Makita BJR181 Manual

Models No.
Description
PRODUCT
TECHNICAL INFORMATION
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
P 1 /14
Model BJR181 has been developed as the first cordless recipro saw that is
powered by 18V/3.0Ah Li-ion battery.
Whilst having the same basic construction as our AC model JR3050T,
features the additional and original advantages, for example, as follows;
Ergonomic grip best-fitting to overhead application
Two-light type LED job light for more illuminated work-surface
Belt clip
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 499 (19-5/8)
91 (3-5/8)
234 (9-1/4)
Note: The standard equipment for the tool shown above may differ from country to country.
BJR181
Cordless Recipro Saw
Recipro saw blade for wood .................................. 1 pc
Recipro saw blade for metal .................................. 1 pc
Charger DC18SC
Charger DC24SA
Charger DC24SC
Li-ion battery BL1830
Assorted recipro saw blades
Battery
Electric brake
Max cutting capacities: mm (")
[when cutting with a 300mm blade] pipe
Length of stroke: mm (")
Cell
Voltage: V
Capacity: Ah
Li-ion
18
3.0
Yes
Variable speed Yes
Net weight*: kg (lbs)
*Includes battery BL1830
3.7 (8.1)
dia. 130 (5-1/8)
wood 255 (10)
28 (1-1/8)
No load speed: min-1=spm 0 - 2,900
Max output (W) 290
BJR181SF
BJR181Z
BL1830DC18SC
NoNo
Model No. type quantity Charger
No
Yes
Plastic
carrying case
1
No
BJR181SFE 2
BJR181
All countries other than
USA, Canada,
Mexico, Panama
USA, Canada,
Mexico, Panama
No
BL1830DC18SC
No
Yes
No
2
Battery
This new product will be available in the following variations.
All models also include the accessories listed below in "Standard equipment".
W
L
H
No
Offered to
All countries

P 2 / 14
Repair
[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 1321B or 1342B, or Loctite 242.
[1] NECESSARY REPAIRING TOOLS
CAUTION: Remove the recipro saw blade and battery cartridge from the machine
for safety before repair/ maintenance !
Fig. 1
38
Blade clamp section
Plane bearing 14A
29
6 Shoulder pin 5
Slider complete Surface that contacts Plane bearing 14A
Surface that contacts Needle bearing 708 (Put approx. 7g.)
Pin head that contacts Driving sleeve
Gear assembly Surface of crank pin that contacts Needle nearing 708
40 Flat washer 14 Surface that contacts Gear assembly
Plane bearing 14A
17 X ring 14 Inside surface that contacts Slider complete
46 Gear housing complete Pin 10 (the gear shaft for Gear assembly)
Gear room (Put approx. 10g.)
Driving sleeve
1R146 L type torx wrench M6 Removing Shoe guide
1R232 Pipe 30
Round bar foe arbor 13-100
Round bar foe arbor 26-100
Spring pin extractor 2.5
Spring pin extractor 1.5
Bearing extractor
Retaining ring S and R pliers
Removing/ installing Needle bearing 1012
1R242 Removing / installing Needle bearing 1012
1R250 Press-fitting Oil seal 14
1R267 Removing Shift button
1R269 Removing Ball bearing 6001DDW
1R291 Removing /installing Retaining rings S-18 and S-12
1R296 Removing Pin 3 from the Blade clamp section
1R314
---
Torx bit VT-25
Recipro saw blade
Removing /installing Torx socket head screw
Assembling Pin 3 to the Blade clamp section
Code No. Description Use for
Item No. Description Portion to be lubricate
Gear housing cover complete
Needle bearing 708

P 3 / 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Blade Clamp Section
1) Remove Shoe. If the Blade clamp section is positioned inside
Gear housing, pull it out of Gear housing. (Fig. 2)
2) After removing Protector, remove Retaining ring S-18 with
Retaining Ring S and R pliers (No.1R291).
Then remove the following parts:
Driving sleeve, Shoulder pin 5, Compression spring 6,
Pin 3 (of 6mm length), Guide sleeve, Driving sleeve guide
Now Sleeve appears. (Fig. 3)
3) Sleeve is still locked at this
stage. Therefore, release it
using a recipro saw blade
as illustrated in Fig. 4.
DISASSEMBLING Fig. 2
Shoe
Blade clamp section
Fig. 3
Driving sleeve
Shoulder pin 5
Compression spring 6
Driving sleeve guide
Pin 3
(of 6mm length) Guide sleeve
Sleeve
Protector
Retaining ring S-18
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, then take Push plate and Compression spring 2 out of the slit of
Slider. (Fig. 6)
Push plate
Compression
spring 2
Sleeve
Slider
Torsion
spring 17
Fig. 5 Fig. 6
Slider
Sleeve
thin bar
Pin 3, 19.8mm long
Fig. 4
Sleeve
groove
[Sleeve Locked] [Sleeve Released]
Pin 3, 19.8mm long
Recipro saw blade Push the recipro saw blade.
Now sleeve can rotate.
Pin 3 is positioned at
the lower end of the
groove on Sleeve
when Sleeve is released.

P 4 / 14
Repair
[3] -1. Blade Clamp Section (cont.)
ASSEMBLING
Fig. 8
1) Assemble Torsion spring 17 to Slider as illustrated in Fig. 7.
Important: Be sure that Torsion spring 17 is not reversible when assemble to Slider.
Follow the instruction described in Fig. 7.
2) Insert Compression spring 2 into the slit of Slider.
3) Install Sleeve on Slider, and lock Pin 3 provisionally by turning Sleeve clockwise. (Fig. 8)
4) Mount Guide sleeve provisionally, then put Push plate into the slit of Slider as illustrated to left in Fig. 9.
Important: Be sure that Push plate is not reversible when installed.
While pushing Push plate straight into Slider with recipro saw blade, insert Pin 3 (of 19.8mm length) through the hole
of Push plate as illustrated to right in Fig. 11. Then remove Guide sleeve.
Note: Guide sleeve is used as a jig, not assembled to Slider yet in this step.
Pin 3, 19.8mm long
Sleeve
Slider
Fig. 9
This projection must
face the blade side.
Push plate
Guide sleeve
Recipro saw blade
Fig. 7
Insert this end
into the slit of
Slider.
This end has to
be positioned
on the Cap side.
Shift button
Slider
Torsion spring 17
Cap
[Side view of cap]
Cap has an insert hole
for Shift button.
Pin 3, 19.8mm long
insert pin 3 through
the hole of push plate.
While pushing recipro saw blade,

P 5 /14
Repair
[3] -1. Blade Clamp Section (cont.)
Fig. 10
5) While fitting the two projections of Driving sleeve in the concavities of Sleeve, push Driving sleeve into Gear housing.
At this time, turn Driving sleeve clockwise so that the protruding portion of Driving sleeve cannot be interfered by
Gear housing. After Driving sleeve is pushed into Gear housing to the full, turn Driving sleeve clockwise to lock Pin 3
in place. (Fig. 10)
Note: Driving sleeve is used as a jig to lock Pin 3 in place, not assembled to Slider in this step.
6) Remove Driving sleeve.
7) Assemble the following parts to Slider (Refer to Fig. 3.):
Driving sleeve guide, Guide sleeve, Pin 3 (of 6mm length), Shoulder pin 5, Compression spring 6
8) Put Driving sleeve over Guide sleeve and secure with Retaining ring S-18 using No.1R291.
Then cover Driving sleeve with Protector. (When installing Driving sleeve, fit its projections in the concavities of
Sleeve and Driving sleeve guide.)
Projections
Concavities
Driving sleeve Driving sleeve
Sleeve
Sleeve
[3] -2. Shift Button and Cap
Shift button can be removed from Gear housing cover by
inserting a thin bar into the hole of Cap and push the bar.
(Fig. 11)
DISASSEMBLING
ASSEMBLING
Fig. 11
Shift button
thin bar
Cap
Fig. 12
1) Replace Cap by new one because removal of Shift button
damages the inside surface of Cap.
2) From Shift button, remove all the plastic dust scraped off
the removed Cap. Insert Shift button through the holes in
the both sides of Gear housing cover.
Then press-fit Shift button in the new Cap by hand.
Important:
Be sure to assemble Shift button to Gear housing cover
so that the two notches of Shift button face the side
opposite to slider as illustrated in Fig. 12.
Slider
Shift button
Cap
These notches of Shift button must
face the side opposite to Slider.

P 6 /14
Repair
Fig. 13
DISASSEMBLING
[3] -3. Slider Section
Insulation cover
LED circuit
Gear housing
cover complete
1) After removing Shoe, then Insulation cover. (Fig. 13)
2) Remove the Blade clamp section. (See "[3] -1. Blade Clamp Section.)
3) Remove Cover from LED circuit, then disconnect the
connector from the connector of Power supply unit.
(Fig. 14)
4) Remove LED circuit from Gear housing cover
complete by lifting up as illustrated in Fig. 15,
5) Remove Gear housing cover complete from Gear
housing complete by unscrewing four M5x25
Pan head screws. (Fig. 16)
Insulation cover
Slider, after removal of
the Blade clamp section
Gear housing
complete
Gear housing
cover complete
Fig. 15 Fig. 16
Pan head screw
M5x25 (4pcs)
For smooth removal of Insulation cover,
apply soapy water into the slit between
Insulation cover and Gear housing cover
complete.
Important: Be careful not to wet
LED circuit with soapy water.
Fig. 14
Cover
Connector of
Power supply unit
LED circuit
Gear housing
cover complete

P 7 /14
Repair
Fig. 18
DISASSEMBLING
ASSEMBLING
[3] -3. Slider Section (cont.)
Plane bearing 14A
Do the reverse of disassembling steps.
Note:
a) Do not forget to apply Makita grease FA No.2 to slider before assembling. (Fig. 19)
b) Both of the two 14A Plane bearings are not reversible when assembled to Slider.
Be sure to assemble as illustrated in Fig. 20.
Plane bearing 14A
Slider
While raising this
end, pull off Slider.
Push Slider toward
the Motor housing side.
Remove Plane bearing 14A
on the Motor housing side.
6) Remove two Plates from Gear housing cover complete
by unscrewing four M5x16 Pan head screws. (Fig. 17)
Note: It is recommended to use impact driver to
remove the screws because they are coated with
threadlocker.
7) Disassemble Slider as illustrated in Fig. 18.
Surface that contacts
Plane bearing 14A: a little amount
Surface that contacts
Needle bearing 708: approx. 7g
Fig. 19
Gear housing cover side
Motor housing side
Blade clamp side
Gear housing side
Stepped portion
Plane bearing 14A Slider Plane bearing 14A
Fig. 20
Pan head screw M5x16,
threadlocker coated
Plane bearing
14A
Gear housing
cover complete
Slider
Fig. 17
Plate
Plate
Plane bearing
14A
Stepped portion

P 8 /14
Repair
[3] -4. Oil Seal 14, X Ring 14
DISASSEMBLING
1) Referring to "[3]- 3. Slider Section", separate Gear
housing cover complete from the tool.
2) Oil seal 14 can be removed by pushing X ring 14 toward
the Blade clamp side using a slotted screwdriver as
illustrated to left in Fig. 21.
3) X ring 14 can now be removed by pushing toward the
Blade clamp side by hand as illustrated to right in Fig. 21.
ASSEMBLING
Fig. 22
1) As illustrated to left in Fig. 22, assemble X ring 14 to Gear housing cover complete from the Blade clamp side,
then put Oil seal 14 onto X ring 14.
Note: Oil seal 14 is not reversible when assembled to Gear housing complete. Be sure to assemble so that
the lip portion of Oil seal 14 faces toward the Blade clamp side.
2) As illustrated to right in Fig. 22, set Round bar for arbor 26-100 (No.1R250) on Oil seal 14, then press down
with arbor press until the end of the lip portion of Oil seal 14 gets is flush with the top surface of the ring installation
hole of Gear housing cover complete.
Oil seal 14
No.1R250
X Ring 14
lip portion
Fig. 21
Oil seal 14 X ring 14
Blade clamp side
Motor housing side
Blade clamp side
Motor housing side

P 9 /14
Repair
[3] -5. Gear Assembly
Fig. 23 Fig. 24
DISASSEMBLING
1) Referring to "[3]- 3. Slider Section", remove Gear housing cover complete from Gear housing complete.
2) Remove two C Plates by unscrewing four M5x14 Torx socket head screws with Torx bit VT-25 (No.1R314). (Fig. 23)
Note: It is recommended to use impact driver to remove the screws because they are coated with threadlocker.
3) The following parts can now be removed from Gear housing complete (Fig. 24);
Gear assembly, Needle bearing 708, Needle bearing 1012, Flat washer 14
Gear housing
complete
Plate C
Torx socket
head screw M5x14
No.1R314
Gear assembly
Needle bearing 708
Needle bearing 1012
Flat washer 14
ASSEMBLING
Do the reverse of the disassembling steps.
Note: a) Apply Makita grease FA No.2 to the following parts, before assembling:
*Flat washer 14: the surface that contacts Gear assembly
*Pin 10 (of Gear housing complete): surface that contacts Gear assembly
b) Torx socket head screw M5x14 is threadlocker coated. Therefore, if reusing the screw, be sure to apply adhesive
before tightening.
Pin 10

P 10 /14
Repair
Fig. 26 Fig. 27
DISASSEMBLING
[3] -6. Armature
3) Remove two M5x16 Pan head screws that fasten Bearing retainer 63 to Gear housing complete.
The assembly of Armature and Bearing retainer 63 can now be removed from Gear housing complete by tapping the end
surface of Gear housing complete. (Fig. 26)
4) Remove Retaining ring S-12 using Retaining ring S and R pliers (No.1R291), then Ball bearing 6001DDW using Bearing
extractor (No.1R269). Bearing retainer 63 can now be removed. (Fig. 27)
Pan head screw M5x16
Do the reverse of the disassembling steps.
Note: Make sure that Stop ring E-10 is assembled in place on Armature shaft
to secure Ball bearing 6001DDW. (Fig. 28)
Bearing
retainer 63
Retaining ring
S-12
Ball bearing
6001DDW
Armature
Bearing
retainer 63
ASSEMBLING Fig. 28
Stop ring E-10
Fig. 25
1) Separate Gear housing cover complete from Gear housing complete. (fFig. 13 to Fig. 16)
2) Remove Carbon brushes. Then separate the assembly of Armature and Gear housing complete from Motor housing
complete by unscrewing four 5x25 tapping screws. (Fig. 25)
Gear housing complete Motor housing complete
Tapping screw 5x25
(4pcs) Carbon brush (2pcs)
Brush holder cap (2pcs)
Armature

P 11 /14
Repair
[3] -7. Handle Section
Fig. 30
DISASSEMBLING
ASSEMBLING
Hook assembly
See Fig. 29.
1) Removing Hook assembly.
2) Remove Handle R by unscrewing six 4x20 Tapping screws.
Do the reverse of the assembling steps.
Note: When assembling Lock-off button to the Handle section, do as illustrated in Fig. 30.
Handle R
Handle L
Lock-off button
Leaf spring
Be sure to remove Hook assembly
before disassembling the handle section,
because this portion interferes with
the removal of Handle R.
Leaf spring
Be careful not to lose these two
M5 Square nuts.
Fig. 29
Lock off button
Fit this convex with either of
the two concaves of Lock-off button.
Fit the curled ends in
the rib on each handle.

Terminal
Circuit diagram
P 12 /14
Color index of lead wires' sheath
Black
White
Red
Orange
Blue
Left view
Left view
Switch
Heatsink
Right view
Brush holder, Left
Brush holder, Right
Power supply
circuit
FET
Protective
tube
Right view
LED circuit
Brush holder, Left
Brush holder, Right
Switch
Connectors
Connectors

Wiring diagram
P 13 /14
1) Handle L
The flag connector has to be so connected that
the wire connecting portion is positioned on
the side of pole marks of Terminal.
Flag connector
Terminal
Connecting Flag Connector to Terminal
Wire connecting portion
Pole marks
Power supply circuit
boss
rib
boss
Connector
Handle L
Lead wire holder
Switch
Terminal
Be careful not to route Brush holder lead wire
(red) over this boss.
Fix Brush holder lead wire
(black) with this lead wire holder.
Fix the following lead wires
with these lead wire holders:
* Lead wire (blue) from
Power supply circuit
to Connector
* Lead wire (blue) from
Switch to Connector
Be careful not to route
lead wire (blue) over this rib.
With this lead wire holder, fix the following
lead wires from Power supply circuit:
*2 Lead wires (black, orange) to Switch
*Lead wire (blue) to Connector
Between this boss and the inside wall
of Handle, route the following lead wires
from Power supply circuit:
*2 Lead wires (black, orange) to Switch
*Lead wire (blue) to Connector
Assemble the Connecting terminals
to Switch as illustrated below.
back of
switch
approx. 30 degrees
Connecting terminal
Fastening Connecting Terminals
to Switch
See bottom left of this page.
Fastening Connecting
Terminals to Switch
See bottom right of this page.
Connecting Flag Connector
to Terminal

Wiring diagram
P 14 /14
Connector of
LED Circuit Connector of Power
Supply Circuit
Put the connectors (connector of LED circuit and that of Power supply circuit) in place as illustrated below.
rib A
rib B
2) Motor Section
3) LED Circuit
Motor housing, viewed from front
Route the two Lead wires (black, white) of Power supply circuit as illustrated below.
Connector of
Power supply circuit
Motor housing
rib A
2 Lead wires (black, white)
of Power supply circuit
rib B Route through this hole
into Motor housing.
Route between rib A and rib B.
Connector of
Power supply circuit
LED circuit