makita BJS160 Cordless Metal Shear Instruction Manual

makita BJS160 Cordless Metal Shear

Explanation of general view

1. Button
2. Red part
3. Battery cartridge
4. Switch lever
5. Indicating lamp
6. Hex wrench
7. Screw
8. Center blade
9. Thickness gauge
10. Side blade
11. Hex wrench
12. Hex socket head bolt
13. Hex wrench
14. Oil supply
15. Center blade
16. Pin
17. Limit mark
18. Brush holder cover
19. Notch
20. Screwdriver
21. Brush holder cap
22. Screwdriver

SPECIFICATIONS

Max. cutting capacities

| Steel up to 400 N/mm2| 1.6 mm (16 ga.)| 1.0 mm (20 ga.)
Steel up to 600 N/mm2| 1.2 mm (18 ga.)| 0.7 mm (23 ga.)
Aluminum up to 200 N/mm2| 2.5 mm (13 ga.)| 2.5 mm (12 ga.)
Min. cutting radius| 250 mm| 30 mm
Strokes per minute (min-1)| 4,300| 4,300
Overall length| 362 mm| 364 mm
Net weight| 1.9 kg| 2.0 kg| 1.9 kg| 2.0 kg
Rated voltage| D.C. 14.4V| D.C. 18V| D.C. 14.4V| D.C. 18V

• Due to our continuing programme of research and development, the specifications herein are subject to change without notice.
• Specifications and battery cartridge may differ from country to country.
• Weight, with battery cartridge, according to EPTA-Procedure 01/2003

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

For Model BJS160
ENG104-1
For European countries only

Noise
The typical A-weighted noise level determined according to EN60745:

• Sound pressure level (LpA): 74 dB(A)
• Uncertainty (K): 3 dB(A)
• The noise level under working may exceed 80 dB (A). Wear ear protection.

Vibration
The vibration total value (tri-axial vector sum) determined according to EN60745:

• Work mode: cutting sheet metal
• Vibration emission (ah): 12.0 m/s2
• Uncertainty (K): 1.5 m/s2

For Model BJS161
ENG104-1
For European countries only

Noise
The typical A-weighted noise level determined according to EN60745:

• Sound pressure level (LpA): 71 dB(A)
• Uncertainty (K): 3 dB(A)
• The noise level under working may exceed 80 dB (A). Wear ear protection.

Vibration
The vibration total value (tri-axial vector sum) determined according to EN60745:

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

For Model BJS100
ENG104-1
For European countries only

Noise
The typical A-weighted noise level determined according to EN60745:

• Sound pressure level (LpA): 71 dB(A)
• Uncertainty (K): 3 dB(A)
• The noise level under working may exceed 80 dB (A).
• Wear ear protection.

Vibration
The vibration total value (tri-axial vector sum) determined according to EN60745:

• Work mode: cutting sheet metal
• Vibration emission (ah) : 12.5 m/s2
• Uncertainty (K): 1.5 m/s2

For Model BJS101
ENG104-1
For European countries only

Noise
The typical A-weighted noise level determined according to EN60745:

• Sound pressure level (LpA): 71 dB(A)
• Uncertainty (K): 3 dB(A)
• The noise level under working may exceed 80 dB (A).
• Wear ear protection.

Vibration
The vibration total value (tri-axial vector sum) determined according to EN60745:

• Work mode: cutting sheet metal
• Vibration emission (ah) : 13.0 m/s2
• Uncertainty (K) : 1.5 m/s2
• ENG901-1
• The declared vibration emission value has been measured in accordance with the standard test method and may be used for comparing one tool with another.
• The declared vibration emission value 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 emission value depending on the ways in which the tool is used.
• 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

We Makita Corporation as the responsible manufacturer declare that the following Makita machine(s):
Designation of Machine:
Cordless Metal Shear
Model No./ Type: BJS100,BJS101,BJS160,BJS161 are of series production and

Conforms to the following European Directives:
98/37/EC until 28th December 2009 and then with 2006/42/EC from 29th December 2009 And are manufactured in accordance with the following standards or standardised documents:
EN60745 The technical documentation is kept by our authorised representative in Europe who is: Makita International Europe Ltd, Michigan, Drive, Tongwell, Milton Keynes, MK15 8JD, England.

General Power Tool Safety
Warnings

WARNING Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference.

CORDLESS SHEAR SAFETY WARNINGS

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

WARNING:
DO NOT let comfort or familiarity with 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

1. Before using battery cartridge, read all instructions and cautionary markings on (1) battery charger, (2) battery, and (3) product using battery.
2. Do not disassemble battery cartridge.
3. If operating time has become excessively shorter, stop operating immediately. It may result in a risk of overheating, possible burns and even an explosion.
4. 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.
5. Do not short the battery cartridge:
6. Do not touch the terminals with any conductive material.
7. Avoid storing battery cartridge in a container with other metal objects such as nails, coins, etc.
8. Do not expose battery cartridge to water or rain. A battery short can cause a large current flow, overheating, possible burns and even a breakdown.
9. Do not store the tool and battery cartridge in locations where the temperature may reach or exceed 50 ﾟC (122 ﾟF).
10. 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.
11. Be careful not to drop or strike battery.
12. Do not use dropped or struck battery.
    SAVE THESE INSTRUCTIONS.

Tips for maintaining maximum battery life

1. Charge the battery cartridge before completely discharged. Always stop tool operation and charge the battery cartridge when you notice less tool power.
2. Never recharge a fully charged battery cartridge. Overcharging shortens the battery service life.
3. Charge the battery cartridge with room temperature at 10 ﾟC – 40 ﾟC (50 ﾟF – 104 ﾟF). Let a hot battery cartridge cool down before charging it.

FUNCTIONAL DESCRIPTION

CAUTION :

• Always be sure that the tool is switched off and the battery cartridge is removed before adjusting or checking function on the tool. Installing or removing battery cartridge Fig.1
• Always switch off the tool before insertion or removal of the battery cartridge.
• To remove the battery cartridge, withdraw it from the tool while sliding the button on the front of the cartridge.
• To insert the battery cartridge, align the tongue on the battery cartridge with the groove in the housing and slip it into place. Always insert it all the way until it locks in place with a little click. If you can see the red part on the upper side of the button, it is not locked completely. Insert it fully until the red part cannot be seen. If not, it may accidentally fall out of the tool, causing injury to you or someone around you.
• Do not use force when inserting the battery cartridge. If the cartridge does not slide in easily, it is not being inserted correctly.

Switch action
Fig.2

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.
• Switch can be locked in “ON” position for ease of operator comfort during extend use. Apply caution when locking tool in “OFF” position and maintain firm grasp on 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.3

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 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 BJS160 and BJS161 only

• Adjust the clearance between the side blade and the center blade according to the thickness of the workpiece. Fig.4
• First use a hex wrench to loosen the screw. Fig.5
• Then use the hex wrench to adjust the clearance by tightening or loosening the bolt. There may be a slight difference between 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.
  Workpiece thickness (mm)| Marking on thickness gauge
  ---|---
  Less than 0.8| 0.5
  0.8 – 1.3| 1.0
  More than 1.3| 1.5
• After adjusting the clearance, tighten the screw securely.

Storing hex wrench
Fig.6
Store the hex wrench as shown in the figure when not in use.

OPERATION

Lubrication
Fig.7
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.8
Turn the tool on and set 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.9

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.10
Remove and check the carbon brushes regularly. Replace 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 slotted bit screwdriver into the notch in the tool and remove the holder cap cover by lifting it up. Fig.11
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.12 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 BJS160 and BJS161

Stainless steel plate

(SUS304)

| 1.2| 150
Aluminum plate

(A-5052)

| 2.5| 400

For BJS100 and BJS101

Stainless steel plate

(SUS304)

| 0.7| 50

010739
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.

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

• Thickness gauge

• Center blade

• Side blade R

• Side blade L

• Hex wrench

• Various type of Makita genuine batteries and chargers.

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