makita DJS161 Cordless Metal Shear Instruction Manual

: June 17, 2024
: Makita

Table of Contents

makita DJS161 Cordless Metal Shear
Product Information
Product Usage Instructions
FUNCTIONAL DESCRIPTION
Switch action
ASSEMBLY
OPERATION
MAINTENANCE
Replacing blades
OPTIONAL ACCESSORIES
References
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Download This Manual (PDF format)

makita DJS161 Cordless Metal Shear

makita-DJS161-Cordless-Metal-SheaR-PRODUCT

Product Information

Specifications

Max. cutting capacities:
- Model DJS161:
- Steel up to 400 N/mm2 : 1.6 mm (16 ga)
- Steel up to 600 N/mm2: 1.2 mm (18 ga)
- Aluminum up to 200 N/mm2 : 2.5 mm (13 ga)
- Model DJS101:
- Steel up to 400 N/mm2 : 1.0 mm (20 ga)
- Steel up to 600 N/mm2: 0.7 mm (23 ga)
- Aluminum up to 200 N/mm2 : 2.5 mm (12 ga)
Min. cutting radius: 30 mm
Strokes per minute (min-1): 4,300
Overall length: 362 mm (DJS161), 364 mm (DJS101)
Net weight: 1.8 – 2.2 kg
Rated voltage: D.C. 18 V
Applicable battery cartridge and charger:
- Battery cartridge:
- BL1815N / BL1820 / BL1820B / BL1830 / BL1830B / BL1840 /
  BL1840B / BL1850 / BL1850B / BL1860B
- Charger:
- DC18RC / DC18RD / DC18RE / DC18SD / DC18SE / DC18SF

Intended Use

The tool is intended for cutting sheet steel and stainless sheet steel.

Vibration

The tool has a vibration emission of 13.0 m/s2 when cutting sheet metal.

Noise

The typical A-weighted noise level is 71 dB(A). The noise level during operation may exceed 80 dB(A). Ear protection is recommended.

Product Usage Instructions

Battery Installation

Ensure the tool is switched off.
Slide the compatible battery cartridge into the tool until it clicks into place.
If using a new battery, ensure it is fully charged before usage.

Cutting Operations

Select the appropriate cutting capacity based on the material being cut.
Hold the tool firmly and align the cutting blades with the desired cutting line.
Press the trigger to activate the shear and guide it along the cutting path smoothly.
Avoid forcing the tool through the material; let the shear blades do the work.
After use, release the trigger and wait for the blades to stop completely before setting the tool down.

Cleaning and Maintenance

After each use, clean any debris or metal shavings from the tool using a brush or cloth.
Regularly check the blades for any signs of wear or damage and replace if necessary.
Keep the tool stored in a dry place away from moisture when not in use.

FAQ

Q: Can I use a different battery cartridge with this tool?
- A : No, only use the specified battery cartridges mentioned in the manual to avoid injury or fire hazards.
Q: What should I do if the tool vibrates excessively during use?
- A : Check that the blade is correctly installed and not damaged. If the issue persists, contact customer support for further assistance.
Q: How often should I lubricate the cutting blades?
- A : It is recommended to apply a small amount of lubricant to the blades after prolonged use or if they start to show signs of friction.

SPECIFICATIONS

makita-DJS161-Cordless-Metal-SheaR-FIG15

Due to our continuing program of research and development, the specifications herein are subject to change without notice.
Specifications may differ from country to country.
The weight may differ depending on the attachment(s), including the battery cartridge. The lightest and heaviest combinations, according to EPTA-Procedure 01/2014, are shown in the table.

Applicable battery cartridge and charger

Battery cartridge : BL1815N / BL1820 / BL1820B / BL1830 / BL1830B / BL1840 / BL1840B / BL1850 / BL1850B / BL1860B

Charger : DC18RC / DC18RD / DC18RE / DC18SD / DC18SE / DC18SF

Some of the battery cartridges and chargers listed above may not be available depending on your region of residence.
WARNING : Only use the battery cartridges and chargers listed above. Use of any other battery cartridges and chargers may cause injury and/or fire.

Intended use

The tool is intended for cutting sheet steel and stainless sheet steel.

Noise

The typical A-weighted noise level determined according to EN62841-2-8:

Sound pressure level (LpA) : 71 dB(A)
Uncertainty (K) : 3 dB(A)

The noise level under working may exceed 80 dB (A).

NOTE : The declared noise emission value(s) has been measured in accordance with a standard test method and may be used for comparing one tool with another.
NOTE : The declared noise emission value(s) may also be used in a preliminary assessment of exposure.

WARNING : Wear ear protection.
WARNING : The noise emission during the actual use of the power tool can differ from the declared value (s) depending on the ways in which the tool is used especially what kind of workpiece is processed.
WARNING : Be sure to identify safety measures to protect the operator that are based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off and when it is running idle in addition to the trigger time).

Vibration

The vibration total value (tri-axial vector sum) determined according to EN62841-2-8:

Work mode : cutting sheet metal
Vibration emission (ah, M) : 13.0 m/s2
Uncertainty (K) : 1.5 m/s2

NOTE : The declared vibration total value(s) has been measured in accordance with a standard test method and may be used for comparing one tool with another.
NOTE : The declared vibration total value(s) may also be used in a preliminary assessment of exposure.

WARNING : The vibration emission during actual use of the power tool can differ from the declared value (s) depending on the ways in which the tool is used especially what kind of workpiece is processed.
WARNING : Be sure to identify safety measures to protect the operator that are based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off and when it is running idle in addition to the trigger time).

EC Declaration of Conformity

For European countries only

The EC declaration of conformity is included as Annex A to this instruction manual.

General power tool safety warnings

WARNING : Read all safety warnings, instruc-tions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

CORDLESS SHEAR SAFETY

WARNINGS

Hold the tool firmly.
Secure the workpiece firmly.
Keep hands away from moving parts.
The edges and chips of the workpiece are sharp. Wear gloves. It is also recommended that you put on thickly-bottomed shoes to prevent injury.
Do not put the tool on the chips of the workpiece. Otherwise, it can cause damage and trouble to the tool.
Do not leave the tool running. Operate the tool only when hand-held.
Always be sure you have a firm footing. Be sure no one is below when using the tool in high locations.
Do not touch the blade or the workpiece immediately after the operation; they may be extremely hot and could burn your skin.
Avoid cutting electrical wires. It can cause serious accidents by electric shock.

SAVE THESE INSTRUCTIONS.

WARNING : DO NOT let comfort or familiarity with the product (gained from repeated use) replace strict adherence to safety rules for the subject product. MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury.

Important safety instructions for battery cartridge

Before using a battery cartridge, read all instruc-tions and cautionary markings on (1) the battery charger, (2) the battery, and (3) the product using the battery.
Do not disassemble the battery cartridge.
If operating time has become excessively shorter, stop operating immediately. It may result in a risk of overheating, possible burns, and even an explosion.
If electrolyte gets into your eyes, rinse them out with clear water and seek medical attention right away. It may result in loss of your eyesight.
Do not short the battery cartridge:
- (1) Do not touch the terminals with any conductive material.
- (2) Avoid storing battery cartridges in a container with other metal objects such as nails, coins, etc.
- (3) Do not expose the battery cartridge to water or rain.
A battery short can cause a large current flow, overheating, possible burns, and even a breakdown.
Do not store the tool and battery cartridge in locations where the temperature may reach or exceed 50 °C (122 °F).
Do not incinerate the battery cartridge even if it is severely damaged or is completely worn out. The battery cartridge can explode in a fire.
Be careful not to drop or strike the battery.
Do not use a damaged battery.
The contained lithium-ion batteries are subject to the Dangerous Goods Legislation requirements. For commercial transports e.g. by third parties, and forwarding agents, special requirements on packaging and labeling must be observed. For preparation of the item being shipped, consulting an expert for hazardous material is required. Please also observe possibly more detailed national regulations. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging.
When disposing the battery cartridge, remove it from the tool and dispose of it in a safe place. Follow your local regulations relating to the disposal of batteries.
Use the batteries only with the products specified by Makita. Installing the batteries to non-compliant products may result in a fire, excessive heat, explosion, or leak of electrolyte.
If the tool is not used for a long period of time, the battery must be removed from the tool.

SAVE THESE INSTRUCTIONS.

CAUTION : Only use genuine Makita batteries. Use of non-genuine Makita batteries, or batteries that have been altered, may result in the battery bursting causing fires, personal injury and damage. It will also void the Makita warranty for the Makita tool and charger.

Tips for maintaining maximum battery life

Charge the battery cartridge before completely discharged. Always stop tool operation and charge the battery cartridge when you notice less tool power.
Never recharge a fully charged battery cartridge. Overcharging shortens the battery service life.
Charge the battery cartridge with room tempera-ture at 10 °C – 40 °C (50 °F – 104 °F). Let a hot battery cartridge cool down before charging it.
Charge the battery cartridge if you do not use it for a long period (more than six months).

FUNCTIONAL DESCRIPTION

CAUTION:

Always be sure that the tool is switched off and the battery cartridge is removed before adjusting or checking the function on the tool.

Installing or removing the battery cartridge

Fig.1: 1. Button 2. Red indicator 3. Battery cartridge

CAUTION:

Always switch off the tool before installing or removing of the battery cartridge.
Hold the tool and the battery cartridge firmly when installing or removing the battery cartridge. Failure to hold the tool and the battery cartridge firmly may cause them to slip off your hands and result in damage to the tool and battery cartridge and a personal injury.

To remove the battery cartridge, slide it from the tool while sliding the button on the front of the cartridge. To install the battery cartridge, align the tongue on the battery cartridge with the groove in the housing and slip it into place. Insert it all the way until it locks in place with a little click. If you can see the red indicator on the upper side of the button, it is not locked completely.

CAUTION:

Always install the battery cartridge fully until the red indicator cannot be seen. If not, it may accidentally fall out of the tool, causing injury to you or someone around you.
Do not install the battery cartridge forcibly. If the cartridge does not slide in easily, it is not being inserted correctly.

Battery protection system

The tool is equipped with a battery protection system. This system automatically cuts off power to the motor to extend battery life.
The tool will automatically stop during operation if the tool and/or battery are placed under one of the following conditions:

Overloaded:

The tool is operated in a manner that causes it to draw an abnormally high current. In this situation, turn the tool off and stop the application that caused the tool to become overloaded. Then turn the tool on to restart.
If the tool does not start, the battery is over-heated. In this situation, let the battery cool before turning the tool on again.

Low battery voltage:

The remaining battery capacity is too low and the tool will not operate. In this situation, remove and recharge the battery.

NOTE : The overheat protection works only with a battery cartridge with a star mark.

Fig.2 : 1. Star marking

Indicating the remaining battery capacity

Only for battery cartridges with the indicator

Fig.3 : 1. Indicator lamps 2. Check button

Press the check button on the battery cartridge to indicate the remaining battery capacity. The indicator lamps light up for a few seconds.

makita-DJS161-Cordless-Metal-SheaR-FIG16

NOTE : Depending on the conditions of use and the ambient temperature, the indication may differ slightly from the actual capacity.

Switch action

Fig.4 : 1. Switch lever

CAUTION:

Before inserting the battery cartridge into the tool, always check to see that the switch lever actuates properly and returns to the “OFF” position when the rear of the switch lever is depressed.
A switch can be locked in the “ON” position for ease of operator comfort during extended use. Apply caution when locking the tool in the “ON” position and maintain a firm grasp on the tool.

To start the tool, slide the switch lever toward the “I (ON)” position. For continuous operation, press the front of the switch lever to lock it. To stop the tool, press the rear of the switch lever, then slide it toward the “O (OFF)” position.

Indication lamp with multi-function

Fig.5: 1. Indicating lamp Indication lamps are located in two positions.

Battery cartridge replacing signal

When the battery power is almost used up during operation, the red lamp lights up and the tool stops immediately. Replace the battery with a fully charged one when the red lamp lights up.

Accidental re-start preventive function

Even if the battery cartridge is inserted on the tool with the slide switch in the “I (ON)” position, the tool does not start. At this time, the lamp flickers slowly and this shows that the accidental re-start preventive function is at work.

To start the tool, first slide the slide switch toward the “O (OFF)” position and then slide it toward the “I (ON)” position.

ASSEMBLY

CAUTION:

Always be sure that the tool is switched off and the battery cartridge is removed before carrying out any work on the tool.

Adjusting the blade clearance

For Model DJS161

Adjust the clearance between the side blade and the center blade according to the thickness of the workpiece.

► Fig.6 : 1. Hex wrench 2. Screw

First, use a hex wrench to loosen the screw.

► Fig.7: 1. Center blade 2. Thickness gauge 3. Side

blade 4. Hex wrench 5. Hex socket head bolt

Then use the hex wrench to adjust the clearance by tightening or loosening the bolt. There may be a slight difference between the clearance of both sides of the center blade.

Check the smaller clearance with the thickness gauge and adjust it.

When using the thickness gauge to adjust the blade clearance, refer to the table.

After adjusting the clearance, tighten the screw securely.

Storing hex wrench

Fig.8 : 1. Hex wrench
Store the hex wrench as shown in the figure when not in use.

OPERATION

Lubrication

Fig.9 : 1. Oil supply 2. Center blade 3. Pin

Before operation, lubricate the contact point of the center blade and the pin. To keep good cutting performance, also use a cutting lubricant from time to time during operation.

OPERATION

Fig.10

Turn the tool on and set the front ends of the side blades on the workpiece. Now simply move the tool forward, keeping the side blades flush with the workpiece surface.

Fig.11

CAUTION:

When cutting a small portion of the workpiece, you may have difficulty completing the end of the cut. In that case, try to cut it again, pulling the workpiece back slightly.

MAINTENANCE

CAUTION:

Always be sure that the tool is switched off and the battery cartridge is removed before attempting to perform inspection or maintenance.

NOTICE:

Never use gasoline, benzine, thinner, alcohol or the like. Discoloration, deformation or cracks may result.

The tool and its air vents have to be kept clean. Regularly clean the tool’s air vents or whenever the vents start to become obstructed.

Replacing carbon brushes

Fig.12: 1. Limit mark

Remove and check the carbon brushes regularly. Replace them when they wear down to the limit mark. Keep the carbon brushes clean and free to slip in the holders. Both carbon brushes should be replaced at the same time. Use only identical carbon brushes.

Insert the top end of the slotted bit screwdriver into the notch in the tool and remove the holder cap cover by lifting it up.

► Fig.13 : 1. Brush holder cover 2. Notch 3. Screwdriver

Use a screwdriver to remove the brush holder caps. Take out the worn carbon brushes, insert the new ones and secure the brush holder caps.

Fig.14: 1. Brush holder cap 2. Screwdriver Reinstall the holder cap cover on the tool.

Replacing blades

The service life of the blades varies in terms of the workpiece to be cut. The following reference tables indicate the approximate service life of the blades. When the blades become dull, ask Makita Authorized Service Centers to replace the blades.

For Model DJS161

makita-DJS161-Cordless-Metal-SheaR-FIG18

For Model DJS101

makita-DJS161-Cordless-Metal-SheaR-FIG19

To maintain product SAFETY and RELIABILITY, repairs, any other maintenance or adjustment should be performed by Makita Authorized Service Centers, always using Makita replacement parts

OPTIONAL ACCESSORIES

CAUTION:

These accessories or attachments are recommended for use with your Makita tool specified in this manual. The use of any other accessories or attachments might present a risk of injury to persons. Only use accessory or attachment forits stated purpose.

If you need any assistance for more details regarding these accessories, ask your local Makita Service Center.