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)

Continuous Rating (W)

Voltage (V) Cycle (Hz) Input Output Max. Output (W)

110

120

240

7.5

50/60

1,650

---

1,700

1,000

1,100

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

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

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

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

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

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

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

5104 220-240V (for Australia etc.)

Fig. D-1B

Fig. D-2B

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