Makita Cordless Saw BJR240 User Manual

Cordless Recipro Saw  
Equipped with Electric Brake  
MODEL BJR240  
I N S T R U C T I O N M A N U A L  
WARNING:  
For your personal safety, READ and UNDERSTAND before using.  
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.  
w w w. m a k i t a t o o l s . c o m  
 
3. Keep bystanders, children, and visitors  
away while operating a power tool. Dis-  
tractions can cause you to lose control.  
Tool Use and Care  
12. Use clamps or other practical way to  
secure and support the workpiece to a  
stable platform. Holding the work by hand or  
against your body is unstable and may lead  
to loss of control.  
Electrical Safety  
4. A battery operated tool with integral bat-  
teries or a separate battery pack must be  
recharged only with the specified charger  
for the battery. A charger that may be suit-  
able for one type of battery may create a risk  
of fire when used with another battery.  
13. Do not force tool. Use the correct tool for  
your application. The correct tool will do the  
job better and safer at the rate for which it is  
designed.  
5. Use battery operated tool only with specif-  
ically designated battery pack. Use of any  
other batteries may create a risk of fire.  
14. Do not use tool if switch does not turn it  
on or off. A tool that cannot be controlled  
with the switch is dangerous and must be  
repaired.  
Personal Safety  
15. Disconnect battery pack from tool or  
place the switch in the locked or off posi-  
tion before making any adjustments,  
changing accessories, or storing the tool.  
Such preventive safety measures reduce the  
risk of starting the tool accidentally.  
6. Stay alert, watch what you are doing, and  
use common sense when operating a  
power tool. Do not use tool while tired or  
under the influence of drugs, alcohol, or  
medication. A moment of inattention while  
operating power tools may result in serious  
personal injury.  
16. Store idle tools out of reach of children  
and other untrained persons. Tools are  
dangerous in the hands of untrained users.  
7. Dress properly. Do not wear loose cloth-  
ing or jewelry. Contain long hair. Keep  
your hair, clothing, and gloves away from  
moving parts. Loose clothes, jewelry, or long  
hair can be caught in moving parts.  
17. When battery pack is not in use, keep it  
away from other metal objects like: paper  
clips, coins, keys, nails, screws, or other  
small metal objects that can make a con-  
nection from one terminal to another.  
Shorting the battery terminals together may  
cause sparks, burns, or a fire.  
8. Avoid accidental starting. Be sure switch  
is in the locked or off position before  
inserting battery pack. Carrying tools with  
your finger on the switch or inserting the bat-  
tery pack into a tool with the switch on invites  
accidents.  
18. Maintain tools with care. Keep cutting  
tools sharp and clean. Properly maintained  
tools with sharp cutting edge are less likely to  
bind and are easier to control.  
9. Remove adjusting keys or wrenches  
before turning the tool on. A wrench or a  
key that is left attached to a rotating part of  
the tool may result in personal injury.  
19. Check for misalignment or binding of  
moving parts, breakage of parts, and any  
other condition that may affect the tool’s  
operation. If damaged, have the tool ser-  
viced before using. Many accidents are  
caused by poorly maintained tools.  
10. Do not overreach. Keep proper footing  
and balance at all times. Proper footing and  
balance enable better control of the tool in  
unexpected situations.  
20. Use only accessories that are recom-  
mended by the manufacturer for your  
model. Accessories that may be suitable for  
one tool may create a risk of injury when  
used on another tool.  
11. Use safety equipment. Always wear eye  
protection. Dust mask, non-skid safety  
shoes, hard hat, or hearing protection must  
be used for appropriate conditions.  
3
 
22. When servicing a tool, use only identical  
replacement parts. Follow instructions in  
the Maintenance section of this manual.  
Use of unauthorized parts or failure to follow  
Maintenance instructions may create a risk of  
shock or injury.  
SERVICE  
21. Tool service must be performed only by  
qualified repair personnel. Service or main-  
tenance performed by unqualified personnel  
may result in a risk of injury.  
SPECIFIC SAFETY RULES  
USB029-2  
DO NOT let comfort or familiarity with product (gained from  
repeated use) replace strict adherence to cordless recipro saw  
safety rules. If you use this tool unsafely or incorrectly, you can  
suffer serious personal injury.  
1. Hold tool by insulated gripping surfaces  
when performing an operation where the  
cutting tool may contact hidden wiring.  
Contact with a “live” wire will make exposed  
metal parts of the tool “live” and shock the  
operator.  
6. Check for the proper clearance beyond  
the workpiece before cutting so that the  
blade will not strike the floor, workbench,  
etc.  
7. Hold the tool firmly.  
8. Make sure the blade is not contacting the  
workpiece before the switch is turned on.  
2. Be aware that this tool is always in an  
operating condition, because it does not  
have to be plugged into an electrical out-  
let.  
9. Keep hands away from moving parts.  
10. Always switch off and wait for the blade to  
come to a complete stop before removing  
the blade from the workpiece.  
3. Always use safety glasses or goggles.  
Ordinary eye or sun glasses are NOT  
safety glasses.  
11. Do not touch the blade or the workpiece  
immediately after operation; they may be  
extremely hot and could burn your skin.  
4. Avoid cutting nails. Inspect workpiece for  
any nails and remove them before opera-  
tion.  
12. Some material contains chemicals which  
may be toxic. Take caution to prevent  
working dust inhalation and skin contact.  
Follow material supplier safety data.  
5. Do not cut oversize workpiece.  
4
 
SAVE THESE INSTRUCTIONS  
WARNING:  
MISUSE or failure to follow the safety rules stated in this  
instruction manual may cause serious personal injury.  
SYMBOLS  
USD301-1  
The followings show the symbols used for tool.  
V .......................volts  
....................no load speed  
n
˚
...................direct current  
.../min................revolutions or reciprocation per  
minute  
IMPORTANT SAFETY INSTRUCTIONS FOR  
CHARGER & BATTERY CARTRIDGE  
USC002-2  
1. SAVE THESE INSTRUCTIONS - This man-  
ual contains important safety and operat-  
ing instructions for battery charger.  
6. To reduce risk of damage to electric plug  
and cord, pull by plug rather than cord  
when disconnecting charger.  
2. Before using battery charger, read all  
instructions and cautionary markings on  
(1) battery charger, (2) battery, and (3)  
product using battery.  
7. Make sure cord is located so that it will  
not be stepped on, tripped over, or other-  
wise subjected to damage or stress.  
8. An extension cord should not be used  
unless absolutely necessary. Use of  
improper extension cord could result in a  
risk of fire and electric shock. If extension  
cord must be used, make sure:  
3. CAUTION - To reduce risk of injury, charge  
only MAKITA rechargeable batteries  
marked on the charger label. Other types  
of batteries may burst causing personal  
injury and damage.  
a. That pins on plug of extension cord  
are the same number, size, and shape  
as those of plug on charger;  
4. Do not expose charger to rain or snow.  
5. Use of an attachment not recommended  
or sold by the battery charger manufac-  
turer may result in a risk of fire, electric  
shock, or injury to persons.  
b. That extension cord is properly wired  
and in good electrical condition; and  
c. That wire size is at least as large as  
the one specified in the table below.  
5
 
Table 1: RECOMMENDED MINIMUM AWG SIZE FOR EXTENSION CORDS FOR BATTERY CHARGERS  
Length of Cord (Feet)  
AWG Size of Cord  
25  
18  
50  
18  
100  
18  
150  
16  
9. Do not operate charger with damaged  
cord or plug - replace them immediately.  
12. To reduce risk of electric shock, unplug  
charger from outlet before attempting any  
maintenance or cleaning. Turning off con-  
trols will not reduce this risk.  
10. Do not operate charger if it has received a  
sharp blow, been dropped, or otherwise  
damaged in any way; take it to a qualified  
serviceman.  
13. If operating time has become excessively  
shorter, stop operating immediately. It  
may result in a risk of overheating, possi-  
ble burns and even an explosion.  
11. Do not disassemble charger or battery  
cartridge; take it to a qualified serviceman  
when service or repair is required, Incor-  
rect reassembly may result in a risk of  
electric shock or fire.  
14. If electrolyte gets into your eyes, rinse  
them out with clear water and seek medi-  
cal attention right away. It may result in  
loss of your eyesight.  
ADDITIONAL SAFETY RULES FOR CHARGER &  
BATTERY CARTRIDGE  
1. Do not charge Battery Cartridge when  
temperature is BELOW 10°C (50°F) or  
ABOVE 40°C (104°F).  
(3) Do not expose battery cartridge to  
water or rain.  
5. Do not store the tool and Battery Car-  
tridge in locations where the temperature  
may reach or exceed 50°C (122°F).  
2. Do not attempt to use a step-up trans-  
former, an engine generator or DC power  
receptacle.  
6. Do not incinerate the Battery Cartridge  
even if it is severely damaged or is com-  
pletely worn out. The battery cartridge can  
explode in a fire.  
3. Do not allow anything to cover or clog the  
charger vents.  
4. A battery short can cause a large current  
flow, overheating, possible burns and  
even a breakdown.  
(1) Do not touch the terminals with any  
conductive material.  
(2) Avoid storing battery cartridge in a  
container with other metal objects  
such as nails, coins, etc.  
6
 
SAVE THESE INSTRUCTIONS  
SYMBOLS  
The following show the symbols used for the charger. Be sure that you understand their  
meaning before use.  
.......... Ready to charge  
.............Charging  
...........Delay charge (Cooling)  
........Defective battery  
....Conditioning  
.............Charging complete  
...........Cooling abnormality  
7
 
FUNCTIONAL  
DESCRIPTION  
CAUTION:  
Always be sure that the tool is switched off and the  
battery cartridge is removed before adjusting or  
checking function on the tool.  
001661  
Installing or removing battery cartridge  
Always switch off the tool before insertion or removal of  
the battery cartridge.  
1
To remove the battery cartridge, withdraw it from the tool  
while sliding the button on the side of the cartridge.  
3
To insert the battery cartridge, align the tongue on the  
battery cartridge with the groove in the housing and slip  
it into place. Always insert it all the way until it locks in  
place with a little click. If you can see the red part on the  
upper side of the button, it is not locked completely.  
Insert it fully until the red part cannot be seen. If not, it  
may accidentally fall out of the tool, causing injury to you  
or someone around you.  
2
1. Red part  
2. Button  
3. Battery cartridge  
Do not use force when inserting the battery cartridge. If  
the cartridge does not slide in easily, it is not being  
inserted correctly.  
001662  
Charging  
1
1. Plug the battery charger into the proper AC voltage  
source. Two charging lights will flash in green color  
repeatedly.  
2
3
4
2. Insert the battery cartridge into charger until it stops  
adjusting to the guide of charger. Terminal cover of  
charger can be opened with inserting and closed with  
pulling out the battery cartridge.  
1. Battery cartridge  
2. Terminal cover  
3. Charging lights  
4. Battery charger  
3. When the battery cartridge is inserted, the charging light  
color will change from green to red and charging will  
begin. The charging light will keep lighting up lit steadily  
during charging. One red charging light indicates  
charged condition in 0 - 80% and two red ones indicates  
80 - 100%.  
4. With finish of charge, the charging lights will change  
from two red ones to two green ones.  
8
 
5. If you leave the battery cartridge in the charger after the  
charging cycle is complete, the charger will switch into  
its trickle charge (maintenance charge)mode which  
will last approximately 24 hours.  
6. After charging, unplug the charger from the power  
source.  
NOTE:  
The battery charger is for charging Makita battery  
cartridge. Never use it for other purposes or for other  
manufacturers batteries.  
When you charge a new battery cartridge or a battery  
cartridge which has not been used for a long period of  
time, it may not accept a full charge. This is a normal  
condition and does not indicate a problem. You can  
recharge the battery cartridge fully after discharging it  
completely and recharging a couple of times.  
If you charge a battery cartridge from a just operated  
tool or battery cartridge which has been left in a location  
exposed to direct sunlight for a long time, the charging  
light may flash in red color. If this occurs, wait for a while.  
Charging will begin after the battery cartridge is cooled  
by the cooling fan installed in the charger. (DC24SA  
only) When the temperature on battery is more than  
approx. 70°C, two charging lights may flash in red color,  
and when approx. 50°C - 70°C, one charging light in red  
color.  
If the charging light flashes alternately in green and red  
color, charging is not possible. The terminals on the  
charger or battery cartridge are clogged with dust or the  
battery cartridge is worn out or damaged.  
Cooling system (DC24SA only)  
This charger is equipped with cooling fan for heated  
battery in order to enable the battery to prove its own  
performance. Sound of cooling air comes out during  
cooling, which means no trouble on the charger.  
Yellow light will flash for warning in the following cases.  
- Trouble on cooling fan  
- Incomplete cool down of battery, such as, being  
clogged with dust  
The battery can be charged in spite of the yellow  
warning light. But the charging time will be longer than  
usual in this case.  
9
 
Check the sound of cooling fan, vent on the charger and  
battery, which can be sometime clogged with dust.  
The cooling system is in order although no sound of  
cooling fan comes out, if the yellow warning light will not  
flash.  
Always keep clean the vent on charger and battery for  
cooling.  
The products should be sent to repair or maintenance, if  
the yellow warning light will frequently flash.  
Conditioning charge (DC24SA only)  
Conditioning charge can extend the life of battery by auto-  
matically searching the optimum charging condition for the  
batteries in every situations.  
The battery employed in the following conditions repeatedly,  
will be worn out shortly, and yellow warning light may flash.  
1. Recharge of battery with its high temperature  
2. Recharge of battery with its low temperature  
3. Recharge of full charged battery  
4. Over-discharge of battery (continue to discharge battery  
in spite of down of power.)  
The charging time of such battery is longer than usual.  
Trickle charge (Maintenance charge)  
If you leave the battery cartridge in the charger to prevent  
spontaneous discharging after full charge, the charger will  
switch into its trickle charge (maintenance charge)mode  
and keep the battery cartridge fresh and fully charged.  
Tips for maintaining maximum battery life  
1. Charge the battery cartridge before completely dis-  
charged.  
Always stop tool operation and charge the battery  
cartridge when you notice less tool power.  
2. Never recharge a fully charged battery cartridge.  
Overcharging shortens the battery service life.  
3. Charge the battery cartridge with room temperature at  
10°C - 40°C (50°F - 104°F).  
Let a hot battery cartridge cool down before charging  
it.  
4. Charge the Nickel Metal Hydride battery cartridge when  
you do not use it for more than six months.  
10  
 
001663  
Adjusting shoe  
1
When the blade loses its cutting efficiency in one place along  
its cutting edge, reposition the shoe to utilize a sharp, unused  
portion of its cutting edge. This will help to lengthen the life of  
the blade. To reposition the shoe, loosen the lever counter-  
clockwise and slide the shoe forward or back to the desired  
position. Then tighten the lever clockwise to firmly secure the  
shoe.  
2
1. Lever  
2. Shoe  
001664  
Switch action  
CAUTION:  
1
Before inserting the battery cartridge into the tool,  
always check to see that the switch trigger actuates  
properly and returns to the OFFposition when  
released.  
2
To prevent the switch trigger from being accidentally pulled, a  
lock-off button is provided.  
1. Lock-off button  
2. Switch trigger  
To start the tool, press in the lock-off button and pull the  
switch trigger. The lock-off button can be pressed in from  
either left or right side of the tool. Tool speed is increased by  
increasing pressure on the switch trigger. Release the switch  
trigger to stop.  
001665  
Speed change  
CAUTION:  
B
A
1
Always set the speed change lever fully to the correct  
position. If you operate the tool with the speed change  
lever positioned half-way, the tool may be damaged.  
Do not use the speed change lever while the tool is  
running. The tool may be damaged.  
1. Speed change lever  
To change the speed, first switch off the tool and then slide  
the speed change lever to the A side (2) for high speed or B  
side (1) for low speed. Be sure that the speed change lever is  
set to the correct position before operation. Use the right  
speed for your job.  
11  
 
ASSEMBLY  
CAUTION:  
Always be sure that the tool is switched off and the  
battery cartridge is removed before carrying out any  
work on the tool.  
Installing or removing the saw blade  
CAUTION:  
Always clean out all chips or foreign matter adhering to  
the blade, blade clamp and/or slider. Failure to do so  
may cause insufficient tightening of the blade, resulting  
in a serious injury.  
001666  
To install the saw blade, always make sure that the blade  
clamp sleeve is in released position before inserting the saw  
blade. If the blade clamp sleeve is in fixed position, rotate the  
sleeve to the released position.  
1
2
3
1. Blade clamp sleeve  
2. Released position  
3. Fixed position  
001667  
Insert the saw blade into the blade clamp as far as it will go.  
The blade clamp sleeve rotates and the saw blade is fixed.  
Make sure that the saw blade cannot be extracted even  
though you try to pull it out.  
1
NOTE:  
If you do not insert the saw blade deep enough, the saw  
blade may be ejected unexpectedly during operation.  
This can be extremely dangerous.  
1. Blade  
001668  
To remove the saw blade, rotate the blade clamp sleeve in  
the direction of the arrow fully. The saw blade is removed and  
the blade clamp sleeve is fixed at the released position.  
1
NOTE:  
If you remove the saw blade without rotating the blade  
clamp sleeve fully, the sleeve may not be fixed. In this  
case, rotate the blade clamp sleeve fully, then make the  
sleeve fixed at the released position.  
1. Blade clamp sleeve  
12  
 
OPERATION  
001669  
CAUTION:  
Always press the shoe firmly against the workpiece  
during operation. If the shoe is held away from the  
workpiece during operation, strong vibration and/or  
twisting will be produced, causing the blade to snap  
dangerously.  
Always wear gloves to protect your hands from hot flying  
chips when cutting metal.  
Always use a suitable coolant (cutting oil) when cutting  
metal. Failure to do so will cause premature blade wear.  
If the tool is operated continuously until the battery  
cartridge has discharged, allow the tool to rest for 15  
minutes before proceeding with a fresh battery.  
Press the shoe firmly against the workpiece. Do not allow the  
tool to bounce. Bring the blade into light contact with the  
workpiece. First, make a pilot groove, using a slower speed.  
Then use a faster speed to continue cutting.  
MAINTENANCE  
CAUTION:  
Always be sure that the tool is switched off and the  
battery cartridge is removed before attempting to  
perform inspection or maintenance.  
001145  
Replacing carbon brushes  
Remove and check the carbon brushes regularly. Replace  
when they wear down to the limit mark. Keep the carbon  
brushes clean and free to slip in the holders. Both carbon  
brushes should be replaced at the same time. Use only iden-  
tical carbon brushes.  
1
1. Limit mark  
13  
 
001670  
Use a screwdriver to remove the brush holder caps. Take out  
the worn carbon brushes, insert the new ones and secure  
the brush holder caps.  
2
1
1. Brush holder cap  
2. Screwdriver  
To maintain product SAFETY and RELIABILITY, repairs, any  
other maintenance or adjustment should be performed by  
Makita Authorized or Factory Service Centers, always using  
Makita replacement parts.  
ACCESSORIES  
CAUTION:  
These accessories or attachments are recommended for  
use with your Makita tool specified in this manual. The  
use of any other accessories or attachments might  
present a risk of injury to persons. Only use accessory  
or attachment for its stated purpose.  
If you need any assistance for more details regarding these  
accessories, ask your local Makita service center.  
Recipro saw blades  
Plastic carrying case  
14  
 
Memo  
15  
 
Memo  
16  
 
First-Class  
Postage  
Required  
Post Office will  
not deliver  
without proper  
postage.  
Makita U.S.A., Inc.  
14930 Northam Street  
La Mirada, CA 90638-5753  
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3. How did you learn about this product:  
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)
2. Use of the product is intended for:  
4. Most favored points are:  
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5. Any comments:  
DATE PURCHASED  
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MODEL NO.  
DAY  
YEAR  
SERIAL NO.  
STATUS  
SEX  
Married Single  
M
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CUSTOMER’S RECORD  
Date Purchased  
When you need service: Send  
complete tool (prepaid) to one  
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Dealer’s Name & Address  
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19  
 
WARNING  
Some dust created by power sanding, sawing, grinding, drilling, and other  
construction activities contains chemicals known to the State of California  
to cause cancer, birth defects or other reproductive harm. Some examples  
of these chemicals are:  
lead from lead-based paints,  
crystalline silica from bricks and cement and other masonry products, and  
arsenic and chromium from chemically-treated lumber.  
Your risk from these exposures varies, depending on how often you do this  
type of work. To reduce your exposure to these chemicals: work in a well  
ventilated area, and work with approved safety equipment, such as those  
dust masks that are specially designed to filter out microscopic particles.  
MAKITA LIMITED 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, return the COMPLETE tool, freight prepaid, to one of  
Makitas Factory or Authorized Service Centers. If inspection shows the trouble is caused by defective  
workmanship or material, Makita will repair (or at our option, replace) without charge.  
This Warranty 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:  
alterations have been made to the tool.  
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CONSEQUENTIAL  
DAMAGES FROM THE SALE OR USE OF THE PRODUCT. THIS DISCLAIMER APPLIES BOTH DURING  
AND AFTER THE TERM OF THIS WARRANTY.  
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED WARRANTIES OF  
MERCHANTABILITYAND FITNESS FOR A SPECIFIC PURPOSE,AFTER THE ONE YEAR TERM OF THIS  
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 incidental or 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 446-8502 Japan  
884429A068  
 

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