Makita JS1600 User manual

MODEL JS1600
Max.cutting capacitles
Mild steel Stainless
I
INSTRUCTION MANUAL
Power
per weight
supply
Net
cutting Strokes Continuous
rating Overall
minute (Input) length cord
radius
DOUBLE
INSULATION
Specifications
2m
1.6" 1.2mm
(1/16~z) ! (3,64,,1 I ;olzm) 1 4,000 1 300 W 230" 1.7 kg
I (9-118") 1 (3.7 Ibs) ! (6.6 ft.1
I I I I I I
Manufacturer reserves the right tochange specifications of parts and accessories without notice.
Note: Specifications of parts and accessories mayvary fromcountry tocountry.

IMPORTANT SAFETY INSTRUCTIONS
WARNING: When using electrictools, basic safety precautions should always be followed
to reducethe riskof fire, electric shock, and personal injury, includingthe following:
READ ALL INSTRUCTIONS.
1. KEEP WORK AREA CLEAN. Clutteredareas and benches inviteinjuries.
2. CONSIDER WORK AREA ENVIRONMENT. Don't use power tools indamp or wet
locations. Keep work area well lit. Don't expose power toolsto rain. Don't use tool
inpresenceof flammable liquidsor gases.
3. KEEP CHILDREN AWAY. All visitors should be kept away from work area. Don't
let visitors contact tool or extensioncord.
4. STORE IDLE TOOLS. When not in use, tools should be stored indry, and highor
locked-upplace
- out of reach of children.
5. DON'T FORCE TOOL. It will do the job better and safer at the rate for which it
was intended.
6. USE RIGHT TOOL. Don't force small tool or attachment todo the job of a heavy-
duty tool. Don't use toolfor purpose not intended.
7. DRESS PROPERLY. Don't wear
loose clothing or jewelry. They can be caught in
moving parts. Rubber gloves and non-skidfootwear are recommendedwhen working
outdoors. Wear protectivehair covering to containlonghair.
8. USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty.
9. DON'T ABUSE CORD. Never carry tool by cord or yank it todisconnect from re-
IO. SECURE WORK. Use clamps or a vise to holdwork. It's safer than usingyour hand
11. DON'T OVERREACH. Keep proper footing and balance at all times.
12. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer
performance. Follow instructionsfor lubricating and changing accessories. Inspect
tool cords periodically and
if damaged, have repaired by authorized service facility.
Keep handles dry, clean, and free from oil and grease.
13. DISCONNECT TOOLS. When not inuse, before servicing, and when changingacces-
sories, such
as blades, bits, cutters.
14. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see
that keysand adjustingwrenches are removedfrom tool before turning it on.
15. AVOID UNINTENTIONALSTARTING. Don't carry plugged-intool with finger on
switch. Be sure switch
is OFF when plugging in.
16. OUTDOOR USE EXTENSIONCORDS. When tool is used outdoors, use only exten-
sion cords intendedfor use outdoors and
so marked.
17. STAY ALERT. Watch what you are doing, use common sense. Don't operate tool
when you are tired.
18. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part
that
is damaged should be carefullycheckedto determinethat it will operate proper-
ly and perform its intendedfunction. Check for alignment of moving parts, binding
of moving parts, breakage of parts, mounting, and other conditions that may affect
its operation. A guard or other part that is damaged should be properly repairedor
ceptacle. Keep cordfrom heat, oil, and sharp edges.
and
it frees both hands tooperate tool.
2

replaced by an authorized service center unless otherwise indicatedelsewhere in this
instruction manual. Have defective switches replaced by authorized service center.
Don't use
tool if switch does not turn it on and off.
19. GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded sur-
faces. Forexample; pipes, radiators, ranges, refrigerator enclosures.
20. REPLACEMENT PARTS. When servicing, use only identical replacement parts.
SAVE THESE INSTRUCTIONS.
VOLTAGE WARNING: Before connecting the toolto a power source (receptacle, outlet, etc.) be sure
the voltage
supplied is the same as that specified on the nameplate of the tool. A power source with
voltage greater than that specified for the toolcan result
in SERIOUS INJURY tothe user - as well as
damage to the tool.
If in doubt, DO NOT PLUG IN THE TOOL. Usinga power source withvoltage
less thanthe nameplate rating is harmfultothe motor.
Shear & Standard Equipment
Tool body
I
I_ 1 Switch lever (Paddle switch1
Yoke

How to use
Switch Operation
0 First, turn the safety lock to the FREE position. Then squeeze the switch lever (paddle
switch) to put on the tool; release
it to put it off.
Note: The switch lever (paddleswitch) does notwork with the safety lock inthe
LOCK
position. Do not try to work the switch lever (paddle switch) with the safety
lock on. Notusing the tool, put on the safety lock.
Material
Mild steel (A)
Hard steel
(B)
Stainlesssteel
Aluminum plate
(In
FREE condition)
~
Tensile Max. cutting
strength thickness
(kg/mm'
) h"
40 1.6 (1/16")
60 1.2 (3/64")
60 1.2 (3/64")
25 2.0 (5/64")
Switch
lever (Paddle switch)
Fig.
1
PermissibleShearingThickness
.The groove on the yoke serves
as a thick-
ness gauge for shearing mild or stainless
steel plate. If the material fits within the
groove, it is shearable.
.The thickness of materials to be sheared
depends upon the type (strength) of the
material. The maximum shearing thick-
ness
is indicated in the table on the right
in terms of various materials. Attempting
to shear materials thicker than indicated
will result in tool breakdown and/or pos-
sible injury. Keep within the thickness
shown at right.
(In LOCK condition)
Fig.
2
Fig. ~
4

IS0
(A) 3574-76
(E) R683
Holding (Fixturing) of Materials
ASTM AIS1
BS DIN NF
JIS
A109-72 1012 1449Part 1-72 1624-77 A36-401-80 SPC
A576 1055 070M55 CK55 xc55 s55c
-
.The materials for cutting
fastened to the work bench
of workholders.
should be
by means
~
Fig. 4
ShearingMethod
0 Keep the shear
material. moving parallel with the
Fig. 5
Blade Inspection
.Before using the tool check the blades for wear. Dull, worn blades will result in poor
shearing action, and the service life
of the tool will be shortened. Replace worn blades
as follows.
+Blades may be used in
8 different locationson the front and back.
When exchanging blades, always put in
a fresh set.
5

ChangingBlade Position
.Use the hex wrench provided to remove
the hex socket hd. bolt holding the shear
blade inplace.
.Turn the shear blade and replace with
a
new one. Some power shears have one
or more washers between the shear blade
and the holder. Be sure to use the same
number of washers when reassembling.
Note: No washers are used for the
sta-
tionary blade.
I I
I I
Fig. 6
Thin-washers
@&
Blade holder
1 Fig. i
.To secure the shear blade, tighten the hex socket hd.bolt with the hex wrench provided.
Keep pressure on the shear blade while tightening it. After fastening the blade, check to
be sure that there
is no clearance between the shear blade and blade holder bevelled
surface.
Blade holder
No clearance
Hex socket hd bolt allowed
Shear blade
Fig. I
6

When installing the stationary blade onto the yoke, the blade should be pressed against
the yoke
so as to be contactingthe bevelled yoke installingportions (A & B) and the tip
of the hex socket hd. hold-downscrew while you tighten the boltwith the hex wrench.
There must be noclearance between
A, B and C during the installation (see below).
+ The hex socket hd. hold-down screw shown in the diagram on the right is factory-
assembled.
Do not tamper with it.
I 1
Yoke
Stationary blade
Stationary
/=-
A
B
Hex socket hd. C
hold-downscrew
(flat tip) /-
Fig. 1
MaximumShearingWidth
.Stay within the specified maximum cutting width
(A): Case of length 1,800 mm
(7-7/8").
Unit: mm (inch)
I
t = under 1.2
Mild steel
No limit
Max. shearing
width
(A) (3-15/16")
Steel plate t = 1.2 t = under 1 .O
(Stainless) (3/64") (0.04")
Max. shearing
width
(A)
I
I
IA
1800 mm
(70-7/8")
No limitCuttino line
I
Unit: mm (inch)
t = under 1.2
I 11 I I \IlIOl (3/64")
I I
No limit
Max. shearing
100
width (A) (3-15/16")
I
1800 mm
I lifi (70-7/8") ,
I (0.04")
7

0 Replace carbon brushes when they wear
ing will occur. Both brushes should be
changed at the same time.
down to about
3 mm (1/8") or spark-
Fig. 1:
*To replace the carbon brushes, use a minus (-1 head screwdriver to remove the brush
holder cap.
e------
L.. .
3mm (1/8")
I I
Fig. 13
Fig. 14
8

Optional Accessories
CAUTION : The accessories specified in this manual are recommended for use with your Makita
Shear. The use
of any other accessory might be hazardous.
Blades
(twoper set of brister package)
Part
No. 191384-8
PROPER BLADE CLEARANCE
ADJUSTMENT
The correct blade clearance is 0.1 - 0.2 mm
(4 mil - 8 mil)
1.
2.
3.
4.
First, fasten carefully and securely the
stationary blade
at position A (as seen
on the right),
so that there is no clear-
ance.
Set the shear blade on the blade install-
ing portion of the blade holder.
Fit as many of the washers as possible
betweenthe blades.
Remove one of the above washers and
insert
it between the blade holder and
shear blade. Then fasten securely with
the hex. screw.
0 Hex wrench
Part No. 783201-2
Stationary blade
Blade
holder
Thin-washers Shear blade
I
Blade holder
Hex rocket hd.bolt
Fig. 17
9

SHEAR
Model JS1600

IFo: "& DESCRIPTION 'FDM DESCRIPTION
MACHINE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
4
1
1
1
1
1
1
1
1
1
1
t
1
1
I
1
1
2
1
1
1
1
1
1
1
-3
1
-
P. H Screw M4x30 (WithWasher1
Gear Housing IWith Needle Bearing 6091
Ball Bearing 627
F Washer 7
Rod
Needle
Bearing 1012
F Washer 10
Crank Shaft IWith
Helical Gear 391
F. Washer 6
Gear Housing Cover
Ball Bearing 608LB
Fan 58
ARMATURE ASSEMBLY
IArrembled Items 11. 12.13. 14
& 151
InsulationWasher
Ball Bearing 627LB
FIELD ASSEMBLY (With Garter Spring x 21
Rubber Pin 4
H. Bolt M4x55 IWith Warher)
Rubber
Pin 4
Pin 6
S Screw MBx16
Protector
S Washer 5
H S H Bolt M5x10
Blade Holder
T. Washer 5
ti. s. ti. Bolt ~4x10
MAC
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
44
45
46
-
47
48
49
UE
1
1
1
1
2
1
2
1
2
2
1
2
1
1
1
1
1
1
1
1
1
H
S ti Bolt M4x20
Yoke
H Nut M4-7
H S S Screw M6x6
P H Screw M4x30 IWith Warherl
Switch Cover
P H Screw M4x18 IWith Warherl
Strain
Relief
Brush Holder Cap
Carbon Brush CB-53
Switch
Rivet 0-5
Name Plate
Motor Housing IWith Brush Holder x 21
Cord Guard
CORD ASSEMBLY
IAsembledCord.
Plug E Cord Guard1
Leaf
Spring
Stop Ring E-3
SWITCH LEVER ASSEMBLY
IArrembled Items45 47
& 491
Switch Lever
P,n 4
Safety
Lock
4CCESSORIES
100 1 Wrench Holder 3-7
iii 1 1 Shear Blade
H Wrench 3

MAKKALIMKED ONE YEAR WARRANTY
Warranty Policy
Every Makita tool is thoroughly inspected and tested before leaving the factory. It is warranted to
be free of defects from workmanship and materials for the period of ONE YEAR from the date of
original purchase. Should any trouble develop during this one-year period, retum the COMPLETE
tool, freight prepaid, to one of Makita’s Factory or Authorized ServiceCenters. If inspection shows
the trouble is caused by defective workmanship or material, Makita
will repair (or at our option,
replace) without charge.
ThisWarranty does not apply where:
repairs have been made or attempted by others:
repairs are required because of normal wear and tear:
The tool has been abused, misused or improperly maintained;
alterationshave been made to the tool.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES FROM THE SALEOR USE OFTHE PRODUCT. THIS DISCLAIMER
APPLIESBOTH DURING AND AFTER THE TERM OF THIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,
AFTER THE ONE-YEAR TERM OFTHIS WARRANTY.
This Warranty gives you specific legal rights, and you may also have other rights which vary from
state to state. Some states do not allow the exclusion or limitation
of incidentalor consequential
damages,
so the above limitation or exclusion may not apply to you. Some states do not allow
limitation
on how long an implied warranty lasts, so the above limitation may not apply to you.
Makita Corporation
3-11-8, Sumiyoshi-cho,
Anjo, Aichi
446 Japan
883248A069 PRINTED IN JAPAN
1991
- 6 - N