Makita 5201NA User manual

260 mm (IO-1/4") MODEL 5201N-A
Equipped with Electric Blade Brake
INSTRUCTION MANUAL
SPECIFICATIONS
Max. cutting capacities
diameter
1-1 N$z:d I ?::;:: I di:ht
260 mm 97 mm 64 mm I 3.700 445 mm 8.3 kg
(1
0- 1 14") I (2-112'7 Rlmin. 1 (17-112") 1 (18.3 Ibs)
* Manufacturer reserves the right tochange specifications of parts and accessories without notice.
Note: Specifications of parts and accessories may differ fromcountry tocountry.

IMPORTANT SAFETY INSTRUCTIONS
WARNING: When using electric tools, basic safety precautionsshould always
befollowedtoreducetheriskof fire, electric shock, and personalinjury, including
the following:
READ ALL INSTRUCTIONS.
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
13.
14.
15.
16.
17.
KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries.
CONSIDER WORK AREA ENVIRONMENT. Don't use power tools
in damp
or wet locations. Keepwork 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 extensioncord.
STORE IDLE TOOLS. When not
in use, tools should be stored in dry, and
high or locked-upplace
- out of reach of children.
DON'T FORCETOOL.
It willdothejob betterandsafer attheratefor which
it was intended.
USE RIGHT TOOL. Don't force small tool or attachment to do the job of
a heavy-dutytool. Don't use tool for purpose not intended.
DRESSPROPERLY. Don't wear looseclothingorjewelry. They canbecaught
in moving parts. Rubber gloves and non-skidfootwear are recommended
when workingoutdoors.Wear protectivehaircoveringtocontainlonghair.
USE SAFETY GLASSES. Also use face or dust mask if cutting operation
is dusty.
DON'T ABUSE CORD. Nevercarrytool
by cordor yank it todisconnectfrom
receptacle. Keep cord from heat, oil, and sharp edges.
SECURE WORK. Use clampsor 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 WITHCARE. Keep tools sharp and cleanfor better and
safer performance. Follow instructions for lubricating and changing ac-
cessories. Inspecttoolcordsperiodicallyand
if damaged, haverepairedby
authorized servicefacility. Inspectextension cords periodically and replace
if damaged. Keep handles dry, clean, and free from oil and grease.
DISCONNECTTOOLS. Whennot
in use, beforeservicing, and whenchang-
ing accessories, such as blades, bits, cutters.
REMOVEADJUSTING KEYS AND WRENCHES. Form habit of checking
to
see that keys and adjustingwrenches are removed from tool beforeturn-
ing
it on.
AVOID UNINTENTIONALSTARTING. Don't carry plugged-intool withfinger
on switch. Be sure switch is OFF when plugging
in.
OUTDOOR USE EXTENSION CORDS. When tool is used outdoors, use
only extension cords intended for use outdoors and
so marked.
STAY ALERT. Watch what youare doing, usecommonsense. Don't operate
tool when you are tired.
2

18.
19.
20.
21.
CHECK DAMAGEDPARTS. Before further use of the tool, a guard or other
part that isdamaged should be carefully checked todetermine that
it will
operate properly and perform its intended function. Check for alignment
of movingparts, binding of movingparts, breakageof parts, mounting, and
any other conditions that may affect its operation. A guard or other part
that isdamaged should be properly repaired or replaced by an authorized
service center unless otherwise indicated elsewhere
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.
GUARDAGAINSTELECTRIC
SHOCK. Prevent body contact with grounded
surfaces. For example; pipes, radiators, ranges, refrigerator enclosures.
PROPER GROUNDING. This tool should be grounded while in use to pro-
tect the operator from electric shock.
EXTENSION CORDS: Useonly three-wire extensioncords which havethree-
pronggrounding-type plugs and three-pole receptacleswhich accept the
tool's plug. Replace or repair damaged or worn cord immediately.
VOLTAGE WARNING: Before connectingthe tool to apower 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 voltagegreater than that specifiedfor the tool can resultinSERIOUS 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

For all grounded tools with Americantype plug.
GROUNDING INSTRUCTIONS: This tool should be grounded while in use to protectthe opera-
tor from electric shock. The tool
is equipped with an approved three-conductor cord andthree-
prong grounding-type plug to
fit the proper grounding-type receptacle. The grwn (or green and
yellow) conductor
in thecord is thegrounding wire. Never connect the green (orgreen andyellow)
wireto
a liveterminal. Your unit
is for use on 115 volts, it has a plugthat looks like Fig. "A.
An adapter, Fig. "B and "C" is availsblefor connecting Fig. "A" plugstotwo-prong receptacles,
(see Note). The green-colored rigid wr, lug, etc., extending from the adapter must be connected
to a permanentgroundsuchai to properlygrounded outlet box.
FIG. A FIG. B FIG. C
Adapter
Grounding Blade Cover of Grounded Outlet
Box
NOTE: THE GROUNDING ADAPTER IS PROHIBITED IN CANADA PER CANA-
DIAN ELECTRICAL CODE-PART
1. THEREFORE, THE INSTRUCTIONS FOR
ITS USE ARE NOT APPLICABLE
IN CANADA.
4

Use Of ExtensionCord
If the extension cord is intended to be used outdoors, the cord shall be markedwith the
suffix W-A following the cord type designation, for example - SJTW-A,to indicate it is
acceptable for outdoor use. Use an extensioncord heavy enough tocarry the current the
tool will draw. Undersize cord will cause
a drop in line voltage resulting in loss of power
and over-heating.Make sure the extensioncord
is ingood condition before using. Use the
table below todetermine the proper wire
size required inthe extensioncord.
25 Ft.
50 Ft.
75 Ft.
100 Ft.
150 Ft.
Ampere rating
2.10- 3.50- 5.10- 7.10- 12.10-
(on nameplate) I :.io I 3.40 I 5.00 I 7.00 1 12.00
1 16.00
18 18 18 18 16 14
18 18 18 16 14 12
18 18 16 14 12 10
18 16 14 12 10
-
16 14 12 12
- -
I Ext.Cable Length I Wire Size (AmericanWire Gauge)
ADDITIONAL SAFETY RULES FOR CIRCULAR SAW
1. Keep Guards InPlace and InWorking Order.
Never wedge or
tie lower guard open. Check operation of lower guard before each
use. Don't use if lower guard does not close brisklyover saw blade. CAUTION: Ifsaw
is dropped, lower guard may be bent, restricting full return.
Sharp blades minimize stalling and kickback.
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: Bladescoast
after turn off.
When cuttingoperation requiresthe resting
of the saw on the work piece,the saw shall
be restedon the larger portion and the smaller piececut off.
Always use
a fence or straight edge guidewhen ripping.
Kickback occurs when the saw stalls rapidly and
is driven back towards the operator.
Release switch immediately if blade binds or saw stalls. Keep blades sharp. Support
large panels. 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 .
2. Keep Blades Clean and Sharp.
3. DANGER: Keep HandsAway From CuttingArea.
4. Support Large Panels
5. Use Rip Fence.
6. Guard Against Kickback.
7. Lower Guard. Raise lowerguardwith the retracting handle.
8. Adjustments. Beforecuttingbe sure depth and bevel adjustmentsare tight.
9. Use Only Correct Blades In Mounting.
IO. Avoid CuttingNails. Inspectfor and remove all nailsfrom lumber before cutting.
Don't use blades with incorrect size holes.
Never use defective or incorrect bladewashers or bolts.
5

11. When operating the saw, keep the cord away from the cutting area and position it so
that it will not be caught on the work pieceduring the cutting operation.
Operate with proper hand support, proper work support, and supply cord routing
away from the work area. Large panels must be supported
as shown below.
12. Never attempt to saw with the circular
saw held upside down in a vise. Thiscan
lead to serious accidents, because
it is
extremely dangerous.
13. Before setting the tool down after completing a cut, be sure that the lower (telescop-
SAVE THESE INSTRUCTIONS.
ing) guard has closed and the blade has come to a completestop.
6

HOW TO USE
CAUTION :
Never wear gloves when operating or adjusting the saw.
When sawing
Grasp the rear handlewith your right hand,
the front grip with your left.
Set the base
plate on the wood to be cut without the
blade making any contact. Then switchthe
saw on. Now simply move the saw forward
over the wood 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 ad-
vance uniform.
*Switch action
There is a lock-off switch button on the
handle. To start the tool, first depress the
lock-off switch button and then pull the
trigger.
Release the trigger tostop.
The trigger will not work before the lock-
off switchbutton
is depressed.
For the cuttingposition
Use the right edge of the top guide for
straight cuts. The small notch on the top
guide
is for bevelcuts.
For straight
t- cuts
For
45' bevel 4
cuts
I
Base plate
7

Adjustingcuttingdepth
By raising the lock lever and looseningthe
screw holdingthe guide plate, the base may
be moved up or down.
Thus the blade protrusion, or depth of the
saw blade, can be adjusted. When
it is com-
pleted, lower and fasten the lock lever back
into place.
0 Replacingsaw blade
Do not replacewith a saw blade larger than
260 mm
(10-1/4”).
TWOwrenches are provided. Use the larger
one (22) to grip the flange hard and the
smaller one
(13) to loosen the bolt in the
direction of the saw revolution. Remove
blade.
(See arrowsinphoto at right).
When installing the new blade, keep the
blade markings on the outside; tighten the
bolt
to the right. For safety’s sake during
the entire operation, always have the tool
unplugged.
The tool
is equipped with an adapter ring
(16) for
a 1” arbor hole. Withoutthe ring,
there is a 5/8” arbor hole,
0 For bevel work
Loosen the wing nuts on the bevel scale
plate on the front
of the base. Set for de-
sired angle
(0 - 45’) by tilting accordingly,
then retightenthe wing nutsfirmly.
8

MAINTENANCE
CAUTION :
Always be sure that the tool is switched off and unpluggedbeforeattempting to perform
inspectionand maintenance.
260-7
Replacingcarbon brushes
Replace carbon brushes when they wear
down to about
6 mm (1/4") or sparking
will occur. Both brushesshould be changed
at the same time. Use only Makita-recom-
260 110-114") 25 131132"l 36 792067-3
mendedcarbon brushes.
NO.
I
6 mm (1/4")
Diameter Hole diameter ,Job Part No,
lmml lmml
ACCESSOR I ES
CAUTION: The accessories specified in this manual are recommended for use with your Makita
Circular Saw. The use of any other accessoriesmight be hazardous.
0 Saw Blades
Cross-cut saw blade
For smoother cross-grain cuts.
Make smoother cuts than
combination blade.
Chiseltoothcombination
saw blade
For ripand cross-cutwork.
Most frequently used for
general carpentry.
Carbide-tipped
saw blade
Faster, smoother, longer sawing
without bladesharpening.
Cuts wood.
Guide Rule
Part No. 164019-4
260-2 I260 l10-1/4"1 I 25 131/32"1 I 80 1 792084.9
0 Wrench 22
Part No. 781011-1
0 Wrench 13
Part No. 781 203-2
"
9

Oec.-20-'83 US
260 mm (IO-1/4")
CIRCULAR SAW
Model 5201N-A
Note: The switch, noise suppressor and other part configurations
may differ from country to country.
10

ITEM NO.
NO. USED
IFo! DESCRIPTION
MACHINE
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
M
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
4
1
2
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
4
1
2
1
1
2
1
1
2
1
1
1
1
Rivet 0-3
Name Plsre
Brush Holder Cap
Carbon Brush
Motor Housing (With Brush Holder x 2
S Screw M5r8 x 2 & Item 19)
Insulation Washer
FIELD ASSEMBLY
(With Garter Spring x 21
P H Screw M5x65 (WithWasher)
Ball Bearing 6200LLB
Dust Sad 10
ARMATURE ASSEMBLY
(Assembled Items 11 - 16)
Fan 106
Dust Seal 15
eaii ~~ZLLB
Baff1* Plate
Rubber Pin 6
Rubber Pin 4
CORD ASSEMBLY
IAssembledCord. Plug & Cora Guard1
CordGuard
Strain Relief
P H Screw M4x14 (With Washed
P H Screw M4x28 (WithWasher)
Handle Cover
P H Screw M4x8 (WifhWashed
Switch
Noom Suppressor
P H Screw M4x8 IWithWashed
Lead Cover
Blade Care
P H Screw M4x6 IWithWasher1
Tension Spring 5
safety COMl
Lever
Retaining Ring S-55
MAC1
37
38
39
40
41
42
43
44
45
46
41
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
100
-
E
1
1
1
1
4
1
1
1
4
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
-
DESCRIPTION
Outer Flange 65
H F H Bolt MBx20
Inner Flange 65
P H Screw M5x12 IWithWasher)
P. H. Screw M5x28 (WithWasher)
C H.Screw M8xm
Toothed Lock Washer 8
Rubber Ring 8
C H Screw M4x12 lWnhWasher)
Bearing Box
Spindle
Key 4
Ball Bearing 6204LLB
Retaining Ring R-47
Helical Gear 54
Retaining Ring S-M
Needle Bearing 1210
P. H. Screw M5xM lWithWasher1
Gear Housing (With Item 181
P. H. Screw M5xlO
Lever 98
H. Bolt M8x20
F. Washer 8
Bare
1. Screw M6xl5
F. Washer 8
S Washer 8
H Nut MB
1. Screw M6x15
S. Washer 6
F. Washer 6
Screw M8
Screw M4
S. Washer 4
Swnge
Grip 37
Ring 16 (Not Illustratedl
11

MAKflA LIMKED 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 worlananslup 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.
This Warranty does not apply where:
repairs have been made or attempted by others:
repairs are required because of normal wear and tear:
The tool has been abused, misused or improperly maintained;
alterationshave been made to the tool.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES FROM THE SALE OR USE OF THE PRODUCT.
THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THE TERM OF THIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES
OF “MERCHANTARILITY” AND “FITNESS FOR A SPECIFIC PURPOSE.”
~~
~- ~~
AFTER THE ONE-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.
maatam -,u.
11-8,3-chome, Sumiyorhi-cho,Anjo, Aichi 446, Japan
883189-069A PRINTED INJAPAN
1985-1 1-N