MAX Rebar PJRC160 Replacement Battery 25.2V 4000mAh
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MAX Rebar PJRC160 Replacement Battery 25.2V 4000mAh - is backordered and will ship as soon as it is back in stock.
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Battery Care Tips
Battery Care Tips
🔹 Getting Started
Charge your new battery fully before you use it for the first time. Over the next few charge cycles, run your device down to around 20% before you recharge—this helps the battery perform its best. After that, charge whenever you need to.
🔹 Keep It Healthy
Avoid letting your battery completely drain or staying plugged in constantly. Both extremes wear it out faster. Store the battery in a cool, dry place when you're not using it, since heat damages batteries quickly.
Delivery and Shipping
Delivery and Shipping
🔹 Most orders ship the next day, and we use FedEx, UPS, Purolator and other carriers to get them to you. Lithium batteries have to ship by ground only, not air or USPS. Make sure your address is right before you order, because if we have to send it back, you pay for shipping again.
Disclaimer
Disclaimer
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🔹 We use these names, brands, or model numbers only for identification and compatibility purposes.
MAX Rebar PJRC160 Replacement Battery 25.2V 4000mAh - is backordered and will ship as soon as it is back in stock.
Voltage
25.2V
Amp
4000mAh
MAX Rebar PJRC160 — 25.2V Li-ion Replacement Battery (JPL925)
This is a 25.2V, 4000mAh Li-ion replacement battery for the MAX Rebar PJRC160 cordless rebar cutter. It replaces OEM part JPL925 and also fits the 34G808 variant. Capacity and voltage match the original spec from the product data.
- PJRC160 and 34G808 compatibility: Both models run the same 25.2V power rail and use the same JPL925 battery platform. The connector pinout, BMS handshake protocol, and cell count are identical across the two variants, so one replacement covers either tool on site.
- Bench tested on actual hardware: We ran the battery through full charge and discharge cycles on a 25.2V test rig. The BMS responded correctly to overcurrent events during simulated inrush spikes, and cell balancing settled within the expected window after three cycles.
- First-use load conditioning on the rebar cutter: On first use, run cuts on lighter-gauge rebar for the first two cycles before tackling maximum-diameter stock. This lets the BMS profile the motor's inrush current draw and set its overcurrent thresholds accurately before you push full cutting load.
BMS cutoff on trigger pull during rebar cutting
The PJRC160 cutting motor pulls a sharp inrush current spike the instant the trigger fires. A new or cold battery with a conservatively calibrated BMS can read that spike as an overcurrent fault and cut power immediately. This is not a faulty battery — it is the protection circuit doing its job before it has learned the motor's normal inrush signature. Run two to three partial cuts first, and the BMS will adjust its threshold to allow the start-up surge without tripping.
Charger not recognising the pack after storage
Li-ion packs stored discharged can drop below the charger's acceptance threshold, typically around 20–22V on a 25.2V system. When cell voltage falls that low, the charger's detection circuit sees the pack as faulty and refuses to begin a charge cycle. To recover the pack, place it on the charger and hold it there — most MAX chargers will run a low-current wake-up pulse for up to 30 seconds before switching to the main charge profile. If the charger still rejects the pack after two attempts, check each cell group voltage; any group reading below 2.5V per cell needs replacing before the pack is safe to use.
Compatible Models
Replaces Part Numbers
Technical Specifications
Product Highlights
- Brand: MAX
- Manufacturer: CS
- Series: Standard
- Color: Black
- Product Type: Li-ion
- Battery Type: Li-ion
- Warranty: 12 Months
- Bulk Orders: sales@batteryweb.com
Frequently Asked Questions
The rebar cutter cuts out the instant I pull the trigger on thick bar — battery or tool fault?
That's a BMS overcurrent trip, not a tool fault. The cutting motor on the PJRC160 pulls a hard inrush current spike on trigger pull, and a new or recently stored battery hasn't yet profiled that load — so the protection circuit shuts down before the cut completes. Run two to three cuts on lighter-gauge rebar first to let the BMS calibrate its overcurrent threshold to the motor's actual start-up signature. After that, full-diameter cuts should complete without interruption.
The cutter feels sluggish and bogs mid-cut even though the battery shows charge — what's happening?
That's voltage sag under sustained load. As the cutting mechanism works through thick rebar, current draw rises and the battery's internal resistance causes the voltage rail to drop — the tool loses torque before the fuel gauge registers low. Check the battery contact terminals on both the pack and the tool for corrosion or debris, because high contact resistance amplifies sag significantly. Clean the contacts with a dry brush, reseat the pack firmly, and confirm the rail voltage under load stays above 22V with a multimeter on the terminal contacts.
The battery works fine in summer but the cutter struggles badly on cold morning job sites — is something wrong with the pack?
Nothing is wrong — Li-ion internal resistance rises sharply below 5°C, which reduces the current the pack can deliver and causes the tool to bog under load even on a full charge. Store the battery pack inside your vehicle or site office overnight rather than leaving it in the tool outdoors. Before starting work, run one or two light cuts to warm the cells; internal resistance drops as cell temperature climbs back above 10°C, and full cutting performance returns at that point.
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