Makita 5104 User manual

Models No.
Description
PRODUCT
TECHNICAL INFORMATION
P 1/ 13
5104, 5104S
Circular Saw 260mm (10-1/4")/ 270mm (10-5/8")
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
Note: The standard equipment for the tool shown above may differ by country.
Models 5104 and 5104S have been developed from Model 5103R
as a portable circular saw for heavy-duty applications.
Compact and lightweight design has been obtained without losing
advantages of Model 5103R.
Model 5104S feature electronic soft start while 5104 does not.
TCT saw blade 260 or 270 ............. 1
Guide rule ...................................... 1
Hex wrench ................ 1
Dust nozzle .................. 1 (for Europe only)
Saw blades
Dimensions: mm (")
Width (W1)
Height (H1)
Length (L)
405 (16)
315 (12-3/8)
323 (12-3/4)
Height (H2) 215 (8-7/16)
Base size: mm (")
Width (W2) 195 (7-11/16)
H1
W1
W2
L
H2
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output (W)
110
120
240
15
14
7.5
50/60
50/60
50/60
1,650
---
1,700
1,000
1,000
1,100
2,100
2,100
2,500
Current (A)
230 9.6 50 2,100 1.350 3,300
Rated amperage for USA: 14A
Model 5104
Model 5104S
260 (10-1/4)/ 270 (10-5/8)
North America: 15.88 (5/8)
Europe: 30.0
Other countries: 25.4 (1)
Size of blade: mm (")
Model
Diameter
Hole diameter
3,800
8.3 (18.3)
Australia, Chile: 2.0 (6.6)
Other countries: 2.5 (8.2)
95 (3-3/4)/ 100 (3-15/16)
69 (2-3/4)/ 73 (2-7/8)
No load speed: rpm= min.-1
Max cutting capacity: mm (")
Net weight: kg (lbs)
Cord length: m (ft)
0 degree
45 degrees
Double insulationProtection against electric shock
Electric brake Yes
Electronic soft start No Yes
5104 5104S

P 2/ 13
[2] LUBRICATION
Apply Makita grease N. No.1 to the following portions designated with the black triangle to protect
parts and product from unusual abrasion.
[1] NECESSARY REPAIRING TOOLS
CAUTION: Unplug the tool and remove the saw blade from the machine for safety
before repair/ maintenance!
Fig. 1
Repair
DescriptionCode No. Use for
Gear extractor (large)1R045 Removing Helical gear 39 and Spindle
45-degree set square1R207
90-degree set square1R208 Setting Saw blade at 90 degrees to Base plate
Bearing extractor1R263 Removing Bearing box
Bearing extrator1R269 Removing Ball bearing 6001
Retaining ring S & R pliers1R291 Removing Retaining ring S-12
Center attachment1R346 Attaching to 1R045 when removing Helical gear 39
Item No. Description
Safety cover Inside of Loop portion where 17 Thickness ring contacts
Whole portion
Whole portion
Whole portion
Gear room where Helical gear 39 rotates
Thickness ring
Lock spring 27
Lock spring 20
Blade case Complete
Portion to lubricate
Setting Saw blade at 45 degrees to Base plate
Bearing box
Spindle
Lock sleeve
Helical gear 39
Ball bearing 6001
6
17
22
23
48

P 3/ 13
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Base
Repair
DISASSEMBLY
M4x5
H.S. Set screw
M8x55 Hex bolt
M6x25 Hex bolt
Flat washer 8
Flat washer 6
Base
Angular plate guide
Wing nut
M6 Wing nut
Remove M6 Wing nut and M6x25 Hex bolt which join Base
and Depth guide.
Remove Wing nut and M8x55 Hex bolt which join Angular
plate and Angular plate guide.
Now Base is separated.
Angular plate guide can be
removed from Base as illustrated
above.
1. Loosen M6 Wing nut slightly; no need to remove in this step.
1) Base can be disassembled as illustrated in Figs. 2 and 3.
2. Loosen M4x5 H.S. Set screw to
remove Pin 6 smoothly.
3. Remove Pin 6.
Angular plate guide
Base
5x20 Tapping screw (2pcs.)
Depth guide
Fig.2
Fig.3

P 4/ 13
[3] DISASSEMBLY/ASSEMBLY
[3] -2. On-off Switch, Brake Switch, Power Supply Cord, Noise Supppressor, Controller
Repair
DISASSEMBLY
ASSEMBLY
1) Disassemble Handle set (L) in the order of Figs. 4 and 5. The electrical Parts can be replaced.
Fig.4
Fig.5
Ring spring 12
Remove Ring spring 12 by pulling off
with Slotted screwdriver.
5x25 Tapping screw (4pcs.)
After replacing the electrical parts, take the disassembling step in reverse. Refer to Figs. 5 and 4.
M5x40 Pan head screw (3pcs.)
Remove Lever 54 by levering
up with Slotted screwdriver. Remove M8 Hex nut.
M8 Hex nut
Remove 5x25 Tapping screws and
M5x40 Pan head screws.
Handle set (L)
Handle set (R)
Handle set (L)
Remove Handle set (L).
The electrical parts in Handle set (R) can be replaced;
no need to disassemble Motor section.
Lever 54
Controller
(5104S only)
Brake switch
ON-OFF
switch
Power supply cord
Noise suppressor

P 5/ 13
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Armature
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Bearing Box, Gear Section with Super Joint System
Repair
DISASSEMBLY
DISASSEMBLY
ASSEMBLY
1) Remove Brush holder caps and Carbon brushes (left in FIg.6). And then remove Ring spring 12, Lever 54 and M8 Hex
nut as illustrated in Fig. 4.
2) Remove Handle set and Motor housing together from Blade case complete. (center in Fig. 6)
3) Remove Armature. (right in Fig. 6)
Fig. 6
Fig. 7
Take the disassembling step in reverse. Refer to Figs. 6 and 4.
1) Disassemble Blade case cover and Rubber ring 8. (Fig. 7)
Armature
Armature
Now Armature can be pulled
off from Blade case complete.
After removing Carbon brush, disassemble Motor housing and Handle
section together by unscrewing M5x65 Pan head screws.
M5x65
Pan head
screw: 4pcs.
Carbon brush
Motor housingHandle set
Brush holder cap
Blade case
complete
4x16 Tapping
screw: 4pcs.
Blade case
cover
Blade case
complete
Remove Blade case cover, by unscrewing 4x16
Tapping screws.
Remove Rubber ring 8 that works as a stopper for Safety cover.
Tension spring connecting-portion on Safety cover comes to
the nearest position to that on Blade case complete by moving
automatically in the direction designated with black arrow.
Now you are ready to remove Tension spring easily.
Tension spring 6 Rubber ring 8
Rubber
ring 8

P 6/ 13
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Bearing Box, Gear Section with Super Joint System
Repair
DISASSEMBLY
Fig.8
Fig.9
Fig.10
M5x16 Countersunk
head screw: 2pcs.
Bearing retainer 34-62
1. Disassemble Bearing retainer 34-62 by unscrewing
M5x16 Countersunk head screws.
2) Gear section can be disassembled in the Order of Fig. 8 to 10.
Now Safety cover can be removed.
Safety cover
Thickness
ring
2. Loosen the linkage of Safety
cover with Blade case complete
by removing of Tension spring’s
hook from Safety cover.
Tension spring’s hook
Safety cover
And disassemble Bearing box by levering up it with 1R263.
Bearing box is removed together with Gear section.
1R263
Helical gear 39
Bearing box
M5x16 Pan head screw: 4pcs.
Retaining
ring S-12
Ball bearing 6001
After removing Retaining ring S-12,
disassemble Ball bearing 6001. Remove Helical gear 39 with Super joint mechanism
from Bearing box, .
1R291 1R269
1R045
Helical gear 39
Lock sleeve
Remove M5x16 Pan head screws.

P 7/ 13
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Bearing Box, Gear Section with Super Joint System
Repair
DISASSEMBLY
ASSEMBLY
3) Super joint system can be removed from Helical gear 39 as illustrated in Figs. 11 and 12.
Take the disassembling step in reverse.
Note: 1) Apply Makita Grease N.No.1 to the whole portion of Lock spring 20 and Lock spring 27.
2) When linking Safety cover with Blade case complete using Torsion spring 6, be sure to follow the instruction
shown in Fig. 13.
Remove Spindle from Helical gear 39.
1R045
Fig.11
Fig.12
Fig.13
Spindle
ClothLock sleeve
Wrapping Lock sleeve and Helical gear 39 with
the cloth individually, twist and remove them.
Lock spring 27
Lock spring 27
Turning Lock sleeve 27 with water pump pliers in the
direction to be loosened, pull off the Lock spring 27.
Then remove Lock spring 20 in the same way.
Lock spring 20
Lock sleeve
Helical gear 39
Helical gear 39
Helical gear 39
water pump pliers
Blade cover
Blade case complete
Tension spring 6
Safety cover
Hook Tension spring 6 from
Blade case complete side.
Hook Tension spring 6 from
Blade cover side.

P 8/ 13
[4] ADJUSTMENT
Repair
Squaring Adjustment of Saw Blade
1R208
Base Base
Hex wrench
Saw blade
Triangular rule
Adjustment to 90 degrees
Adjsut by turning Hex wrench until
both Saw blade and Base contact
1R208 closely.
Set the machine to fully tilted position.
And adjust by turning Hex wrech until
both Saw blade and Base contact
the triangular rule closely.
Adjustment to 45 degrees
Saw blade
Fig.14
Fig.15
Lever 54
The assembled Lever 54 and Base have to be adjusted at most 30 degrees
to the level of Base when the machine is set at the max. cutting depth.
30 degrees
Base

Circuit diagram
Wiring diagram
P 9/ 13
White Red
ON-OFF
Switch
Noise
Ssuppressor
Field
Orange
Yellow
Color index of lead wires' sheath
5104 110V-127V
(for North America and Taiwan, etc.)
5104 110V-127V
(for North America and Taiwan, etc.)
Black
ON-OFF switch
Noise
suppressor
Pull Field lead wires to Handle set
side in order not to slacken them
in Motor housing.
Fix Lead wires with
Lead wire holder.
Power supply cord
Choke coil
Fig. D-1A
Fig. D-2A

Circuit diagram
Wiring diagram
P 10/ 13
Blue
White
Red
ON-OFF Switch
Brake switch
Noise
suppressor
Field
Orange Yellow
Purple
Color index of lead wires' sheath
5104 220-240V (for Australia etc.)
Brown
Brake
Switch
ON-OFF
switch
Power supply cord
Noise
suppressor
Pull Field lead wires to Handle set side
in order not to slacken them in Motor
housing.
Fix Lead wires with
Lead wire holder.
Choke coil
Choke coil
5104 220-240V (for Australia etc.)
Fig. D-1B
Fig. D-2B

Circuit diagram
P 11/ 13
Blue
White
Red
ON-OFF
switch
Power Supply cord
Brake
switch
Controller Noise
suppressor
Noise
suppressor
Field
Orange
Black
Choke coil
Choke coil
Yellow
Purple
Color index of lead wires' sheath
5104S 220-240V (for Europe, Turkey, Bhutan, South Aftrica, etc.)
Brown
Insulated connector
Insulated connector
Fig. D-1C

Wiring diagram
P 12/ 13
5104S 220-240V (for Europe, Turkey, Bhutan, South Aftrica, etc.)
Brake
Switch
Controller
Noise
suppressor
ON-OFF
switch
Insulated
connector
Insulated connector
Insulated connector
Power
supply cord
Choke coil
Noise
suppressor
Fig. D-2C
Pull Field lead wires to Handle set side
in order not to slacken them in Motor
housing.
Fix Lead wires with
Lead wire holder.

Wiring diagram
P 13/ 13
Angular plate
guide side
(Front grip side)
3 Lead wires of Field
3 Lead Wires of Field
Two Lead wires
of Field to Brake
switch
Field
Motor housing
Fig. D-3 Fig. D-4
Fig. D-5
Destinations Model No.
5104
5104S
* Twiwan,
* North America
* Orange
* Red
* Yellow
* Europe
* South Africa
* Bhutan
* Black
* Orange with Choke coil
* Yellow
* Australia
* Orange with Choke coil
* Red
* Yellow
Pulling out five Lead wires of Field
in order to route them into Hanlde set.
Bring three Lead wires of Field to Angular plate guide side
(Front grip side).
The three Lead wires are listed below.
Tighten Field with two M5x80 Pan head scerws.
M5x80 Pan head scerw: 2pcs.
Pulling Lead wires not to slacken in
Motor housing, install Field into Motor
housing.
Put Field lead wires in the order of Fig.D-3, Fig.D-4 and Fig.D-5.
Hole
Field Lead wires in Motor Housing