Makita M5802 Manual

Dimensions: mm (")
Length(L) 297 (11-3/4)
Width (W)
232 (9-1/8)
132 (5-3/16)
Height (H)
255 (10)
Models M5802 is 185mm (7-1/4") Circular Saw and has been developed as
Makita-mt-series.
Its main features are:
· New appearance; Features the same design concept as maktec/SSP-Makita brand
series; however, the logo has been replaced by “Makita-mt-” for new series
development.
· Orange housing
· Industrial performance and durability at less expense
· Ergonomically designed handle with Soft grip
· In compliance with the regulations of the EC directives
Model
Specification
Makita-mt-
M5802
Saw
blade
Type TCT saw blade
Number of teeth 12 *1
Diameter mm (") 185 (7-1/4) *2
Hole diameter mm (") 30 (1-3/16) *3
Continuous rating input (W)
1,050
Bevel angle : degree (°)
0-45
Maximum
cutting capacity
0 degrees mm (")
68(2-11/16")/66(2-5/8")
45 degrees mm (")
46(1-13/16")/44(1-3/4")
Power supply cord : m (ft)
2.0(6.6ft)
Dimensions (L x W x H) mm(")
297x232x255
(11-3/4"x9-1/8"x10")
Weight according to
EPTA-Procedure 01/ ver.2.1: kg(lbs)*4 4.0(8.8lbs)
*1 12 for European countries, 24 for Gulf countries, 40 forAsian countries
*2190mm for European and Gulf countries, 185mm (7-1/4") for Asian countries
*3 30mm for European countries, 20mm for Gulf and Asian countries
*4 Weight with Dust nozzle and TCT saw blade
Guide rule ............................... 1 pc
Hex wrench 5 .......................... 1 pc
Dust nozzle .............................. 1 pc (for European countries only)
TCT saw blade ........................ 1 pc
Note: The standard equipment may vary by country or model variation.
Dust nozzle with M5x 14WR P.H.screw................ 1 pc
March 2016
L
H
W
Voltage (V) Current (A) Cycle (Hz)
Continuous Rating(W)
Max Output (W)
Input
Output
110
10
50/60
1,050
650
1,300
120
8.5
50/60
----
570
1,300
220
5.0
50/60
1,050
650
1,300
230
4.8
50/60
1,050
650
1,300
240
4.6
50/60
1,050
650
1,300
M5802
185(7-1/4”)mm / 190(7-1/2”) Circular Saw
P1/ 8
1/ 12

P 2 / 12
Repair
[1] NECESSARY REPAIRING TOOLS
Code No. Description Use for
1R003 Removing Retaining ring S-38 from Bearing box
1R032 Removing Spindle from Helical gear 38
1R217
1R269
1R280
1R291
1R340
RETAINING RING PLIERS ST-2N
BEARING SETTING PLATE 8.2
RING 22
BEARING EXTRACTOR Removing Ball bearings
Removing Spindle from Helical gear 38
ROUND BAR FOR ARBOR 6-50
RETAINING RING S AND R PLIERS Removing / Assembling Retaining ring S-12
Removing / Assembling Bearing retainer 19-33BEARING RETAINER WRENCH
Supporting Bearing box, when disassembling Gear section
[2] LUBRICATION
Fig. 1
Item No. Description
Blade case complete Gear room Approx. 5 g
a littleWhole portionO ring 26 mounted in (20)
Reverse side view of (20)
Amount
Symbol of
lubricant
Portion to lubricate
Apply the following kinds of lubricant to the parts.
Makita grease FA. No.2 to the parts designated with black triangle to protect parts and product from unusual abrasion.
(20)
(20a)
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
(20)
Helical gear 38
(20a)
Index
[1] NECESSARY REPAIRING TOOLS P 2
[2] LUBRICATION
[3] DISASSEMBLY/ASSEMBLY P 3 - 4
[3]-1 Base
[3]-2-a Armature P 5 - 6
[3]-2-b Safety cover P 6 - 7
[3]-2-c Blade case complete P 7
[3]-3. Bearing box, Gear section P 8- 9
[3]-4. Adjustment of Lever plate P 10
Circuit diagram P 11
Wiring diagram P 12

P 3 / 12
Fig. 2
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Base
DISASSEMBLING
(1) Remove saw blade in accordance with the instruction manual. First, remove M8x24 Flat headsquare
neck bolt on Depth guide side, as shown in Fig. 2.
M8-13 Hex nut
3. Remove M8-13 Hex nut, and then, remove Flat washer 8.
Consequently, M8x24 Flat headsquare neck bolt may fall
onto reverse side of Safety cover.
See the illustration bellow.
Flat washer 8
4. Remove Rubber sleeve 6, unscrewing
one M6x20 Pan head screw.
5. Now Safety cover swing toward Angular
plate side. And M8x24 Flat headsquare
neck bolt can be removed.
Now, Base section is free from the
machine on the depth guide side.
M8-13
Hex nut
M8x24 Flat
headsquare
neck bolt
Lever plate
Depth guide side
Depth guide
Angular plate side
Angular plate
1. Loosen M8-13 Hex nut, by turning Lever plate.
See the illustration below.
2. Remove Bow stop ring E-12 by turning
it with slotted head screwdriver.
See the photograph below.
Lever plate
Bow stop ring E-12 Slotted head
screwdriver
Rubber sleeve 6
M6x20 Pan head screw
Safety cover
M8x24 Flat headsquare neck bolt
may fall onto reverse side of
Safety cover.

P 4 / 12
Fig.3
Fig.4
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Base
DISASSEMBLING
(2) Remove M5 Pan head screw on Angular plate side as shown in Fig. 3.
(3) Base section is removed from the machine, as shown in Fig. 4.
Depth guide side
Depth guide
Angular plate side
Angular plate
1. Fixing M5 Hex nut with Wrench 8,
unscrew M5 Pan head screw.
3. Now, Base section is free from the machine both on Depth guide side and Angular plate side in this step.
2. Remove M5 Pan head screw and
M5 Hex nut, while paying attention
not to lose Spring washer 5.
Wrench 8
Screwdriver
M5 Hex nut
M5 Pan head
screw
Angular plate
Blade case
M5 Pan head
screw
M5 Hex nut
Spring washer 5
Base section

P 5 / 12
Fig.5
Fig.6
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Base
ASSEMBLING
(1) Assemble Base by taking reverse step of Disassembling. Refer to Fig. 4, Fig. 3, Fig. 2.
DISASSEMBLING
1. Do not forget to mount Spring washer 5,
when assembling on Angular plate side.
2. Bow stop ring E-12 has to be mounted as shown in
the illustration below.
So, Bow stop ring E-12 can transmit the pressure
force from M8-13 Hex nut.
[3] -2-a Armature
Spring washer 5
M5 Hex nut
(1) Take out Armature as shown in Fig. 6.
M5x40 Pan head
screw ( 3 pcs.)
Motor housing
complete
1. First , remove Brush holder cap and
Carbon brush. And unscrew M5x40
Pan head screw.
2. Remove Motor housing
complete.
< Note >
Be careful, not to lose Flat washer 14, and O ring 18,
when separating Motor housing.
3. Pull off Armature assembly
from Gear room of Blade case.
Armature
Brush
holder cap
Carbon brush
Carbon brush
O Ring 18
Flat washer 14
Brush
holder cap
M5 Pan
head screw
< Note >
Pay attention to the matters in Fig. 5, when assembling Base.
Bow stop ring E-12
M8x24 Flat
headsquare neck bolt
M8-13 Hex nut Lever plate

P 6 / 12
Fig. 7
Fig. 8
Repair
[3] DISASSEMBLY/ASSEMBLY
ASSEMBLING
DISASSEMBLING
DISASSEMBLING
[3] -2-a Armature
[3] -2-b Safety cover
(2) Remove Ball bearings from the Armature as shown in Fig. 7.
(1) Mount Flat washer 10 to the drive end of Armature. And assemble Ball bearing 6000ZZ to the same end of
Armature. Refer to the right illustration in Fig. 7.
(2) Mount Insulation washer and Ball bearing 608ZZ to the commutator end of Armature. Refer to the left photograph
in Fig. 7.
Water pump pliers
1R269
1R269
2. Remove Ball bearing 6000ZZ with
1R269.
And then,take off Flat washer 10.
Claw
Ball bearing 608ZZ
1. The space between Ball bearing 608ZZ and Insulation washer
is too tight to engage the claw of 1R269.
Fixing the claw of 1R269 firmly with Water pump pliers,
remove Ball bearing 608ZZ.
Insulation washer
1. Remove Retaining ring S-38 from Bearing
box with 1R003.
2. Remove Safety cover from Bearing box,
while dis-linking from Tension spring 4
Ball bearing
6000ZZ
Flat washer 10
(3) Mount Armature to Blade case. Make sure that Shaft lock is mounted to the Blade case.
Refer to the right illustration in Fig. 6.
(4) Putting O ring 18 and Flat washer 14 into Bearing box section of Motor housing complete,
assemble Motor housing complete. Refer to center illustration in Fig. 6.
(5) Secure Motor housing complete with three M5x40 Pan head screws. And mount Carbon brush and Brush holder cap.
Refer to left illustration in Fig. 6.
Retaining
ring S-38
Disassemble Safety cover as shown in Fig. 8.
Safety cover
Tension spring 4
Thickness ring

P 7 / 12
Fig. 9
Fig. 10
Repair
[3] DISASSEMBLY/ASSEMBLY
ASSEMBLING
[3] -2-b Safety cover
DISASSEMBLING
[3] -2-c Blade case complete
Assemble Safety cover as shown in Fig. 9.
2. Pass the hook of Tension spring 3
through the hole of Safety cover,
by approaching from Bearing box
side.
3. Pass the another hook of Tension
spring 3 thruogh the hole of Blade
case, by approaching from the
Safety cover side.
4. Secure the Safety cover with
Retaining ring S-38.
1. Make sure, that Thickness
ring is mounted to Bearing
box section in advance.
Retaining
ring S-38
Thickness ring
(1) Make Base free from Blade case complete on Depth guide side. See Fig. 2.
(2) On Angular plate side, make Base free from Blade case complete. See Fig. 3.
So, Base can be separated from Blade case complete. See Fig. 4.
(3) Disassemble Safety cover as shown in Fig. 8. And Blade case complete can be disassembled as shown in Fig. 10.
1. First , remove Brush holder cap
and Carbon brush. And unscrew
M5x40 Pan head screw.
2. Disassembling Motor housing
complete, remove Armature
assembly and Shaft lock.
Pay attention, not to lose Flat
washer 14, O Ring 18 and
Compression spring 5.
3. Unscrewing M5x16 Pan head
screw, remove Bearing box
section. Now, Blade case
complete can be replaced.
M5x40 Pan head
screw ( 3 pcs.)
Carbon
brush
Carbon brush
Shaft lock
Compression spring 5
Brush
holder cap
Flat washer 14
O Ring 18
M5x16 Pan head
screw ( 2 pcs.)
Bearing box
Armature
assembly

P 8 / 12
Fig. 11
Repair
[3] DISASSEMBLY/ASSEMBLY
DISASSEMBLING
(1) Assemble Bearing box to Blade case complete. Refer to right illustration in Fig. 10.
(2) Assemble Compression spring 5 and Shaft lock to Blade case complete.
And then, assemble Armature assembly to Blade case complete.
Putting O ring 18 and Flat washer 14 into Bearing box of Motor housing
complete, assemble the Motor housing complete to Blade case complete.
So, Base can be separated from Blade case complete. See Fig. 4.
(3) Fasten Motor housing complete to Blade case complete with three M5x40 Pan head
screws. Refer to left illustration in Fig. 10.
(4) Further step of Assembling can be proceeded by taking reverse step of Disassembling. Refer to Fig. 3, Fig. 2.
ASSEMBLING
[3] -2-c Blade case complete
[3] -3 Bearing box, Gear section
Refer to center illustration in Fig. 10.
(1) Disassemble Safety cover as shown in Fig. 8.
(2) Disassemble Bearing box from Blade case complete. And remove Ball bearing 606ZZ and Retaining ring S-12
as shown in Fig. 11.
(3) Disassemble Spindle and Helical gear 38 from Bearing box as shown in Fig. 12.
Bearing box
Ball bearing 606ZZ
Retaining
ring S-12
Thickness ring
4. Remove
Thickness ring.
Spindle
Helical gear 38
1R269
1. Unscrewing M5x16 Pan head screw,
remove Bearing box.
2. Remove Ball bearing
606ZZ with 1R269.
3. Remove Retaining
ring S-12 with 1R291.
1R291
M5x16 Pan head screw
(2 pcs.)
1R280
Fig. 12
Bearing box
Helical gear 38
1R032
1R217
Arbor press
1. Put Bearing box on 1R217, then applying 1R032 to the stepped portion
of Spindle as illustrated below, strike the 1R032 with Arbor press to push
out Spindle halfway as illustrated below.
2. Replacing with 1R032,
apply 1R280 to Spindle.
Press the 1R280 with Arbor press.
Now, Spindle is disassembled
from Helical gear 38.
Spindle, pushed
out halfway
Helical gear 38
Ring 12
Spindle
< Note >
Ball bearing 6201ZZ in Bearing box
has been damaged by the shock of Arbor press.
Do not re-use the removed one.

P 9 / 12
Fig. 13R
Fig. 13F
Fig. 14
Repair
[3] DISASSEMBLY/ASSEMBLY
DISASSEMBLING
ASSEMBLING
[3] -3 Bearing box, Gear section
(4) Remove Ball bearing 6201ZZ as shown in Fig. 13R.
(1) Assemble Bearing box section. Refer to Fig. 13R.
(2) Mount Helical gear 38. Refer to Fig. 12.
Secure the helical gear with Retaining ring S-12. And assemble Ball earing 606ZZ.
Refer to the illustrations in Fig. 11.
1. Fix Bearing box with Vise. Applying 1R340 to Bearing retainer 19-33, turn the tool.
So Bearing retainer 19-33 is removed from Bearing box. Replace Ball bearing 6201ZZ.
< Note >
Do not use the removed Ball bearing 6201ZZ. Because the Ball bearing has been damaged
in the step of Disassembling Spindle and Helical gear 38 from Bearing box. See Fig. 12.
Bearing box
Ball bearing 6201ZZ
(damaged)
Bearing retainer 19-33
Drum portion
< Note >
Do not hold Bearing box at its drum
portion. Because, it is difficult to
stabilize Bearing box, when repair work.
< Note >
Hold Bearing box at its straight
flanged portion, for keeping
stabilized condition, when repair
work.
1R340
Straight flanged portion
Wrong
Right
Thickness ring
(3) Do not forget to assemble thickness ring. See Fig. 14.
Bearing box
Turn clockwise
for unscrewing.
12
3
6
9

P 10 / 12
Fig. 15
Repair
[3] DISASSEMBLY/ASSEMBLY
ADJUSTMENBT
[3]-4. Adjustment of Lever plate
30 degrees
Adjust Lever plate so that cut depth, desired by user, can be set at the position shown in the photograph below.
See Fig. 15.
Lever plate

P 11 / 12
Fig. D-1
Circuit diagram
White
Blue
Brown
AWG 18
AWG 18
AWG 18
AWG 18
< Note >
AWG: American Wire Gage
Field
Power supply cord
Circuit of Inside of Switch
AWG 20
Switch
Item No.
(1)
(2)
(2)
(2)
(1)
(1)
Noise suppressor
AWG 20
Color index of lead wires' sheath
Black
Insulated terminal (M3.5)
Symbol of electrical parts
Spring terminal

P 12 / 12
Fig. D-2
Wiring diagram
Lead wire
holder (B)
Lead wire
holder (A)
Put Field lead wires to
Lead wire holders (A),
(B) in Handle section.
Put sag of the Field lead
wires to the space between
Lead wire holder (B) and
Power supply cord.
Field lead wire
Pass Field lead wires through grooves,
tightening them in Motor housing
complete.
Groove
Groove
Switch
Motor housing
complete
Wiring in Motor housing complete
Noise suppressor
Power supply cord