210
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 into place.
Be sure to close the
set plate fully before
usingthe tool.
Approx 60 mtn
Battery cartridge
9000
Fig. 8
Approx 60 min
0 Do not use force when inserting the battery cartridge.
Ifthe cartridge does not slide in easily,
it is not being insertedcorrectly.
Charging
Your new batterycartridge is not charged.
You will need tocharge
it before use. Use
the fast charger Model DCI 290 to charge
the battery cartridge.
0 Plug the fast charger into the proper A/C
voltage source.
0 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 itrestson the charger port floor.
Charging light
Start button
'$ -
Reset button "f
F8g. !
Press the start button (red).The charging light will come on and chargingwill begin. If
the charging light does not come on, press the reset button (yellow)first, then the start
button (red). If the charging light goes out within
10 seconds even after pressing the
reset buttonand
start button a couple of time, the batterycartridge is dead. (CAUTION:
Wait for more than 5 seconds after the charginglight goes out to press the reset button
again.) Replace
it with a new one.
When the charginglight goes out after about onehour, you may removethe fully charged
fast charger.
After charging, unplug the charger from the power source. Referto the table below for
the chargingtime.
DC1290
9

CAUTION :
.The fast charger Model DC1290 is specifically designed to charge only Makita battery
cartridges. Never use
it for other purposesor 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, the charging light may not comeon. Ifthis occurs, just press
the reset button (yellow) first, then the
start button (red) as described before. Charging
wil I begin .
When you charge a new battery cartridge or a battery catridge which has not been used
for a long period of time, it may not accept a full charge. This is a normal conditionand
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 exposedto direct sunlight or heat for a long time, sometimes
the charging light will not some on. If this occurs,
let the cartridge cool off for a while.
Then re-insert it and try tocharge it once more.
If you wish tocharge two battery cartridges, allow 15 minutes betweenchargings on the
fast charger.
.Do not keep the button pressed in with tape, etc. or the circuit will not function pro-
perly. Also,
a malfunction of thecharger may result possibly causingoverheating,etc.
Removing
or installingthe saw blade
CAUTION :
Always be sure that the tool is switched off and the battery cartridge is removedbefore
installingor removingthe 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.
Fig. 1
L
10

To install the blade, follow the removal
procedure in reverse.
BE SURE TO TIGHTEN THE
BOLT
SE CU RELY.
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 removethe blade.
Hex wrench storage
When not in use, the hex wrench can be
conveniently stored.
Hex wrench
Fig. 1:
11

Adjustingthe 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 guidewith the graduations on
its right side. (Note: This can be done for 0" bevelcutting only.) At the desireddepth of
cut, secure the base by tighteningthe screw.
Base Screw
Top of notch
Fig. 13 Fig. 14
CAUTION :
Use a shallow depth of cut when cutting thinworkpiece for cleaner, safer cuts.
0 After adjusting the depth of cut, alwaystighten the screw securely.
Bevel cutting
Loosen the screw on the bevel scale plate
on the front of the base. Set for the desired
angle
(0" -45") by tilting accordingly, then
the screw securely.
Bevel scale plate
Fig. 15
CAUTION :
After adjusting the depth of cut and bevel cutting angle, be sure totightenthe 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.
Switch action
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.
/ Top guide
- For 45" bevel cuts ::
For sttaight cuts c~~~~~~ line
Fig
Switch ti igger 7, !\Lock-off lwei
1
Fig. 1
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
I
i- . Base
sawing line straight and your speed of
advance uniform.
I
Fig. 1
CAUTION :
.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.
If the tool is operatedcontinuously untilthe 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.
Clamp screw
14

MAINTENANCE
CAUTION :
Always be sure that the tool is switched off and the battery cartridge is removedbefore
attempting or perform inspection or maintenance.
To maintain product SAFETY and RELIABILITY, repairs, maintenanceor adjustment
should be performed by Makita Authorized or Factory Service Centers, always using
Makita replacementparts.
15

ACCESSOR I ES
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.
79261 1-2
721005-A
0 Battery cartridge 1210
Part No. 632277-5
(12
V)
85 (3-318") 15 (19/32") 20
85 (3-318") 15 (19132") 24
0 Fast charger
Model DC1290
Part No. 113119-108
Part No, Diameter Hole diameter
(mm)
(mm)
721003-8 85 (3-318") 15 (19/32")
0 Hex wrench
Part No. 783202-0
No.
teeth
50
Battery cartridge 9000 (optional)
Part
No. 632470-1
(9.6
V)
Fast charger
Model DC1201
Part No. 113126-0
*Guide rule (Ripfence)
0 Battery cover
Part No. 164095.8
Part No. 414938-7
0 Tungsten carbide tipped
saw blade
For wood
0 Combinationsaw blade
Fot-rip and cross-cut work.
Has fewer teeth than
cross-cut blade for
faster cutting.
0 Plywoodsaw blade
For smooth splinter-free
cutting of plywoodand
other thin laminates.
Q
Part No, I Di;;;;er 1 Hole(di;x?ter
No.
I teeth
Part No, I Di(am;;er I Hole(;;lli;wter
No.
1 teeth
_____
792299-8 I 85 (3-318") I 15 (19/32") I 50
16

Sei, 19-'95 US
85 mm (3-3/8")
CORDLESS CIRCULAR SAW
Model 5092D
Note: The switch and other part configurations
may differ from country to country.
17

MODEL 5092D
IFOM ,,I:, DESCRIPTION
sev-19- 95 us
ILLM AtD DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1 6
17
18
1
4
20
21
22
21
24
25
1
1
1
1
1
1
2
1
1
1
1
6
1
1
1
1
1
1
1
1
1
MACHINE
~
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
41
48
49
50
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
Slop Ring E 4
iex Nu1 M5
3all Bearing 6000LLB
Narning Card
:ampresslo" spmg 3
sxh Off Lever
JC Motor 12 V
Wofor Housing
uame Plate
inusmy SPI IWith them 131
Swch
set Pldfe
Baiiery Holder
SW,tCh Lever
Screw M5x10
Spring Washer 5
Flal Washer 5
Base
S~mw M5x10
Spr~ny
Pin 4 40
Flat Wahtier 5
sprinq Wdahcr 5
Scr~w M5x10
rapping screw dXi8
Tapping Screw 4x1 8
18

Recycling the Battery
The only way to dispose of a Makita battery is
to recycle it. The law prohibits any other
method
of disposal.
1 Ni-Cd 1
To recycle the battery:
1. Remove the battery from the tool.
2. a). Take the battery to your nearest Makita FactoryService 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 inspected and tested before leaving the 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 Service Centers. 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:
repairs have been made or attempted by others:
repairs are required because of normal wem and tear:
The tool has been abused, misused or improperly maintained;
alterations have been made tothe tool.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES FROM THE SALE OR USE OFTHE PRODUCT. THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THETERM
OF THISWARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,”
AFTER THE ONE-YEAR TERM OFTHISWARRANTY.
This Warranty aves 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
884050 - 063 PRINTED IN USA
1995 - 11 - C