Makita BJV140 Manual

Models No.
Description
PRODUCT
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
P 1 /13
Note: The standard equipment for the tool shown above may differ by country.
BJV140, BJV180
Cordless Jig Saw
Models BJV140 and BJV180 are MAKSTAR cordless jig saws powered by
3.0Ah Li-ion battery, featuring;
Compact and lightweight design
The same mechanism as used for the popular AC jig saw Model 4340FCT
Jig saw blade assortment ......... 1 set*3
Cover plate ............................... 1 pc
Anti-splintering device ............ 1 pc
Hex wrench 4 ........................... 1 pc
Dust nozzle .............................. 1 pc (for European countries only)
Plastic carrying case ................ 1 pc
Jig saw blades
Guide rule set
Guide rail
Guide rail adapter set
Anti-splintering device
Hose complete 28-5
Dust nozzle
Battery BL1430 (for BJV140 only)
Battery BL1830 (for BJV180 only)
Fast charger DC18RA
Charger DC18SC
Charger DC24SA (for North America only)
Charger DC24SC (for all countries except North America)
Battery
Specification
Net weight*2: kg (lbs)
Capacity: Ah
Cell
Voltage: V 18
No load speed: strokes per min.
SteelCapacities: mm (")
Wood*1
10 (3/8)
Aluminum 20 (25/32)
135 (5-5/16)
2.8 (6.1)
14.4
2.7 (5.9)
3.0
Li-ion
250 340
0 - 2,600
Length of stroke: mm (") 26 (1)
*1when cutting with optional blade No.B-16L *2with battery
Max output (W)
Model BJV140 BJV180
L
H
W
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 255 (10) 257 (10-1/8)
BJV140 BJV180
73 (2-7/8)
208 (8-3/16)
TECHNICAL INFORMATION
These products available in the following variations.
All models also include the accessories listed below in "Standard equipment".
BJV140
BJV140RFE
BJV140Z
BJV140 BL1430
(Li-ion 3.0Ah) DC18RA
No No
Model No. type quantity Charger Offered to
All countries
North America
All countries other than
North America
2
BJV140RF 1
Battery
BJV180
BJV180RFE
BJV180Z
BJV180 BL1830
(Li-ion 3.0Ah) DC18RA
No No
Model No. type quantity Charger Offered to
All countries
North America
All countries other than
North America
2
BJV180RF 1
Battery
(Illustrated above is BJV180.)
*3includes each 2 pcs of B-10, BR-13, B-22

P 2 /13
[1] NECESSARY REPAIRING TOOLS
CAUTION: Remove the jig saw blade from the machine for safety before repair/ maintenance,
in accordance with the instruction manual!
Repair
1R235 Round bar for arbor 6-100 Locking Crank complete when removing/fastening
M4x12 Hex socket head bolt
1R291 Retaining ring S and R pliers Removing/installing Retaining ring S-8 from/on the shaft portion
of Gear housing Complete
1R220 Ratchet head 9.5
1R222 Socket adaptor
1R254 Torque wrench shaft 2-6N.m
Removing/fastening M4x12 Hex socket head bolt from/to Crank complete
A-33750 Bit adaptor assembly
1R228* 1/4 Hex shank bit M4
1R311 Retaining ring pliers Removing/installing Retaining ring R-18 from/on Blade holder
DescriptionCode No. Use for
Fig. 1
Linear guide Groove portion where 28 Slider slides
Seal plate
Seal plate
Retainer
Blade holder
Gear housing cover complete Needle bearing 407
Gear complete
Crank complete
Balance plate
Push plate
Gear housing complete
Push pin Whole surface
Surface that contacts Gear housing cover complete
Surface that contacts Retainer
Upper, middle and lower portions of gear room
Surface that contacts Seal plate when Push plate moves downward
Inside surface of the large elliptic hole that contacts Gear complete
Each inside surface of the three small elliptic holes that contacts
corresponding pin on Gear housing complete
Slider
Rod
Groove portion where Needle bearing 407 slides
Item No. Description Portion to lubricate
*1R014 (1/4 Hex shank bit M4) can also be used.
[2] LUBRICATION and ADHESIVE APPLICATION
Apply Makita grease FA. No.2 to the following portions designated with the black triangle
to protect parts and product from unusual abrasion.
If you remove M4x12 Hex socket head bolt from Crank complete,
be sure to apply Loctite 241/242 or Threebond 1321/1342 to the bolt
when reinstalling. (Fig. 2)
LUBRICATION
ADHESIVE APPLICATION Fig. 2
Gear complete
Crank complete
Hex socket head
bolt M4x12
Apply machine oil #120 here
for smooth reciprocating of Rod.

P 3 /13
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Tool Opener
Repair
ASSEMBLING
1) Remove Base from Gear housing cover complete by unscrewing M5x18 Hex socket head bolt. (Fig. 3)
2) By unscrewing M4 + Pan head screw, Tool opener can be disassembled from Gear housing cover complete together
with Torsion spring 6. (Fig. 4)
1) Put Torsion spring 6 in the through hole of Tool opener, then fasten Tool opener to Gear housing cover complete
with M4 + Pan head screw. (Fig. 4)
2) Set the end of Torsion spring 6 in place by turning clockwise (viewed from the side of Base) with a small slotted
screwdriver or the like. (Fig. 5)
Tool opener
Torsion spring 6
+ Pan head screw M4
Fig. 3 Fig. 4
Fig. 5
Tool opener assembled to Gear housing cover complete
(viewed from Base side)
Blade holder
Tool opener
end of Torsion spring 6 set in place
Base
Square nut M5-8
Gear housing cover complete
Clamp plate
Hex socket head bolt M5x18
Tool opener
+ Pan head screw M4 Be sure to engage this end of Tool opener
with the hook of Blade holder.
Otherwise, you can not turn Blade holder
with Tool opener when changing blade.
DISASSEMBLING

P 4 /13
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear Housing Cover Section
Repair
1) Remove seven Tapping screws that fasten Handle (R) to Handle (L). (Fig. 6)
2) Remove Handles (R) and (L) from Motor housings (R) and (L) as illustrated in Fig. 6A.
3) Separate Gear housing cover section from Gear housing complete by unscrewing four CT4x16 Tapping screws.
(Fig. 7)
Fig. 6
Fig. 7
Tapping screw CT4x16 (4 pcs) Gear housing cover section
Packing
Gear housing complete
Motor housing (R)
Motor housing (L)
Gear housing
cover section
Gear housing cover section side
Handle (R)
Handle (L)
Motor housing (L)
Fig. 6A
Motor housing (R)
A
Tapping screws that fasten
Handle (R) to Handle (L):
A: Tapping screw 4x18 (5 pcs)
B: Tapping screw 4x40 (1 pc)
C: Tapping screw 4x50 (1 pc)
B
C
A
By pulling Handles (R) and (L)
towards Gear housing cover
section side, each hook portion
of Handles (R) and (L) can be
disengaged from the notch between
Motor housings (R) and (L).
If you are disassembling Gear housing cover section
without removing Tool opener, unscrew this Tapping
screw while opening Tool opener fully.
DISASSEMBLING

P 5 /13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear Housing Cover Section (cont.)
5) Disassemble Gear housing cover section by following the steps 1 to 5 described below in Fig. 8 to Fig. 11.
Stop ring E-3
Fig. 8
Fig. 11
Fig. 9
Fig. 10
Pan head screw
M4x10 (4 pcs)
Linear guide
(2 pcs)
Slider
Pin 4 (268090-1)
Leaf spring
[with Pin 4 (256117-9)
and Plane bearing 4]
DISASSEMBLING
Gear housing cover complete
Pin 4
(268090-1)
Rod
Slider
1. Remove Stop ring E-3
from Pin 4 (268090-1)
with a small slotted
screwdriver.
Gear housing cover section
(viewed from Motor housing side) 3. Disconnect Slider from Rod
by pulling Pin 4 (268090-1)
in the direction of the arrow.
2. Pull down Rod until it stops.
4. Pull off Rod from
Gear housing cover
complete.
5. By unscrewing four M4x10 Pan head screws, Gear housing cover section
can be disassembled as illustrated below.
Gear housing
cover complete
Plane bearing 4
Leaf spring
1) Assemble Pin 4 (256117-9) and Plane bearing 4 to Leaf spring if they are removed.
2) Put Leaf spring in place into Gear hosing cover complete. (Fig. 12)
3) Assemble Blade holder section to Gear housing cover complete as illustrated in Fig. 13.
Pin 4 (256117-9)
Motor housing side
Rod
Blade holder
Fig. 12 Fig. 13
ASSEMBLING
Gear housing cover complete
Note: Plane bearing 4 must be placed
on Motor housing side. hook
Note: The through hole of Rod and
the hook of Blade holder
must be placed as illustrated
to left.
through hole
Blade holder section
Motor housing side

P 6/13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear Housing Cover Section (cont.)
Fig. 15Fig. 14
4) Put Slider on Rod while aligning the two holes of Slider with the hole of Rod, and insert Pin 4 (268090-1) through
the aligned through holes from left side as illustrated to right in Fig. 14.
5) Swivel Slider in the direction of the black arrow, and insert two Linear guides to each side of Slider. (Fig. 15)
Rod
Pin 4
(268090-1)
Slider
Rod
Linear guide (2pcs)
Slider
6) Lay down Linear guides on Gear housing cover complete while lifting up Leaf spring, and place Leaf spring on
Linear guides. (Fig. 16)
7) Push Slider to the center of Linear guides. Fasten Leaf spring through Linear guides to Gear housing cover complete
with two M4x10 Pan head screws, then fasten Linear guides to Gear housing cover complete with the other two
M4x10 Pan head screws. (Fig. 17)
8) Assemble Stop ring E-3 to Pin 4 (268090-1) as illustrated in Fig. 18.
Note: Check whether Slider reciprocates smoothly on Linear guides. If not, Linear guide(s) can be tilted.
In this case, reassemble Linear guide(s) to Gear housing cover complete correctly.
Linear guide
Leaf spring
Slider
Fig. 16
Pan head screw M4x10 (4pcs)
Fig. 17
Linear guide
Stop ring E-3
Pin 4 (268090-1)
Rod
Fig. 18
Slider
ASSEMBLING
Leaf spring
Gear housing cover complete
Rod
Linear guide, set in place
between Leaf spring and
Gear housing cover complete
Gear housing cover complete
A
[Gear housing cover section viewed from A]
Leaf spring
Linear guide
Push Slider to
the center of
Linear guides.

P 7/13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear Housing Cover Section (cont.)
9) Lubricate the parts assembled to Gear housing cover
complete with reference to "Lubrication" in page 2.
10) While fitting Needle bearing 407 on Crank complete
in the groove portion of Slider, assemble Gear housing
cover section to Gear housing complete as illustrated
in Fig. 19.
Note: Do not forget to put Packing between Gear
housing cover complete and Gear housing.
(Fig. 7 in page 4)
ASSEMBLING
ASSEMBLING
[3] -3. Blade Holder
Retaining ring R-18
Blade holder
1) Take out Rod from Gear housing cover section. (Figs. 6, 7 in page 4; Figs. 8, 9, 10 in page 5)
2) Remove Dust cover and Retaining ring R-18 as illustrated in Fig. 20.
3) Blade holder and Torsion spring 15 can now be separated from Rod. (Fig. 21)
Note: Be careful not to lose Push pin.
Fig. 20 Fig. 21
Dust cover
DISASSEMBLING
Crank complete
Needle bearing 407
groove portion
of Slider
Gear housing
complete
Gear housing
cover complete
Gear housing cover section
Fig. 19
Torsion spring 15
Push pin
1) Apply Makita grease FA No.2 to Push pin. Put Push pin in the hole of Rod, and assemble Torsion spring 15 to Rod
as illustrated in Fig. 22.
2) Put Rod on Blade holder while aligning Push pin with the mark on Blade holder. (Fig. 23)
3) Turn the outward bent end of Torsion spring in the direction of the arrow, and put in the protruding space of Blade
holder. (Fig. 24)
3) Secure Blade holder with Retaining ring R-18 using 1R311, then assemble Dust cover to Rod. (Fig. 20)
Blade holder
Fig. 22 Fig. 23 Fig. 24
Push pin
mark
Rod
1R311
Blade holder
Insert the inward bent end of
Torsion spring 15 into the hole of Rod.
Push pin
Torsion spring 15
Rod
inward bent end
outward bent end
protruding space
outward bent end
of Torsion spring 15

P 8/13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Balance Plate, Crank Complete
ASSEMBLING
1) Separate Gear housing cover section from Gear housing complete. (Figs. 6, 7 in page 4)
2) Lock Crank complete using 1R235 or the like, and remove two M4x12 Hex socket head bolts. (Fig. 25)
Note: It is recommended to use impact driver to remove the bolts because threadlocker is applied to them.
3) By removing Retaining ring S-8 using 1R291, Balance plate and Crank complete can be disassembled from
Gear housing as illustrated in Fig. 26.
Fig. 25 Fig. 26
DISASSEMBLING
1) Assemble Flat washer 8 to the shaft portion of Gear housing complete. (Fig. 27)
2) Assemble Seal plate on Push plate. Mount Push plate on Gear complete, then assemble Gear complete to the shaft
portion of Gear housing complete. (Fig. 28)
3) Lubricate the parts with reference to "Lubrication" in page 2.
4) Assemble Balance plate to Gear complete while inserting the three pins of Gear housing complete through the
corresponding small elliptic holes of Balance plate. (Fig. 29)
Fig. 27 Fig. 28 Fig. 29
Push plate
Seal plate
Flat washer 8
Gear housing complete
Balance plate
Gear complete
Crank complete
Needle bearing 407
Retaining ring S-8
Hex socket head bolt
M4x12 (2 pcs)
Crank complete
Balance plate
1R235
or the like
Retaining ring S-8 Gear housing complete
Gear housing complete
Flat washer 8
Push plate
Seal plate
shaft portion
Gear complete
Balance plate
pin

P 9/13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Balance Plate, Crank Complete (cont.)
Fig. 30
ASSEMBLING
5) Mount Crank complete on the shaft portion of Gear housing complete.
While swiveling Crank complete, push it in the direction of Gear complete to put the raised portion of Crank complete
in the hole of Gear complete. The groove for Retaining ring S-8 can now be seen on the end of the shaft portion of
Gear housing complete. (Fig. 30)
6) Lock Crank complete using 1R235 or the like, and fasten Crank complete with two M4x12 Hex socket head bolts using
1R254, 1R220, 1R222, A-33750 and 1R228 or 1R014. (Fig. 31)
Note: 1. Do not forget to apply threadlocker to the two bolts.
2. The recommended fastening torque is 2.4-3.5 N.m.
7) Assemble Retaining ring S-18 to the shaft portion of Gear housing complete using 1R291. (Fig. 32)
8) Lubricate the parts with reference to "Lubrication" in page 2.
Crank complete
Fig. 32
Retaining ring S-8 Flat washer 8
Push plate
Seal plate
Balance plate
Gear complete
groove for Retaining ring S-8
Fig. 31
Crank complete
Balance plate
1R235 or the like
1R220 1R222
A-33750
1R228 or 1R014
1R254
A
shaft portion
Gear housing complete
[Viewed from A] Enlarged view
of the encircled portion
Gear housing complete
Gear complete
holeraised portion
Crank complete
shaft portion
Gear complete
raised portion
Hex socket head bolt M4x12 (2 pcs) Gear housing complete
Crank complete
shaft portion

P 10/13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Armature
Fig. 33
Gear housing
complete
1) Remove Handles (R) and (L) and Gear housing cover section. (Figs. 6, 7 in page 4)
2) Remove Retaining ring S-8 from the shaft portion of Gear housing complete.
By tapping the end surface of Gear housing complete with plastic hammer, remove the assembly of reciprocating
mechanism (including Crank complete, Balance plate, Gear complete) from Gear housing complete. (Fig. 33)
3) Remove Gear housing complete from Motor section by unscrewing four 4x30 Tapping screws. (Fig. 34)
4) Remove Brush holder caps and Carbon brushes from Motor housing.
5) By unscrewing four 4x18 Tapping screws, Motor section can be disassembled as illustrated in Fig. 35.
Retaining ring S-8
Crank complete
Gear complete
Balance plate
Tapping screw 4x30 (4 pcs)
Motor section
Fig. 34
Fig. 35
Motor housing (R)
Armature
Yoke unit
Endbell complete
Tapping screw 4x18 (4 pcs)
DISASSEMBLING
assembly of
reciprocating mechanism
Motor housing (L)
Do the reverse of the disassembling steps.
Important: Yoke unit is not reversible when assembled to Armature. Be sure to assemble so that the red mark of Yoke
unit is positioned on the drive-end side of Armature as illustrated to left in Fig. 36.
Note 1: Because Armature is pulled strongly towards Yoke unit by the magnet force of Yoke unit;
1) Be sure to hold the gear portion of Armature as illustrated to left in Fig. 37. Do not hold the Armature core
as illustrated to right or your fingers will be pinched between Yoke unit and the fan of Armature.
2) Be careful not to damage the copper wire of Armature.
ASSEMBLING
Fig. 36 Fig. 37
Your fingers can be pinched
and injured.
[Wrong][Correct] [Wrong][Correct]
Red marking
Armature remains in
Motor section in this step.
Red marking

P 11/13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Armature (cont.)
[3] -6. Switch
Fig. 40
Note: Be sure to place both of the two projections of Switch inside Switch lever as illustrated to left in Fig. 40
DISASSEMBLING
ASSEMBLING SWITCH LEVER TO SWITCH
1) Remove Handles (R) and (L) and Gear housing cover section. (Figs. 6, 7 in page 4)
2) Disassemble Lever from Gear housing complete as illustrated in Fig. 41.
Fig. 41
[3] -7. Lever 17
Stop ring E-5
Lever 17
Remove Stop ring E-5 from the
shaft portion of Lever 17 using
slotted screwdriver or the like.
Pull off Lever 17 from Gear housing
complete. Compression spring 3 and
Cap 5 can now be removed from
Lever 17.
Compression spring 3
Cap 5
[Wrong][Correct]
Gear housing complete
The two projections of
Switch serves as the guide
for Switch lever.
Switch
Switch lever
projection
The projection will
be broken if placed
outside of Switch lever.
Turn Lever 17 to the position III
(= large orbital cutting action).
Note 2: Place the wire connecting portions upside when assembling Endbell complete to Motor housings (R) and (L)
as illustrated in Fig. 38. And route Lead wires of Endbell complete through the space between the cut portions
of Motor housings (R) and (L). (Fig. 39)
ASSEMBLING
Endbell complete
wire connecting portion
cut portion
Motor housing (L)
Motor housing (R)
Fig. 38 Fig. 39
cut portion
space between the cut portions
of Motor housing (R) and (L)
Lead wires

P 12/13
Circuit diagram
Terminal
Switch
Connector
LED
M1
M2 (on the opposite side)
White
Fig. 42
Color index of lead wires' sheath
Black
Red
Orange
Endbell complete
FET

P 13/13
Fig. 43
Wiring diagram
Route Lead wires as illustrated in Fig. 43.
1 Lead wires of Endbell (black):
Route between the rib and the boss, and connect to No.M1 terminal of Switch.
Note: Be sure to fix with Lead wire holder A.
2 Lead wires of Endbell (red):
Route between the rib and the boss, and connect to No.M2 terminal of Switch.
Note: Be sure to fix with Lead wire holders A and B.
3 Lead wire of Switch (black):
Connect to minus pole of Terminal
Note: Be sure to fix with Lead wire holder A.
4 Lead wire of Switch (orange):
Connect this lead wire to plus pole of Terminal.
Note: Be sure to fix with Lead wire holder A.
5 Lead wire of Light circuit:
Route between the pin and the inside wall of Handle (L).
Wiring in Handle (L)
Lead wire holder B
Lead wire holder A
Switch lever
Endbell complete
Switch
Handle (L)
Terminal
FET
Gear housing complete
Lead wires of Endbell (red, black)
must be tight in this area.
Gear housing cover complete
Light circuit
boss
rib
pin
Connector
Handle (L)
Handle (R)
stepped edge
Heat sink
Assembling Heat sink to Handle (L)
1
2
3
4
5
Heat sink
Be sure to place the stepped edge on Handle (R) side.