Makita JS1601 Manuel

Model No.

Description

CONCEPT AND MAIN APPLICATIONS

P 1/ 12

Specification

Standard equipment

Optional accessories

Continuous Rating (W)

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

110

120

220

230

240

3.6

3.3

1.8

1.7

50/60

380

---

380

160

280

Current (A)

Note: The standard equipment for the tool shown above may vary by country.

JS1601

JS1000

Straight Metal Shear 1.6mm (16Ga)

Metal Shear 1.0mm (20Ga)

Dimensions: mm (")

Width 1 (W1)*1

Height (H)

Length (L)

Model No. JS1601 JS1000

322 (12-5/8)

320 (12-5/8)

56 (2-3/16)

Width 2 (W2)*2

70 (2-3/4)

78 (3-1/16)

Models JS1601 and JS1000 are aesthetic change models of

the current JS1660 and JS1670.

Feature the same easy-to-grip, slim housing as used for

GA4030 series angle grinders, providing more comfort and

control and better maneuverability.

Model JS1601 is designed mainly for straight cutting,

and JS1000 for curve cutting.

The different parts between JS1601 and JS1000 are

Center blade and Side blades.

Center blade

Side blade (L)

Side blade (R)

Hex wrench 3 ...................................... 1

Thickness gauge (= Feeler gauge) ...... 1 (for JS1601)

*1 diameter at barrel

*2 width at tool head, including the protruding

portion of the vents

* Weight according to EPTA-Procedure 01/2003, with Hex wrench

Max cutting capacities:

mm (Ga)

Steel with tensile strength

up to 600N/mm2

Net weight*: kg (lbs) 1.4 (3.1)

1.2 (18)

Steel with tensile strength

up to 800N/mm20.8 (21)

Aluminum with tensile

strength up to 200N/mm22.5 (12)

Steel with tensile strength

up to 400N/mm21.6 (16)

No load speed: min-1= spm (strokes per minute) 4,500

Minimum cutting radius: mm (") 250 (9-7/8)

0.7 (23)

0.5 (26)

2.5 (12)

1.0 (20)

30 (1-3/16)

Power supply cord: m (ft) Europe: 4.0 (13.1) Australia, Brazil: 2.0 (6.6)

Other countries: 2.5 (8.2)

Specification Model JS1601 JS1000

PRODUCT

ECHNICAL INFORMATION

Repair

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

[1] NECESSARY REPAIRING TOOLS

[2] LUBRICATIONS

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Center blade

Fig. 1

Code No. Description Use for

1R031 Bearing setting pipe 28-20.2 Removing Helical gear 40 from Crank shaft

1R269 Bearing extractor Removing Ball bearings

1R281 Round bar for arbor 7-50 Blocking Switch knob when disassembling Switch lever

1R366 Feeler gauge set Adjusting clearance between Center blade and Side blades

Item No.

Apply the following lubricants to the portions to protect the parts and product from unusual abrasion.

Description Lubricant

AmountPortion to lubricate

DISASSEMBLING

(1) Remove Crank housing complete from Gear housing complete. And then remove Shoulder pin 7 from Gear housing

complete (Fig. 2)

Rod

a little

Pin 5

Center blade

Dust cover

Shoulder

pin 7

4x50 Tapping

Screw (4pcs.)

1. Remove 4x50 Tapping screws and

separate Crank housing from Gear housing.

2. Remove Stop ring E-4 from

the left end of Shoulder pin 7.

3. Remove Shoulder pin 7

which secures Center blade.

Shoulder

pin 7

Stop ring E-6Stop ring E-4

Link

25 Shoulder pin 7

33 Helical gear 40

Whole portion

Drum portion where Center blade contacts

Gear teach where Armature gear teeth contact

Fig. 2

Crank housing

Gear housing Crank housing

P 2/ 12

Makita grease FA No.2

Lubricant VG100

Makita grease FA No.2

(2) Disassemble Center blade section as illustrated in Fig. 3.

Strike the edge of Crank housing.

Center blade section (Rod, Helical gear 40, Link etc.) can be removed.

Note: Do not lose Thin washers 7

and Teflon washers.

Fig. 3

Center blade

Thin washer 7

(2pcs.)

Teflon

washer 7

(2pcs.)

Helical

gear 40

Rod

Link

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Center blade

DISASSEMBLING

ASSEMBLING

(1) Reverse the disassembling step to assemble Center blade section. Be careful to the direction of Dust cover shown in

Fig. 4,

Note: Do not forget to set two Flat washers 5 in place.

(2) Assemble Gear housing section with Center blade section to Crank housing as illustrated in Fig. 5.

Fig. 5

Gear housing

Crank housing

complete

Width

Dust cover

2. Mount the assembled Center

blade section to Gear Housing.

3. Assemble Crank housing complete to Gear housing

while aligning Dust cover’s width with that of space

in Crank housing complete.

Gasket

1. Put Gasket on

Gear housing.

Repair

P 3/ 12

(3) Center blade section can be disassembled as illustrated in Fig. 4.

1. Remove Pin 5 from Link. 2. Center blade can be removed from

Link together with Dust cover.

3. Remove Center blade from

the slit of Dust cover.

Center blade

Slit of Dust cover Height

Width

(Note: It has to be longer than height)

Pin 5

Flat washer 5

Fig. 4

Link

Dust cover

(3) Assemble Washers and Shoulder pin 7 as illustrated in Fig. 6.

(4) Adjust the clearance between Center blade and Side blade, referring to “ Adjusting the Blade clearance”.

1. Insert the set of Thin washer 7 and Teflon

washer 7 into the clearance between

Center blade and Crank housing complete,

setting Thin washer 7 to Center blade side.

2. Insert Shoulder pin 7

from Side blade (R)

side (the opposite

side of Switch knob)

through the two sets

of Washers and

Center blade.

3. Mount Stop ring E-4 to the other end

of Shoulder pin 7 to secure Center blade

and Washers.

Fig. 6

Thin washer 7

Center blade

Teflon washer 7

Side blade (R) Side blade (L)

Stop ring E-4

Shoulder pin 7

Side blade (R)

Center blade

Note: Do not lose Flat washer 5.

[3] DISASSEMBLY/ASSEMBLY

[3]-2 Side Blade R, L

DISASSEMBLING

ASSEMBLING

Side blades can be removed as

illustrated in Fig. 7.

(1) Do the reverse step of Disassembling. Do not forget to assemble Spacer under Side blade L.

Refer to Fig. 7.

(2) Adjsut the clearance between Center blade and Side blade, referring to “ Adjsuting the Blade Clearance”.

Fig. 7

M5x10 Hex socket

countersunk

head screw (2pcs.)

Remove two M5x10 Hex socket

countersunk head screws.

Side blades (R and L) can be removed.

Be careful not to lose Spacer

under Side Blade (L)

Side blade (R)

Slip plate (R) Slip plate (L)

Spacer

Side blade (L)

Repair

P 4/ 12

[3]-3 Crank Shaft Section (Helical gear 40, Ball bearings, Sealing screw)

DISASSEMBLING

(1) Disassemble Center blade section as illustrated in Fig.2, Fig. 3.

(2) Crank shaft section can be disassembled as illustrated in Fig. 8, 9 and 10.

Fig. 8

1R269

Fig. 9

Fig. 10

Remove Crank shaft section from Rod of Center blade section.

Rod

Ball bearing 627ZZ

Ball bearings 627ZZ and 696ZZ can be removed

with 1R269. Remove Flat washer 7 from Crank shaft.

Center blade

section

Crank shaft section

Ball bearing 696ZZ

Ball bearing 6000ZZ

Flat washer 7

Sealing screw

Because of the tight clearance between

Ball bearing 6000ZZ and Sealing screw,

it is difficult to insert the jaws of 1R269

into the clearance. While gripping the legs

of 1R269 with Water pump pliers, remove

Ball bearing 6000ZZ. Ball bearing 6000ZZ

Water pump

pliers

Sealing screw

Helical gear 40

1R031

Crank shaft

Putting Sealing screw onto 1R031,

remove Crank shaft from Helical

gear 40 by pressing with Arbor press.

Crank shaft

Helical gear 40

[3] DISASSEMBLY/ASSEMBLY

[3]-3 Crank shaft section (Helical gear 40, Ball bearings, Sealing screw (cont.)

DISASSEMBLING

1. Disassemble Rear cover by loosening

4x18 Tapping screw.

2. Shifting the tails of Spiral springs from Carbon brushes,

disconnect the carbon brushes from Armature’s commutator

by pulling up halfway.

Fig. 12

Fig. 13

Fig. 11

Removing four 4x50 Tapping screws, separate Gear

housing complete and Crank housing as illustrated below.

4x18 Tapping screw

(1) Removing Rear cover, disconnect Carbon brush from Armature’s commutator to protect the Commutator against

scratching by Carbon brush, as illustrated in Fig. 11.

(2) Disassemble Armature as illustrated in Figs. 12 and 13.

Rear cover

Gear housing

complete

Crank housing

complete

Motor housing

Ball bearing 608ZZ

Ball Bearing 608ZZ and Ball bearing 607ZZ can be removed with 1R269.

Ball bearing 607ZZ

Insulation washer

Labyrinth rubber ring 19

Motor housing

Armature

Armature can be removed as illustrated below.

4x50 Tapping

screws (4pcs.)

Repair

P 5/ 12

[3]-4 Armature

ASSEMBLING

Assemble Crank shaft section by reversing the disassembling step. Refer to Fig. 10, 9 and 8.

Do not forget to mount Flat washer 7 to Crank shaft, before assembling Ball bearing 627ZZ.

Refer to Fig. 8.

[3] DISASSEMBLY/ASSEMBLY

[3]-4 Armature

[3]-5 Switch Lever

ASSEMBLING

Fig. 14

Fig. 15

Refer to Fig. 15.

Switch Knob on left side viewed from Cord guard side

Cord guard

Gear housing completeCrank housing

complete

Crank and Gear housing completes have to be assembled to Motor housing

so that Switch knob is located on left side viewed from Cord guard side,

and that Center and Side blades are located on belly side viewed from

Cord guard side.

Center and Side blades Belly side

(1) Assemble Armature, referring to Fig. 13.

(2) Assemble Crank and Gear housing completes to Motor housing as illustrated in Fig. 14.

DISASSEMBLING

Bending Switch lever, pull out it

from Motor housing.

Blocking Switch knob to OFF position by

inerting 1R281, push Switch lever strongly

toward the 1R281.

Only Switch lever can be moved, while Switch

konb can not move because of 1R281.

The linkage of Switch knob is disconnected from Switch lever.

Consequently, Switch knob can be removed.

Switch lever

1R281

Switch knob

Switch

Switch knob

Switch lever

Repair

P 6/ 12

Fig. 16

Assemble Switch lever and Switch knob as illustrated in Fig. 16.

Inserting Switch lever into Motor housing, push it toward

Gear housing complete side until the hole for receiving

Switch knob comes into sight through the hole of Motor

housing.

And engage the Switch knob’s hook to the hole of Switch

lever then release Switch lever.

ASSEMBLING

Switch knob’s hook

Hole for receiving

Switch lever

Switch knob Switch lever

Hole on

Motor housing

Switch

P 7/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-6 Field

1. Remove Baffle plate from

Motor housing.

Remove 4x70 Tapping screws and

Spacer from Motor housing.

Note: Do not strike the edge of Motor

housing when removing Field.

Because the thin portion on the

edge is easy to broken.

2. To protect the edge of Motor

housing from breakage, mount

Gear housing complete and Crank

housing completes to Motor housing

temporarily.

(1) Remove Rear cover and then disconnect Carbon brush

from Armature’s commutator to protect Commutator

from being scratched.

Disconnect Field lead wire (red) from Brush holder. (Fig. 17)

(2) Remove four 4x50 Tapping screws and then separate Gear

housing complete and Crank housing. And remove Armature

from Motor housing as illustrated in Fig. 11.

(3) After removing Baffle plate, make preparation for removing

Field as illustrated in Fig. 18.

(4) Remove Field from Motor housing as illustrated in Fig. 19.

DISASSEMBLING

4x70 Tapping screw (2pcs.)

Gear housing

complete

Crank housing

complete

Motor housing

4x50 Tapping screws (4pcs.)

Baffle plate

Spacer

Fig. 18

Fig. 19

1. Strike Crank housing complete with Plastic hammer

to shift Field from the original position.

2. Disassemble Crank and Gear housing completes again,

if Field is shifted halfway out of Motor housing.

3. Screwing four 4x50 Tapping screws to

Motor housing, strike the screw heads

with plastic hammer.

Field can be removed from Motor housing.

Fig. 17

Field

Crank housing

Field lead wire

(red)

Slide Spring tails of Brush holders

and disconnect Carbon brushes

from Armature’s commutator.

Brush holder

[4] ADJUSTMENT

Fig. 20

Fig. 21

1. Loosen M6x10 Hex socket head set

screw, turning it by 360 degrees with

Hex wrench in order to reserve the

turning angle for adjustment.

2. Select the proper Leaves of 1R366,

according to the following table.

Adjust the clearance between Center blade and Side blades as illustrated in Figs. 20, 21 and 22.

Hex wrench 3

less than 0.8

More than 1.3

0.8 - 1.29

0.1

0.3

0.2

0.04 + 0.06

0.1 + 0.2

0.05 + 0.15

Workpiece

Thickness (mm)

Clearance (mm) between

Center and Side blades

Combination of

Leaves of 1R366

M6X10 Hex socket

head set screw

Fig. 22

Leaves of 1R366 selected

from the table in Fig. 20

Hex wrench 3 set on

M4x25 Hex socket

head bolt (on Switch

knob side)

Inserting Leaves of 1R366 between Center blade and Side blades,

adjust the clearance by turning M4x25 Hex socket head. bolt (on

Switch knob side) with Hex wrench 3.

Center blade

Side blades

Switch knob side

Switch knob

side

Hex wrench 3

M6X10 Hex socket

head set screw

Switch knob side

After adjusting the clearance, tighten M6x10 Hex socket head set screw with Hex wrench 3.

P 8/ 12

Repair

Circuit diagram

Wiring diagram

White

Blue

Brush holder

Field

Brush holder

Polyolefin Tube

Polyolefin

tube

Power Supply Cord

Polyolefin tube

Connect the Lead wires of Power supply cord to Switch, as illustrated in Fig. D-2R.

Brown

Color index of lead wires' sheath

Black

Red

Fig. D-1

Fig. D-2R Fig. D-2F

Blue Lead wire is used

for some countries.

Brown Lead wire is used

for some countries.

Switch

Noise

suppressor

Noise suppressor is not used

for some countries.

ON-OFF Button

Connect Lead wires of Power supply cord to Switch

terminal, approaching from ON-OFF Button side.

The protruding portion interferes with Switch

in assembling to Switch box on Motor housing.

P 9/ 12

Wiring diagram

P 10/ 12

Field lead wires (red) have to be

guided out from the opening of

right side .

Switch knob

Motor

housing

Right

Left

(Switch knob side)

Left

(Switch knob side)

Wiring of Field lead wires

Field lead wires (red)

Field lead

wires (red)

Motor housing

Switch knob

Left

Right

Facing the connecting portion

of long Lead wire (red) to left,

insert Field into Motor housing.

Switch knob

Connecting portion of

long Lead wire (red)

Left

Right

Fig. D-3

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