Makita JS1601 Manual

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
1.7
50/60
50/60
50/60
50/60
50/60
380
---
380
380
380
160
160
160
160
160
280
280
280
280
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
L
W2
H
W1
PRODUCT
ECHNICAL INFORMATION
T

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
25
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)
18
17
3g
Rod
a little
Pin 5
33
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
18
17
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
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
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
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
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
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
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