ECHNICAL INFORMATION
PRODUCT
T
P 1/ 8
L
BJN160/ BJN161 (LXNJ01*1)
Model No.
Description
H
1.6mm (16Ga) Cordless Nibbler
*1 Model number for North and Central
W
BJN160
American countries
L
H
CONCEPT AND MAIN APPLICATIONS
Models BJN160 and BJN161 (LXNJ01*1) are cordless nibblers developed with
the same design concept as AC tool JN1601, featuring slim motor housing of
DC angle grinder BGA450.
W
BJN161
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
Dimensions: mm (")
BJN160 BJN161
313 (12-3/8)
78 (3-1/16)
Length (L)
Width (W)
• BL1830 (18V) for BJN161 (LXNJ01*1)
Note: 1.3Ah Li-ion battery BL1415/ BL1815 cannot be used for these models.
Height (H) 174 (6-7/8) 189 (7-7/16)
These products will be available in the following variations.
Battery
Quantity
Battery
cover
Plastic
Model No.
Charger
No
Offered to
Type
No
carrying case
BJN160Z
BJN160RFE
BJN161Z
No
2
No
1
No
Yes
No
All countries except
North and Central
American countries
DC18RC BL1430
No No
DC18RC BL1830
No No
DC18RA BL1830
No
2
No
1
BJN161RFE
LXNJ01Z*1
LXNJ01*1
Yes
No
No
No
2
No
1
North and Central
American countries
All models also include the accessories listed below in "Standard equipment".
Specification
Specification
Model
BJN160
BJN161 (LXNJ01*1)
Cell
Li-ion
Voltage: V
Capacity: Ah
Energy capacity: W
Charging time (approx.): min.
14.4
44
18
Battery
3.0
54
22 with DC18RC (DC18RA*1)
Max output (W)
280
350
No load speed: min.ˉ¹=spm (strokes per minute)
1,900
Mild steel with tensile
strength up to 400N/mm²
1.6 (16)
Max cutting capacities:
mm (Ga)
Stainless steel with tensile
strength up to 600N/mm²
1.2 (18)
2.5 (12)
Aluminum with tensile
strength up to 200N/mm²
Minimum cutting radius: Cut SPCC sheet of
mm (") 1.6mm (16Ga) thick
Inner edge: 45 (1-3/4),
Outer edge: 50 (2)
Overload protection by current limiter
Weight according to EPTA-Procedure 01/2003*2: kg (lbs)
*2 with Punch, Die and Battery
Yes
2.1 (4.6)
2.2 (4.8)
Standard equipment
Punch .................... 1
Die .................... 1
Hex wrench 2.5 .................... 1
Wrench 32 .................... 1
Note: The standard equipment for the tool shown above may vary by country.
Optional accessories
Punch
Fast charger DC18RA (for USA, Canada, Guam, Panama, Mexico, Colombia)
Fast charger DC18RC (All countries except the countries above)
Charger DC24SC
Die
Battery BL1430 for Model BJN160
Battery BL1830 for Model BJN161
Charger DC18SD
(LXNJ01*1) Automotive charger DC18SE
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P 2/ 8
Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
[1] NECESSARY REPAIRING TOOLS
Code No.
1R030
1R032
1R217
1R282
Description
Bearing setting pipe 25-17.2
Bearing setting plate 8.2
Ring 22
Use for
assembling Spur gear 31 to Crank shaft
supporting Crank shaft when assembling Spur gear 31
supporting Spur gear 31 when removing Crank shaft
removing Crank shaft from Spur gear 31
Round bar for Arbor 8-50
[2] LUBRICATION
Apply Makita grease FA No.2 to the following portions designated with the black triangle to protect parts and product
from unusual abrasion.
Item No.
Description
Spur gear 31
Portion to lubricate
Amount
Teeth portion where the small gear of 10 engages
Approx. 3 g
Approx. 4 g
Approx. 1 g
Approx. 1 g
Gear complete 16-36 Teeth portion of large gear where Armature’s gear engages
a Currve of hourglass shaped portion
Ram
b narrow portion between small rim and large rim
Gear housing
complete
Rod
Fig. 1
Crank shaft
Punch holder
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Gear housing complete
DISASSEMBLING
(1) Separate Gear housing complete as drawn in Fig. 2.
Fig. 2
2. Separate Gear housing complete together with Die holder section
from Gear housing cover complete by unscrewing four 4x40
Tapping screws.
1. Remove Lock nut with Wrench 32
by turning it counterclockwise.
Gear housing
complete
Gear housing
cover complete complete
Gear housing
Lock nut
Wrench 32
4x40 Tapping screw
(4 pcs.)
Die holder section
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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.
Fig. 3
1. Remove Stopper by unscrewing
Bind CT4x12 Tapping screw.
2. Pull off Die holder section from
Gear housing complete.
3. Set Punch to the lowest position
by turning Gear complete 16-36.
Bind CT4x12 Tapping
screw
Gear complete
16-36
Gear housing
complete
Stopper
Die holder
section
Punch
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.
6. Lift up Spur gear 31 until the
space for twisting Spur gear 31
and Crank shaft is reserved.
Gear complete 16-36
Spur gear 31
Ram
Flat washer 6
Punch holder
Punch
7. Remove Super gear 31 together with Crank section
while turning them 90°.
Note: Be careful not to lose Flat washer 8.
Flat washer 8
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P 4/ 8
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Gear Housing Complete (cont.)
DISASSEMBLING
(3) Disassemble Spur gear 31 and Crank section as drawn in Fig. 4.
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.
1R282
Crank shaft
Rod
Crank shaft
1R217
Ram
Pin 6
Spur gear 31
Spur gear 31
Crank shaft
Woodruff key 3
ASSEMBLING
(1) Assemble Spur gear 31 and Crank section as drawn in Fig. 5.
Fig. 5
2. Put Super gear 31 and Crank
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.
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.
section onto 1R032.
Then, Press the Gear down
with 1R030 until it stops.
Crank shaft
Rod
groove
Flat washer 8
1R030
Spur gear 31
stepped side
Spur gear 31
Crank shaft
Spur gear 31
slim end
Crank shaft
1R032
Ram
Woodruff key 3
Pin 6
(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)
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P 5/ 8
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Armature
DISASSEMBLING
(3) Disassemble Carbon brushes and Armature as drawn in Fig. 6.
Fig. 6
1. Remove Holder cap cover by levering it up
with a slotted screwdriver.
2. Remove Brush holder caps and Carbon brushes.
Brush holder caps
Holder cap cover
Holder cap cover
Carbon brush
Carbon brush
Holder cap cover
3. Separate Gear housing complete from Housing set by unscrewing
four 4x20 Tapping screws.
4. Pull off Armature from
Housing set.
Armature
Gear housing
complete
Armature
4x40 Tapping screw
(4 pcs.)
[3] -3. Yoke unit
ASSEMBLING
Assemble Yoke unit to Housing L while aligning the notch of Yoke unit to the projection on Housing L. (Fig. 7)
Fig. 7
Yoke unit
notch
projection
Housing L
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P 6/ 8
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Die and Punch
DISASSEMBLING
(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.
Fig. 8
1 Pull off Die holder from Gear housing complete.
2 Remove Punch by loosening M5x8 Hex socket
set screw with Hex wrench.
3
M3x12 Hex socket
head screw (2 pcs.)
Die
2
Hex
wrench
Punch
Punch
holder
3 Remove Die from Die holder
by unscrewing two M3x12
Hex socket head screws.
1
Die holder
M5x8 Hex socket set screw
ASSEMBLING
Assemble Punch and Die holder as drawn in Fig. 9.
Fig. 9
1. Insert Punch into Punch holder until it stops
while aligning its concave portion with the screw
hole of Punch holder.
2. Assemble Die holder to Gear housing complete
while aligning the window of Die holder to
the stepped portion of Punch.
And tighten M5x8 Hex socket set screw.
Punch
Die holder
concave for fitting the screw end
of M5x8 Hex socket set screw
window of Die holder
screw hole of
Punch holder
M5x8 Hex socket
set screw
stepped portion of Punch
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P 7/ 8
Circuit diagram
Fig. D-1
Color index of lead wires' sheath
Black
Red
Switch
Endbell
complete
Controller
LED Circuit
Line filter
Terminal
Line filter is not used
for some countries
Wiring diagram
Fig. D-2
Setting Endbell Complete on Housing L
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.
Top side
Rear side
Front side
Lead wire (red)
Lead wire (black)
Belly side
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P 8/ 8
Wiring diagram
Fig. D-3
Wiring to Switch
Connect Insulated terminals to Switch while facing their wire
connecting portions to the opposite side of Switch button.
Wire connecting portions
of Insulated terminal
Switch button
Fig. D-4
Wiring in Housing L
Pass Lead wires of Controller
through the space between
Housing L and Controller.
Set Switch to Housing L as follows:
* Face Switch button to Controller side.
* Face Insulated terminals connected side
(See Fig. 3D.) to Housing L.
Terminal
Lead wires of Controller
Endbell complete
Switch
LED Circuit
Lead wire holder
Controller
Line filter
Put Line filter in the
space as drawn above
if it is used.
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.
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