Makita 5402-A User manual

Circular Saw
at 90"
diameter
415 mm (16-5/16") MODEL 5402-A
Equippedwith Electric Blade Brake
speed length weight
at 45"
INSTRUCTION MANUAL
415"
(1 6-5/16")
S PECl F ICATIONS
157.5 mm 106mm 2,200 615mm 14 kg
(6-3/16") (4-3/16") R/min. (24-3/16") (30.8
Ibs)
* Manufacturer reservesthe right to changespecificationswithout notice.
Note: Specifications may differ from country to country.

IMPORTANT SAFETY INSTRUCTIONS
WARNING: When using electric tools, basic safety precautions should always
befollowed toreducethe risk of fire, electric shock, and personalinjury, including
the following:
READ ALL INSTRUCTIONS.
1. KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries.
2. 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.
3.
KEEP CHILDREN AWAY. All visitors should be kept away from work area.
Don't let visitors contact tool or extension cord.
4.
STORE IDLE TOOLS. When not in use, tools should be stored in dry, and
high or locked-up place
- out of reach of children.
5.
DON'T FORCE TOOL. It will do thejob better and safer atthe ratefor which
it was intended.
6. USE RIGHT TOOL. Don't force small tool or attachment to do the job of
a heavy-duty tool. Don't use tool for purpose not intended.
7.
DRESS PROPERLY. Don't wear looseclothing or jewelry. They can be caught
in moving parts. Rubber gloves and non-skid footwear are recommended
whenworkingoutdoors. Wear protective haircovering tocontainlonghair.
8. USE SAFETY GLASSES. Also use face or dust mask if cutting operation
is dusty.
9. DON'T ABUSE CORD. Nevercarry tool by cord or yank it todisconnect from
receptacle. Keep cord from heat, oil, and sharp edges.
IO. 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.
11. DON'T OVERREACH. Keep proper footing and balance at all times.
12. MAINTAIN TOOLS WITH CARE. Keeptoolssharp and clean for better and
safer performance. Follow instructions for lubricating and changing ac-
cessories. Inspect tool cords periodicallyand ifdamaged, have repaired by
authorized service facility. Inspect extension cords periodically and replace
if damaged. Keep handles dry, clean, and free from oil and grease.
13. DISCONNECT TOOLS. 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 removed from tool before turn-
ing
it on.
15. AVOID UNINTENTIONALSTARTING. Don't carry plugged-intool with finger
on switch. Be sure switch is OFF when plugging
in.
16. OUTDOOR USE EXTENSION CORDS. When tool is used outdoors, 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.
L

18.
19.
20.
21.
CHECK DAMAGEDPARTS. 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 its intended function. Check for alignment
of movingparts, 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
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.
GUARDAGAINST ELECTRIC SHOCK. Preventbody contact withgrounded
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 extension cords which have three-
prong grounding-type plugs and three-pole receptacles which accept the
tool's plug. Replace or repair damaged or worn cord immediately.
VOLTAGE WARNING: Before connectingthe 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.
For
all grounded tools with American type plug.
GROUNDING INSTRUCTIONS: This tool should be groundedwhile in use toprotect the operator
from electric shock. The tool
is equipped witha three-conductor cord and three-pronggrounding-
type plug tofit the proper grounding-type receptacle. The green (or green and yellow) conductor
in the cord
is the grounding wire. Never connect the green (or green and yellow) wire to a live
terminal. Your unit
is for use on 115 volts andhas a plug that looks like Fig. "A".
An adapter, Fig.
"B" and "C" is available for connecting Fig. "A" type plugstotwo-prongrecep-
tacles. The green-colored rigid ear, lug, etc., extending from the adapter must
be connectedto a
permanent ground, such as a properly grounded outlet
box.
FIG. A 1- -7 FIG. B
I
FIG. C
Adapter
FIG. A
3
- GroundingMeans
GroundingBlade Cover of Grounded Outlet
Box
3

Use Of Extension Cord
If the extensioncord is intended to be used outdoors, the cord shall be marked with 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 inline voltage resulting in loss of power
and over-heating. Makesure the extensioncord
is ingood condition beforeusing. Use the
table belowtodeterminethe proper wire
size requiredin the extensioncord.
Ampere rating 0- 2.10- 3.50- 5.10- 7.10-
(on nameplate) 2 .oo 3.40 5 .OO 7.00 12.00 12.10-
16.00
Ext. Cable Length I Wire Size (AmericanWire Gauge)
~~
25 Ft.
50 Ft.
75 Ft.
100 Ft.
150 Ft.
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
- -
ADDITIONAL SAFETY RULES
1. Keep Guards In Place and InWorkingOrder.
Never wedge or
tie lower guard open. Check operation of lower guard before each
use. Don’t use if lower guard does notclose briskly over saw blade. CAUTION:
If saw
is dropped, lower guard may be bent, restrictingfull return.
2. Keep Blades Clean and Sharp.
Sharp blades minimizestallingand kickback.
3. 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 materialwhen blade
is moving. CAUTION : Blades coast
after turn off.
4. Support Large Panels.
Large panels must be supported
as
shown in Fig. 1 to minimizethe risk of
blade pinchingand kickback.
When cutting operation requires the
resting of the saw on the work piece,
the saw shall be rested on the larger
portion and the smaller piececut off.
A typical illustration of support large
panels.
To avoid kickback, support the panel
near
the cut.
Fig.
4

5. Use Rip Fence.
6. GuardAgainst Kickback.
Always use
a fence or straight edge guide when ripping.
Kickback occurs when the saw
stalls rapidly and is driven back towards the operator.
Release switch 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.
7. Lower Guard. Raise lower guard with the retracting handle.
8. Adjustments. Beforecuttingbe sure depth and bevel adjustments are tight.
9. Use Only Correct Blades In Mounting. Don't use blades with incorrect size holes.
Never use defective or incorrect blade washers or bolts.
10. Avoid Cutting Nails. Inspectfor and remove all nailsfrom lumber before cutting.
11. When operating the saw, keep the cord
away from the cutting area and posi-
tion
it so that it will not be caught
on the workpiece during the cutting
operation.
Operate with proper hand support,
proper work support, and supply cord
routing away fromthe work area.
WARNING:
It is important to support the work
properly and toholdthe saw firmly to
prevent
loss of control which could
cause personal injury. Fig.
2 illustrates
typical handsupport
of the saw.
A typical illustration of proper hand
support,
work support, and supply
cord routing.
Fig.
2
12. Never attempt tosaw with the circular
saw held upside down in
a vise. This
can lead to serious accidents, because
it is extremely dangerous.
Fig. 3
13. Before setting the tool downafter completing a cut, be sure that the lower (telescop-
SAVE
THESE INSTRUCTIONS.
ing) guard has closed and the blade has cometo
a complete stop.
5

HOW TO USE
CAUTION :
Never wear gloves when operatingor adjustingthe saw.
When sawing
Grasp the rear handle with 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 switch the
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
Before plugging in the tool, check the trig-
ger action. Pull the trigger inthe handle to
be sure that
it reverts to the OFF position
after being released.
The switch
is made to prevent unintended
or careless switch-on that might endanger
the operator or bystanders. The lock-off
button must be pressed in and the trigger
in the handle pulled for the tool to be
switchedon. When the trigger inthe handle
is released, the lock-off mechanism cuts in
automatically to lock the tool in the
OFF
condition.
Fig. 1
Fig. 5
CAUTION :
Grip the tool handle firmly when starting or stopping the tool, since there is an initial
and final reaction.
6

For the cutting position
There is a slot on the front base. The right
side of the slot
is straight.
Align
it with your cutting line on the
wood, if you intend to do straight cutting.
For bevel cutting, use the left side
of the
notch for 45" cuts.
Adjusting cutting depth
By raising the lock lever and loosening the
screw holding the 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.
Replacing saw blade
Do not replace with a saw bladelarger than
415 mm(16-5/16").
Two wrenches are provided. Use the larger
one
(22) to grip the flange hard and the
smaller one (13) to loosen the bolt in the
directionof the saw revolution.
Remove blade.
(See arrows in photo 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.
For 45' bevel ~ For straight
Base plate
Fig.
6
Fig.
Fig.
8
7

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 tiltingaccordingly,
then retighten the wing nuts firmly.
Fig. 9
MAINTENANCE
CAUT ION :
Always be sure that the tool is switched off and unpluggedbefore attempting to perform
inspection,andmaintenance.
Carbon brushes
Replace carbon brushes when they wear
down to about 6 mm
(1/4") or sparking
will occur. Both brushes should be changed
at the same time. Use only Makita-recom-
mendedcarbon brushes.
U
6 mm (1 /4")
I
Fig. 1(
Any other maintenanceshould be performed by an authorized service representative.
8

ACCESSORIES
CAUTION:
The accessories or attachments specified in this manual are recommendedfor
use with your Makita
Circular Saw. The
use of any other accessories or attachments might increase the risk of injury to
persons. The accessories or attachmentsshould be used only inthe proper and intended manner.
Saw blades
Cross-cutsaw blade
For smoother cross-graincuts.
Makes smoother cuts than
combination blade.
Rip saw blade
For faster cutting with grain.
Like combination bladeintooth
shape, but has larger teeth for
better chip clearanceand
t
minimize binding.
NO. 1 ':iiyr 1 di!+r 1 t:; I Part No.
792115-4
415-2 (16-5/16") (31/32")
NO. 1 "i,["r 1 diF.r 1 t:k 1 Part No.
(mm) (mm)
792114-6
415-3 (16-5/16") (31/32")
Chisel tooth combination saw blade
For riDand cross-cutwork.
NO. 1 "iy:"r 1 di7::er I t: Part No.
(mm) (mm)
792116-2
415-7 (16-5/16") (31/32")
Carbide-tipped saw blade
Fastest, smoothest, longer sawing
without bladesharpening.
Cuts wood, dry wall, plastic,
hardwood, etc
*Guide rule (Part No. 164019-4)
NO. 1 "i,"' 1 di!::er 1 tzi, 1 Part No.
(mm) (mm)
792118-8
415-1 (16-5/16") (31/32")
*Wrench 22 (Part No. 781011-1)
Wrench 13 (Part No. 781203-2)
9

Jan.-12-'84 US
415 mm (16-5/16")
CIRCULAR SAW
Model 5402-A
Note: The switch, noise suppressor and other part configurations
may differ from country to country.
10

MODEL 5402-A
""0" $tD DESCRIPTION
MACHINE
~
1 1 Blade Case
2 1 Noise Suppressor
3 1 Handle Cover
4 1 P H Screw M4x28 (With Washer)
5 3 P H Screw M4xl6 [With Washer)
6 2 P H Screw M4x8 (With Washerl
7 1 Lead Cover
8 2 P H Screw M4x8 [With Washer)
9 1 Switch
10 2 P H Screw M4x8 (WithWasher)
11 1 Plate
12 2 P H Screw M4x12 [With Washer)
13 1 Strain Relief
14 1 Cord Guard
15 1 CORD ASSEMBLY
[AssembledCord
Plug & Item 14)
16 1 Grip
17 1 P H Screw M6xl6 [With Washerl
18 1 Sleeve 7
19 1 Makita Label
20 1 P H Screw M4x8 [With Washer]
21 1 Chip Guide
22 2 P H Screw M6x30
23 2 S Washer 6
24 1 P H Screw M6x25
25 2 P H Screw M6x25
26 2 S Washer 6
27 4 Rivet 0-5
28 1 Name Plate
29 2 Insulation Washer
30 2 Rubber Pin 6
31 1 Bearing Cover 42
32 2 P H Screw M5x12 [With Washerl
33 1 Motor Housing [With Brush Holder x 2
S Screw M5x8 & Item 301
34 2 Carbon Brush
35 2 Brush Holder Cap
37 2 P H Screw M5x85 (WithWasher)
38 1 Ball Bearing 6200LLB
39 1 Dust Seal 10
40 1 ARMATURE ASSEMBLY
41 1 Fan 92
42 1 Dust Seal 15
43 1 Ball Bearing 6202LLB
44 1 Baffle Plate
45 1 H F H BoliM8x20
36 1 FIELD ASSEMBLY
(Assembled Items 38 - 431
Note The switch noise suppressor and other part specifications may
Jan -12-'84 US
DESCRIPTION
MACHINE
46 1 Outer Flange 90
47 1 Inner Flange 90
48 4 C H Screw M4x12 [With Washer)
49 1 Bearing Retainer 26 73
50 1 Safety Cover
51 1 Tension Spring 7
52 2 P H Screw M4x8 [With Washerl
53 1 Ball Bearing 6204LLB
54 1 Ring 20
55 4 P H Screw M5x25 (With Washerl
56 1 P H Screw M5xB (WithWasher1
57 2 P H Screw M5x35
58 2 S Washer 5
59 1 Ball Bearing 6201LLB
60 1 Retaining ring S-20
61 1 Gear Housing [With Item 891
62 2 S Washer 5
63 2 P H Screw M5x25
64 1 Helical Gear 73
65 1 Gear Housing Cover
66 1 Woodruff Key 4
67 1 Spindle
68 1 Rubber Ring 8
69 1 Sleeve 8
70 1 F Washer 8
71 1 P H Screw M8x25 [With Washerl
72 1 Lever 96
73 1 P H Screw M5x10
14 1 H Bolt M8x20
75 1 F Washer 8
76 1 T Screw M6x25
77 1 Sleeve 7
76 1 S Washer 6
79 1 F Washer 6
80 1 F Washer 8
81 1 H Nut M8
82 1 T Screw M6x15
83 1 S Washer 8
84 1 T Screw Max20
85 1 S Washer 8
86 1 F Washer 8
87 1 Base
88 1 Screw M8
89 1 P H Screw M4x8 [With Washerl
~
differ from country to country
11

MAKITA LIMITED ONE YEAR WARRANTY
Warranty Policy
Every Makita tool is thoroughlyinspected 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, toone 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:
e repairs are required because of normal wear and tear:
e The tool has been abused, misused or improperly maintained;
e 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 OFTHE PRODUCT. THIS DISCLAIMER
APPLIESBOTH DURING AND AFTER THE TERM OF THIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES
OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,”
AFTER THE ONE-YEAR TERMOFTHIS 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 incidentalor 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.
h
Makita Corporation
3-11 -8, Sumiyoshi-cho,
Anjo, Aichi
446 Japan
883191 - 365 0
PRINTED IN JAPAN
1991 - 4 - N