Makita BJR141 Handbuch

Models No.

Description

PRODUCT

TECHNICAL INFORMATION

CONCEPT AND MAIN APPLICATIONS

Specification

Standard equipment

Optional accessories

P 1 /10

Model BJR141 has been developed as the successor model to

the current Model JR140D 14.4V cordless recipro saw.

While having the same basic construction as Model JR140D,

features the following additional advantages;

Lightweight design achieved by using Li-ion battery

as a power unit instead of Ni-cd battery.

More work amount on a single full battery charge

Non-skid handle angled and contoured ergonomically for

best-fitting to reciprocating cutting

Dimensions: mm (")

Width (W)

Height (H)

Length (L) 466 (18-3/8)

79 (3-1/8)

226 (8-7/8)

Note: The standard equipment for the tool shown above may differ from country to country.

BJR141

Cordless Recipro Saw

Recipro saw blade for metal ............................................................... 1

Recipro saw blade for composite material (wood plus metal) ........... 1

Plastic carrying case ........................................................................... 1

Charger DC18RA

Charger DC24RC

Charger DC24SC

Li-ion battery BL1430

Assorted recipro saw blades

Battery

Electric brake

Max cutting capacities: mm (")

[when cutting with a 160mm blade] pipe

Length of stroke: mm (")

Cell

Voltage: V

Capacity: Ah

Li-ion

14.4

3.0

Yes

Variable speed Yes

Net weight*: kg (lbs)

*Includes battery BL1430

3.1 (6.8)

90 (3-1/2)

wood 90 (3-1/2)

23 (7/8)

No load speed: min-1=spm 0 - 2,700

Max output (W) 280

BJR141RF

BJR141Z

BL1430DC18RA

NoNo

Model No. type quantity

Charger

Yes

Plastic

carrying case

BJR181RFE 2

Battery

This product is available in the following variations.

P 2 /10

Repair

[2] LUBRICATION and ADHESIVE

Lubrication: Apply Makita grease FA No.2 to the following portions designated with the black triangle to protect

parts and product from unusual abrasion. (Fig. 1)

Adhesive: When reusing threadlocker coated screws, be sure to apply adhesive before tightening.

Recommended adhesives are Threebond 1342 or Loctite 242.

[1] NECESSARY REPAIRING TOOLS

CAUTION: Remove recipro saw blade and battery cartridge from the machine

for safety before repair/ maintenance !

Fig. 1

Blade clamp section

4 Shoulder pin 5

Slider complete Surface that contacts Needle bearing 708 (Put approx. 9g.)

Pin head that contacts Driving sleeve

2 Gear housing cover complete Inside surface of the lip portion of Dust seal 14

(Any kind of lubricating grease can be used.)

43 Gear housing Gear room (Put approx. 9g.)

1R030 Bearing setting pipe 2.5-17.2 Press-fitting Dust seal 14 in Gear housing cover complete

Bearing extractor

Retaining ring S and R pliers

1R269 Removing Ball bearing 6001DDW from the drive-end of Armature

1R291 Removing/installing Retaining ring S-18 from/on Blade clamp section

--- Recipro saw blade Assembling Pin 3 to Blade clamp section

Code No. Description Use for

Item No. Description Portion to be lubricate

Dust seal 14

Driving sleeve

Needle bearing 708

P 3 /10

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Blade Clamp Section

1) Remove Shoe as illustrated in Fig. 2.

Note: If the Blade clamp section is positioned inside Gear housing, pull it out of Gear housing.

2) Remove Retaining ring S-18 using 1R291. The following parts can now be removed (Fig. 3):

Driving sleeve, Shoulder pin 5, Compression spring 6, Pin 3 (of 6mm length), Guide sleeve, Driving sleeve guide

Note: Sleeve is still locked on Slider in this step.

3) Unlock Sleeve from Slider as illustrated in Fig. 4.

DISASSEMBLING

Fig. 3

Fig. 2

Fig. 4

Driving sleeve Shoulder pin 5

Compression spring 6

Driving sleeve guide

Pin 3 (of 6mm length)

Guide sleeve

Retaining ring S-18

Sleeve

Slider

Sleeve

Slider

Pin 3

(of 19.8mm length)

Pull up Sleeve until it stops against

Pin 3 (of 19.8mm length).

Turn Sleeve in the direction

of the arrow.

Sleeve is now unlocked.

Turn Lever 60 in the direction of the arrow.

Remove Pan head screw M4x10.

Remove Lever 60.

Note: Hex nut M4 will be left in Lever 60.

Be careful not to lose it.

By unscrewing Hex bolt M8x25, Shoe can now

be removed as illustrated below.

Hex nut M4

Pam head screw

M4x10

Shoe Blade clamp section

Lever 60

[View from top]

Hex bolt M8x25

Sleeve 9

Lock plate

Inner plate

Blade clamp section

Shoe Insulation cover

Insulation cover

P 4 /10

Repair

[3] -1. Blade Clamp Section (cont.)

ASSEMBLING

1) Assemble Torsion spring 17 to Slider then Sleeve to Slider as illustrated in Fig. 7.

Important: Torsion spring 17 is not reversible when assembled to Slider.

2) Put Compression spring 2 into the slit of Slider by provisionally locking Sleeve with Pin 3 (of 19.8mm length). (Fig. 8)

Fig. 8

Fig. 7

Slider

Shoulder pin 5

insertion hole

Torsion spring 17

Put this end in

the slit of Slider.

Sleeve

hole

Gear housing

cover complete

Turn Sleeve in the direction

of the arrow so that Pin 3

insertion hole can be seen.

Insert Pin 3 (of 19.8mm length) into

the hole provisionally.

Note: Be sure that the top of Pin 3

is not seen in the slit of Slider.

Sleeve

Put Compression spring 2 into

the slit of Slider.

Pin 3 (of 19.8mm length)

Compression

spring 2

Be sure that this end is

positioned on the opposite

side to Shoulder pin 5

insertion hole.

Put this end of

Torsion spring 17

into the hole of

Sleeve.

4) While putting your finger on the top of Slider to close the slit of Slider, remove Pin 3 (of 19.8mm length) by pushing

with a thin bar. (Fig. 5)

Note: Be sure to put your finger on the top of Slider or Push plate will pop out from the slit of Slider.

5) Remove Sleeve and Torsion spring 17 from Slider. Take out Push plate and Compression spring 2 from the slit of

Slider. (Fig. 6)

Sleeve

Torsion

spring 17

Fig. 5 Fig. 6

Slider

Sleeve

thin bar

Pin 3

(of 19.8mm length)

Push plate

Compression

spring 2

P 5 /10

Repair

[3] -1. Blade Clamp Section (cont.)

3) Install Guide sleeve on Sleeve provisionally. Put Push plate into the slit of Slider as illustrated in Fig. 9.

Note: 1. Push plate is not reversible when installed.

2. Guide sleeve is used as a jig in this step. Do not assemble to Slider yet.

4) Insert Push plate straight into Slider using recipro saw blade until the hole of Push plate is aligned with the hole of Slider.

Insert Pin 3 (of 19.8mm length) through the holes of Push plate and Slider. (Fig. 10)

5) Remove Guide sleeve, and install Driving sleeve on Sleeve provisionally. Then lock Sleeve as illustrated in Fig. 11.

Note: Driving sleeve is used as a jig to lock Sleeve in this step. Do not assemble to Slider yet.

Fig. 10

6) Remove Driving sleeve.

7) Assemble the following parts to Slider (Refer to Fig. 3.):

Driving sleeve guide, Guide sleeve, Shoulder pin 5,

Compression spring 6, Pin 3 (of 6mm length)

8) Install Driving sleeve on Guide sleeve and secure with

Retaining ring S-18 using 1R291.

Note: When installing Driving sleeve, fit its protrusions

in the notches of Sleeve and Driving sleeve guide.

(Fig. 12)

Pin 3 (of 19.8mm length)

Fig. 9

Fig. 12

Fig. 11

Push plate

Guide sleeve

Pin 3

(of 19.8mm length)

This protrusion must

face the blade side.

Compression spring 2

Sleeve

hole of Slider

recipro saw blade

Push Sleeve towards

Gear housing side.

Hold Driving sleeve and turn it together with Sleeve

in the direction of the arrow until Sleeve stops against

Pin 3 (of 19.8mm length). Sleeve is now locked.

Driving sleeve

Driving sleeve guide

Sleeve

Driving sleeve

Sleeve

Pin 3

(of 19.8mm length)

[Gear housing side]

protrusion

notch

P 6 /10

Repair

[3] -2. Slider Section

1) Remove Shoe. (See Fig.2in page 3.)

2) Remove Blade clamp section. (See [3] -1. Blade Clamp Section in pages 3 and 4.)

3) Remove Insulation cover;

If replacing with new one, cut away using cutter knife.

If reusing removed Insulation cover, remove as illustrated in Fig. 13.

4) Separate Gear housing cover complete from Gear housing

by unscrewing four M5x18 Pan head screws. (Fig. 14)

5) Remove two Plates that fix Plane bearing 14 by unscrewing

four M5x16 Pan head screws.

Remove Plane bearing 14 on the Motor housing side. (Fig. 15)

6) Move Slider towards the Motor housing side.

Slider can now be removed together with Plane bearing 14 on

the blade side by pulling in the direction of the gray arrow.

(Fig. 16)

Fig. 13

Fig. 15 Fig. 16

Fig. 14

DISASSEMBLING

raised portion (A)

raised portion (B)

Insulation cover,

viewed from rear

Insulation cover has two raised

portions on its inside surface to

prevent from falling off from

the machine.

Insulation cover

Turn Insulation cover inside out

by hand until the raised portion (A)

is reached.

Pull Insulation cover in the direction

of the arrow bit by bit while levering

off from Gear housing section using

two slotted screwdrivers.

Gear housing section

Pan head screw M5x16 (4pcs)

Plate (2pcs)

[blade side]

[Motor housing side]

Plane bearing 14

Slider

Gear housing

cover complete

Plane bearing 14,

on the blade side Slider

Pan head screw M5x18 (4pcs)

Slider section

Gear housing

cover complete

Gear housing

P 7 /10

Repair

[3] -2. Slider Section (cont.)

Do the reverse of the disassembling steps.

Note 1: If replacing Dust seal 14 of Gear housing cover complete, press-fit using 1R030 as illustrated in Fig. 18.

Note 2: Plane bearing 14 is not reversible when assembled to Slider. Be sure to assemble each Plane bearing 14 to Slider

so that the stepped end of each Plane bearing is placed as illustrated in Fig. 19.

Note 3: Apply threadlocker to four M5x16 Pan head screws when fastening Slider section to Gear housing cover complete.

(Recommended adhesives: Threebond 1342, Loctite 242) (Fig. 20)

Note 4: Do not to forget to apply Makita grease FA No.2 to the crank portion of Slider. (Fig. 20)

Note 5: When assembling Gear housing cover complete to Gear housing, tighten four M5x18 Pan head screws while

pushing Gear housing cover complete against Motor housing (Fig. 21).

Note 6: Apply water or soap water to the inside surface of Insulation cover for easy installation over Gear housing section.

Fig. 22

ASSEMBLING

[3] -3. Spiral Bevel Gear Section

1) Remove Plate C from Gear housing by unscrewing two M5x12 Hex socket head bolts. Remove Spiral bevel gear section

from Gear housing by unscrewing three M5x8 Pan head screws. Remove Needle bearing 708. (Fig. 22)

DISASSEMBLING

Hex socket head bolt

M5x12

Gear housing

Fig. 18 Fig. 19

Fig. 20 Fig. 21

Pan head screw

M5x16 (4pcs)

Gear housing

cover complete

Plane bearing 14

[blade side]

[Motor housing side]

stepped end

Slider

: portion to apply threadlocker

: portion to apply Makita grease FA No.2

Plate C

Pan head screw M5x8 (3pcs)

Spiral bevel gear section

Needle bearing 708

Gear housing

cover complete

Dust seal 14

1R030

tapered end

Fit the tapered end of 1R030 to Dust seal 14.

Gear housing

cover complete

Motor housing

Pan head screw M5x18 (4pcs)

Gear housing

P 8/10

Repair

[3] -3. Spiral Bevel Gear Section (cont.)

Fig. 26Fig. 25

Fig. 28Fig. 27

[3] -4. Motor Section

2) Fix Spiral bevel gear section in vise by clamping the flats of Gear shaft, then remove Torx socket head bolt M6x15

using Torx screwdriver applicable to T20 Torx socket. (Fig. 23)

Note: Securely fit Torx driver in the socket of Torx socket head bolt M6x15 because Threadlocker is applied to the bolt.

Spiral bevel gear section can now be disassembled as illustrated in Fig. 24.

DISASSEMBLING

1) Remove Carbon brushes. Turn Insulation cover inside out as illustrated in Fig. 25.

2) Remove Motor housing and Baffle plate by unscrewing four 5x35 Tapping screws. (Fig. 26)

3) Separate Armature from Gear housing by unscrewing two M4x12 Pan head screws. (Fig. 27)

4) Remove two E-10 Stop rings. Remove Ball bearing 6001DDW from Armature shaft using 1R269.

Bearing retainer B and Fan guide can now be removed. (Fig. 28)

DISASSEMBLING

Fig. 23 Fig. 24

Torx socket head bolt M6x15

Spiral bevel gear 48

Bearing retainer A

Ball bearing 6000LLB

Ball bearing 6900LLB

Ring 10

Gear shaft

Do the reverse of the disassembling steps.

Note: When tightening Torx socket head bolt M6x15, be sure to apply Threebond 1342 or Loctite 242 to the threaded

portion of the bolt.

ASSEMBLING

Gear shaft

Vise

Torx socket head bolt M6x15

(with T20 Torx socket)

Insulation cover

Tapping screw

5x35 (4pcs)

Motor housing

Armature

Stop ring E-10

Ball bearing 6001DDW

Baffle plate

Pan head screw M4x12

Gear housing

Fan guide

Bearing retainer B

P 9/10

Repair

[3] -4. Motor Section (cont.)

Do the reverse of the disassembling steps.

Note: When inserting Armature into Motor housing, Armature will be pulled strong towards Motor housing

by the magnet force of Yoke unit. Be careful not to damage the copper wire of Armature or not to pinch

your fingers.

ASSEMBLING

Terminal

Circuit diagram

Color index of lead wires' sheath

Black

Red

Brush holder, Left

Brush holder, Right

Left side

Heatsink

Right side

Brush holder, Left Brush holder, Right

Switch

FET

Left side Switch

Right side

Terminal

(+) Terminal (-) Terminal

Fig. 29

P 10/10

Wiring diagram

2) Handle L

1) Motor Housing

boss

rib on Motor housing

lead wire holder

on Motor housing

Switch

Route all lead wires between the rib and the boss.

Assemble Insulated connectors to

Switch terminals at such an angle

that the Insulated connectors do not

touch the rib.

Motor housing

Brush holder, right

Brush holder, left

lead wire holder

on Bush holder

red black

Route two Lead wires (black, red) from Brush holder as illustrated in Fig. 30.

Fix with the lead wire holder

on Motor housing.

Do not route over the rib

on Motor housing.

Fix with the lead wire holder

on Brush holder.

Handle L

rib

Terminal

Fig. 30

Fig. 31

The flag connector has to be so connected that

the wire connecting portion is positioned on

the side of pole marks of Terminal.

Flag connector

Terminal

Connecting Flag Connector to Terminal

Wire connecting portion

Pole mark

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