Makita BJN160 Manual

PRODUCT
P 1/ 8
Model No.
Description
CONCEPT AND MAIN APPLICATIONS
BJN160/ BJN161
1.6mm (16Ga) Cordless Nibbler
Specification
Standard equipment
Optional accessories
Punch
Die
Battery BL1430 for Model BJN160
Battery BL1830 for Model BJN161
Note: The standard equipment for the tool shown above may vary by country.
Punch .................... 1 Die .................... 1 Hex wrench 2.5 .................... 1 Wrench 32 .................... 1
These products will be available in the following variations.
All models also include the accessories listed below in "Standard equipment".
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 313 (12-3/8)
78 (3-1/16)
174 (6-7/8) 189 (7-7/16)
BJN160 BJN161
L
W
BJN160
BJN161
Models BJN160 and BJN161 are cordless nibblers developed with
the same design concept as AC tool JN1601, featuring slim motor housing of
DC angle grinder BGA450.
Punch and die (that are the same as those of JN1601), and following 3.0Ah
Li-ion batteries provide high cutting capacity.
• BL1430 (14.4V) for BJN160
• BL1830 (18V) for BJN161
Note: 1.3Ah Li-ion battery BL1415/ BL1815 cannot be used for these models.
*2 with Punch, Die and Battery
Battery
Max cutting capacities:
mm (Ga)
Stainless steel with tensile
strength up to 600N/mm²
Cell
Voltage: V
Capacity: Ah
Li-ion
14.4 18
3.0
Weight according to EPTA-Procedure 01/2003*2: kg (lbs) 2.1 (4.6) 2.2 (4.8)
1.2 (18)
Aluminum with tensile
strength up to 200N/mm² 2.5 (12)
Mild steel with tensile
strength up to 400N/mm² 1.6 (16)
No load speed: min.ˉ¹=spm (strokes per minute) 1,900
Max output (W)
Minimum cutting radius:
mm (")
Inner edge: 45 (1-3/4),
Outer edge: 50 (2)
Overload protection by current limiter Yes
280 350
Specification Model BJN160 BJN161
Charging time (approx.): min.
H
L
W
H
Model No. Type Quantity Charger Plastic
carrying case
Battery
cover
No
Battery
BJN160Z No No
BJN160RFE DC18RC Yes2
BL1430 1
NoNo
NoBJN161Z No No
BJN161RFE DC18RC Yes2BL1830 1
NoNo
No--- No No
--- DC18RA No2BL1830 1
NoNo
Offered to
All countries except
North and Central
American countries
North and Central
American countries
44
22 with DC18RC (DC18RA*1)
54Energy capacity: W
Cut SPCC sheet of
1.6mm (16Ga) thick
Fast charger DC18RA (for USA, Canada, Guam, Panama, Mexico, Colombia)
Fast charger DC18RC (All countries except the countries above)
Charger DC24SC
Charger DC18SD
Automotive charger DC18SE
TECHNICAL INFORMATION
OFFICIAL USE
for ASC & Sales Shop

Repair
Apply Makita grease FA No.2 to the following portions designated with the black triangle to protect parts and product
from unusual abrasion.
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Gear housing complete
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Code No. Description Use for
1R030 Bearing setting pipe 25-17.2 assembling Spur gear 31 to Crank shaft
1R032 Bearing setting plate 8.2 supporting Crank shaft when assembling Spur gear 31
1R217 Ring 22 supporting Spur gear 31 when removing Crank shaft
1R282 Round bar for Arbor 8-50 removing Crank shaft from Spur gear 31
[2] LUBRICATION
Fig. 1
Item No. Description
Spur gear 31
Gear complete 16-36
Teeth portion where the small gear of 10 engages
Teeth portion of large gear where Armature’s gear engages
Ram a Currve of hourglass shaped portion
b narrow portion between small rim and large rim
Rod
Crank shaft
AmountPortion to lubricate
DISASSEMBLING
Gear housing
complete
Punch holder
(1) Separate Gear housing complete as drawn in Fig. 2.
Lock nut
1. Remove Lock nut with Wrench 32
by turning it counterclockwise.
2. Separate Gear housing complete together with Die holder section
from Gear housing cover complete by unscrewing four 4x40
Tapping screws.
4x40 Tapping screw
(4 pcs.)
Gear housing
cover complete
Gear housing
complete
Die holder section
Approx. 4 g
Approx. 1 g
Approx. 1 g
Approx. 3 g
Gear housing
complete
Fig. 2
Wrench 32
P 2/ 8

P 3/ 8
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Gear Housing Complete (cont.)
DISASSEMBLING
(2) Disassemble the component parts from Gear housing complete as drawn in Fig. 3.
1. Remove Stopper by unscrewing
Bind CT4x12 Tapping screw.
Stopper
Bind CT4x12 Tapping
screw
Die holder
section
2. Pull off Die holder section from
Gear housing complete.
Fig. 3
Punch
Gear housing
complete
4. Remove Punch holder together
with Punch from Ram.
5. Remove Gear complete 16-36
from Gear housing complete.
Note: Be careful not to lose
Flat washer 6.
3. Set Punch to the lowest position
by turning Gear complete 16-36.
Gear complete
16-36
Ram
Punch holder
Punch
Spur gear 31
6. Lift up Spur gear 31 until the
space for twisting Spur gear 31
and Crank shaft is reserved.
7. Remove Super gear 31 together with Crank section
while turning them 90°.
Note: Be careful not to lose Flat washer 8.
Flat washer 6
Flat washer 8
Gear complete 16-36

Repair
DISASSEMBLING
ASSEMBLING
(3) Disassemble Spur gear 31 and Crank section as drawn in Fig. 4.
(1) Assemble Spur gear 31 and Crank section as drawn in Fig. 5.
(2) Assemble Spur gear 31, Crank section and the other component parts to Gear housing complete by reversing
the disassembly procedure. (Refer to Fig. 3)
Note: Do not forget to mount Flat washer 6 to Gear complete 16-36. (Refer to the center drawn in Fig. 3)
Fig. 4
1. Separate Ram by removing Pin 6, and then
remove Spur gear 31 together with Crank
shaft from Rod.
2. Place Super gear 31 and Crank shaft on 1R217.
Then, press Crank shaft down with 1R282.
Note: Be careful not to lose Woodruff key 3.
Woodruff key 3
Pin 6
Ram
Ram
Spur gear 31 Spur gear 31
1R282
1R030
Crank shaft
Crank shaft
Rod
Crank shaft
1R217
Woodruff key 3
Crank shaft
Crank shaft
1. Set Woodruff key 3 to Crank shaft.
And then, insert the slim end of
Crank shaft into Spur gear 31
from its stepped side while fitting
Woodruff key 3 to the groove of
Spur gear 31.
2. Put Super gear 31 and Crank
section onto 1R032.
Then, Press the Gear down
with 1R030 until it stops.
slim end
stepped side
Spur gear 31
Spur gear 31
groove
1R032
3. Insert Crank shaft into Rod, and
assemble Ram to the other end
of Rod with Pin 6.
Note: Do not forget to mount
Flat washer 8.
Rod
Spur gear 31
Crank shaft
Pin 6
Flat washer 8
Fig. 5
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Gear Housing Complete (cont.)
P 4/ 8

[3] DISASSEMBLY/ASSEMBLY
[3] -2. Armature
[3] -3. Yoke unit
DISASSEMBLING
ASSEMBLING
(3) Disassemble Carbon brushes and Armature as drawn in Fig. 6.
Fig. 6
Fig. 7
1. Remove Holder cap cover by levering it up
with a slotted screwdriver.
3. Separate Gear housing complete from Housing set by unscrewing
four 4x20 Tapping screws.
2. Remove Brush holder caps and Carbon brushes.
Holder cap cover
Holder cap cover
Holder cap cover
Carbon brush
Carbon brush
Brush holder caps
4x40 Tapping screw
(4 pcs.)
Gear housing
complete
notch
Yoke unit
Assemble Yoke unit to Housing L while aligning the notch of Yoke unit to the projection on Housing L. (Fig. 7)
Housing L
projection
4. Pull off Armature from
Housing set.
Armature
Armature
P 5/ 8
Repair

[3] DISASSEMBLY/ASSEMBLY
[3] -4. Die and Punch
DISASSEMBLING
Fig. 8
Fig. 9
Die holder
1 Pull off Die holder from Gear housing complete.
2 Remove Punch by loosening M5x8 Hex socket
set screw with Hex wrench.
3 Remove Die from Die holder
by unscrewing two M3x12
Hex socket head screws.
(1) Remove Lock nut with Wrench 32 by turning it counterclockwise. (See the left drawn in Fig. 2)
(2) Disassemble Die and Punch as drawn in Fig. 8.
Hex
wrench
M5x8 Hex socket set screw
Assemble Punch and Die holder as drawn in Fig. 9.
concave for fitting the screw end
of M5x8 Hex socket set screw
screw hole of
Punch holder
1. Insert Punch into Punch holder until it stops
while aligning its concave portion with the screw
hole of Punch holder.
And tighten M5x8 Hex socket set screw.
Punch
Punch
holder
Die
M3x12 Hex socket
head screw (2 pcs.)
M5x8 Hex socket
set screw
2. Assemble Die holder to Gear housing complete
while aligning the window of Die holder to
the stepped portion of Punch.
Die holder
window of Die holder
stepped portion of Punch
Punch
ASSEMBLING
1
2
3
P 6/ 8
Repair

Circuit diagram
Wiring diagram
Color index of lead wires' sheath
Black
Red
LED Circuit
Set Endbell complete on Housing L as follows:
* Face its Lead wires to the belly side of Housing L.
* Face Lead wire (black) to Housing L.
Setting Endbell Complete on Housing L
Fig. D-1
Fig. D-2
Endbell
complete
Line filter
Line filter is not used
for some countries
Controller
Terminal
Switch
Lead wire (black)Lead wire (red)
Belly side
Top side
Rear side Front side
P 7/ 8

Wiring diagram
Wiring to Switch
Wiring in Housing L
Switch button
Set Switch to Housing L as follows:
* Face Switch button to Controller side.
* Face Insulated terminals connected side
(See Fig. 3D.) to Housing L.
Wire connecting portions
of Insulated terminal
Connect Insulated terminals to Switch while facing their wire
connecting portions to the opposite side of Switch button.
Controller
Lead wires of Controller
Put Line filter in the
space as drawn above
if it is used.
Line filter Lead wire holder
Terminal Endbell complete
LED Circuit
Switch
Fig. D-3
Fig. D-4
Guide lead wires of LED circuit
along the wall side of Housing L
as drawn above. And then fix
the wires with Lead wire holder.
Wire connecting portions
Connect Flag connectors
so that their wire connecting
portions are located over
the mark of + - poles.
Pass Lead wires of Controller
through the space between
Housing L and Controller.
P 8/ 8