ECHNICAL INFORMATION
PRODUCT
T
P 1 /10
Models No. BJR141
W
Description
Cordless Recipro Saw
CONCEPT AND MAIN APPLICATIONS
H
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
L
as a power unit instead of Ni-cd battery.
More work amount on a single full battery charge
Dimensions: mm (")
Non-skid handle angled and contoured ergonomically for
best-fitting to reciprocating cutting
Length (L) 466 (18-3/8)
Width (W) 79 (3-1/8)
Height (H) 226 (8-7/8)
This product is available in the following variations.
Battery
Plastic
Model No. Charger
type quantity
carrying case
BJR141Z No No No No
BJR141RF 1
Yes
DC18RA BL1430
BJR181RFE 2
Specification
Voltage: V 14.4
Battery Capacity: Ah 3.0
Cell Li-ion
Max output (W) 280
Length of stroke: mm (") 23 (7/8)
No load speed: min-1=spm 0 - 2,700
wood 90 (3-1/2)
Max cutting capacities: mm (")
[when cutting with a 160mm blade]
pipe 90 (3-1/2)
Variable speed Yes
Electric brake Yes
Net weight*: kg (lbs) 3.1 (6.8)
*Includes battery BL1430
Standard equipment
Recipro saw blade for metal ............................................................... 1
Recipro saw blade for composite material (wood plus metal) ........... 1
Plastic carrying case ........................................................................... 1
Note: The standard equipment for the tool shown above may differ from country to country.
Optional accessories
Charger DC18RA Li-ion battery BL1430
Charger DC24RC Assorted recipro saw blades
Charger DC24SC
P 2 /10
Repair
CAUTION: Remove recipro saw blade and battery cartridge from the machine
for safety before repair/ maintenance !
[1] NECESSARY REPAIRING TOOLS
Code No. Description Use for
1R030 Bearing setting pipe 2.5-17.2 Press-fitting Dust seal 14 in Gear housing cover complete
1R269 Bearing extractor Removing Ball bearing 6001DDW from the drive-end of Armature
1R291 Retaining ring S and R pliers Removing/installing Retaining ring S-18 from/on Blade clamp section
--- Recipro saw blade Assembling Pin 3 to Blade clamp section
[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.
Item No. Description Portion to be lubricate
Inside surface of the lip portion of Dust seal 14
2 Gear housing cover complete
(Any kind of lubricating grease can be used.)
4 Shoulder pin 5 Pin head that contacts Driving sleeve
17 Slider complete Surface that contacts Needle bearing 708 (Put approx. 9g.)
43 Gear housing Gear room (Put approx. 9g.)
Fig. 1
Dust seal 14
Blade clamp section
Driving sleeve
17
Needle bearing 708
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Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Blade Clamp Section
DISASSEMBLING
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.
Fig. 2
Turn Lever 60 in the direction of the arrow. By unscrewing Hex bolt M8x25, Shoe can now
Remove Pan head screw M4x10. be removed as illustrated below.
Remove Lever 60.
Note: Hex nut M4 will be left in Lever 60.
Blade clamp section
Be careful not to lose it.
Shoe Insulation cover
[View from top]
Insulation cover
Shoe
Blade clamp section
Sleeve 9
Lever 60 Inner plate
Lock plate
Pam head screw
M4x10
Hex bolt M8x25
Hex nut M4
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.
Fig. 3
Retaining ring S-18
Shoulder pin 5
Driving sleeve
Compression spring 6
Pin 3 (of 6mm length)
Guide sleeve
Driving sleeve guide
Sleeve
Slider
Fig. 4
Pull up Sleeve until it stops against Turn Sleeve in the direction Sleeve is now unlocked.
Pin 3 (of 19.8mm length). of the arrow.
Slider
Pin 3
(of 19.8mm length)
Sleeve
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Repair
[3] -1. Blade Clamp Section (cont.)
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)
Fig. 5 Fig. 6
Push plate
Sleeve
Pin 3
(of 19.8mm length)
Compression
Slider
spring 2
Sleeve
Torsion
spring 17
thin bar
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. 7
Be sure that this end is
Torsion spring 17
positioned on the opposite
Sleeve
side to Shoulder pin 5
insertion hole.
hole
Shoulder pin 5 Put this end in
insertion hole the slit of Slider.
Slider
Gear housing
cover complete
Put this end of
Torsion spring 17
into the hole of
Sleeve.
Fig. 8
Turn Sleeve in the direction Insert Pin 3 (of 19.8mm length) into Put Compression spring 2 into
of the arrow so that Pin 3 the hole provisionally. the slit of Slider.
insertion hole can be seen. Note: Be sure that the top of Pin 3
Compression
is not seen in the slit of Slider.
spring 2
Pin 3 (of 19.8mm length)
Sleeve
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)
Fig. 9 Fig. 10
recipro saw blade
This protrusion must
face the blade side.
Pin 3 (of 19.8mm length)
hole of Slider
Push plate
Sleeve
Guide sleeve
Pin 3
(of 19.8mm length)
Compression spring 2
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. 11
Hold Driving sleeve and turn it together with Sleeve
Push Sleeve towards
in the direction of the arrow until Sleeve stops against
Gear housing side. Sleeve is now locked.
Pin 3 (of 19.8mm length).
Driving sleeve
Sleeve
Pin 3
(of 19.8mm length)
[Gear housing side]
6) Remove Driving sleeve.
Fig. 12
7) Assemble the following parts to Slider (Refer to Fig. 3.):
Driving sleeve guide, Guide sleeve, Shoulder pin 5,
protrusion
Driving sleeve
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.
Driving sleeve guide
(Fig. 12)
notch
Sleeve
notch
P 6 /10
Repair
[3] -2. Slider Section
DISASSEMBLING
1) Remove Shoe. (See Fig. 2 in 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.
Fig. 13
Insulation cover has two raised Pull Insulation cover in the direction
portions on its inside surface to Turn Insulation cover inside out of the arrow bit by bit while levering
prevent from falling off from by hand until the raised portion (A) off from Gear housing section using
the machine. is reached. two slotted screwdrivers.
Insulation cover,
viewed from rear Insulation cover
Gear housing section
raised portion (B)
raised portion (A)
4) Separate Gear housing cover complete from Gear housing Fig. 14
by unscrewing four M5x18 Pan head screws. (Fig. 14)
Pan head screw M5x18 (4pcs)
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
Slider section
the blade side by pulling in the direction of the gray arrow.
(Fig. 16)
Gear housing
cover complete
Gear housing
Fig. 15 Fig. 16
Pan head screw M5x16 (4pcs)
Plate (2pcs)
Plane bearing 14,
[blade side]
on the blade side Slider
Plane bearing 14
Slider
Gear housing
cover complete
[Motor housing side]
P 7 /10
Repair
[3] -2. Slider Section (cont.)
ASSEMBLING
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. 18 Fig. 19
Fit the tapered end of 1R030 to Dust seal 14.
[blade side] Plane bearing 14
1R030
Slider
Gear housing
tapered end
cover complete
Plane bearing 14
Dust seal 14
stepped end
[Motor housing side]
Fig. 20 Fig. 21
: portion to apply threadlocker
Pan head screw M5x18 (4pcs)
: portion to apply Makita grease FA No.2
Pan head screw
Gear housing
M5x16 (4pcs)
cover complete
Motor housing
Gear housing
cover complete
Gear housing
Slider
[3] -3. Spiral Bevel Gear Section
DISASSEMBLING
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)
Fig. 22
Needle bearing 708
Hex socket head bolt
M5x12
Spiral bevel gear section
Plate C
Gear housing
Pan head screw M5x8 (3pcs)
P 8/10
Repair
[3] -3. Spiral Bevel Gear Section (cont.)
DISASSEMBLING
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.
Fig. 23 Fig. 24
Torx socket head bolt M6x15
Torx socket head bolt M6x15
(with T20 Torx socket)
Spiral bevel gear 48
Bearing retainer A
Gear shaft
Ball bearing 6000LLB
Ring 10
Ball bearing 6900LLB
Vise
Gear shaft
ASSEMBLING
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.
[3] -4. Motor Section
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)
Fig. 25 Fig. 26
Insulation cover
Armature
Motor housing
Tapping screw
5x35 (4pcs)
Baffle plate
Fig. 27 Fig. 28
Ball bearing 6001DDW Bearing retainer B
Pan head screw M4x12
Stop ring E-10
Fan guide
Gear housing
P 9/10
Repair
[3] -4. Motor Section (cont.)
ASSEMBLING
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.
Circuit diagram
Fig. 29
Brush holder, Right
Brush holder, Left
Right side
Left side
Switch
(-) Terminal
(+) Terminal
Terminal
Heatsink
Brush holder, Left Brush holder, Right
FET
Color index of lead wires' sheath
Black
Red
Left side Right side
Terminal
Switch
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Wiring diagram
1) Motor Housing
Route two Lead wires (black, red) from Brush holder as illustrated in Fig. 30.
Fig. 30
black
Motor housing
red
Fix with the lead wire holder lead wire holder
on Motor housing. on Motor housing
Do not route over the rib
rib on Motor housing
on Motor housing.
Fix with the lead wire holder lead wire holder
on Brush holder. on Bush holder
Brush holder, left
Brush holder, right
2) Handle L
Fig. 31
Handle L
rib
Route all lead wires between the rib and the boss.
boss
Assemble Insulated connectors to
Switch terminals at such an angle
Switch
that the Insulated connectors do not
touch the rib.
rib
Connecting Flag Connector to Terminal
The flag connector has to be so connected that
the wire connecting portion is positioned on
the side of pole marks of Terminal.
Wire connecting portion
Pole mark
Terminal
Flag connector
Terminal