NT 65GB GAS FINISH NAILER NT 65GB. E047 Aug. 2011

Transcription

1 NT 65GB GAS FINISH NAILER NT 65GB N E047 Aug. 2011

2 REMARK: Throughout this TECHNICAL DATA AND SERVICE MANUAL, a symbol(s) is(are) used in the place of company name(s) and model name(s) of our competitor(s). The symbol(s) utilized here is(are) as follows: Symbols Utilized Company Name Competitors Model Name P Paslode (USA)/IM65AF16 (EU)

3 CONTENTS Page 1. PRODUCT NAME MARKETING OBJECTIVE APPLICATIONS SELLING POINTS SPECIFICATIONS Specifications Explanation of the Nailing Action Nail Selection Nail Driving Force COMPARISON WITH SIMILAR PRODUCTS PRECAUTIONS ON SALES PROMOTION Handling Instructions Warning Label Related Laws and Regulations MECHANISM AND PRINCIPLE OF OPERATION Mechanism Principle of Operation TROUBLESHOOTING GUIDE Problems Caused by Improper Handling Troubleshooting and Corrective Action Checking for Sparking and Corrective Action Regrinding the Driver Blade DISASSEMBLY AND REASSEMBLY General Precautions on Disassembly and Reassembly Disconnecting and Reconnecting Wiring between the Cylinder Head Section and Handle Section Disassembly and Reassembly of the Cylinder Head Section Disassembly and Reassembly of the Housing Section Disassembly and Reassembly of the Handle Section STANDARD REPAIR TIME (UNIT) SCHEDULES Assembly Diagram for NT 65GB

4 1. PRODUCT NAME Hitachi 65 mm (2-1/2 ) Gas Finish Nailer, Model NT 65GB 2. MARKETING OBJECTIVE These days one company has been monopolizing the gas nailer market. We will enter the finish nailer market by releasing the new Model NT 65GB Gas Finish Nailer to expand our market share. The main features of the Model NT 65GB are as follows: (1) Compact and lightweight, with lithium-ion batteries (2) Battery located at end of the handle for better balance (3) New aggressive appearance (4) 2-action nail feeding (5) Comfortable grip (6) Fully charged in one hour (7) Two lithium-ion batteries included (8) AC charger and DC charger (car battery charger) included 3. APPLICATIONS Finish-nailing of door casings and similar frame assemblies. Fastening of drawer bottoms and similar assembly work in the construction of various cabinets and cases. 4. SELLING POINTS Lightweight, only 1.8 kg (4.0 lbs.) and good balance New aggressive appearance Comfortable grip AC/DC charger Fully charged in one hour Hook is attachable on either side 2-action nail feeding Tool-less depth adjustment Easy-to-use, clogged nail release mechanism -1-

5 5. SPECIFICATIONS 5-1. Specifications (1) Gas finish nailer Model Item Driving system Weight Dimensions (length x height x width) Nail feed system Nail capacity Packaging Package dimensions (length x height x width) Standard accessories Optional accessories 500 x 460 x 150 mm (19-11/16 x 18-5/32 x 5-29/32 ) -For North America- Safety glasses (Code No ) Battery (Code No ) x 2 UC 3SML Charger (with AC/DC adapter) Case (Code No ) Allen wrench for M5 screws (Code No ) Allen wrench for M4 screws (Code No ) Nose Cap (Code No ) -For North America- Lubricant oil (A) (Code No ) Fuel cell (Code No ) Grease (Code No ) UC 3SFL Charger NT 65GB Reciprocating piston type 1.8 kg (4.0 lbs.) 268 x 282 x 85 mm (10-5/8 x 11-1/8 x 3-3/8 ) Ribbon spring 100 nails (2 strip) Plastic case 420 x 427 x 165 mm (16-35/64 x 16-13/16 x 6-1/2 ) -For Europe- Safety glasses (Code No ) Battery (Code No ) x 2 UC 3SML Charger (with AC/DC adapter) Case (Code No ) Allen wrench for M5 screws (Code No ) Allen wrench for M4 screws (Code No ) Nose Cap (Code No ) -For Europe- Lubricant oil (A) (Code No ) Fuel cell (Code No ) Grease (Code No ) UC 3SFL Charger 5-2. Explanation of the Nailing Action To meet the requirements of "ANSI SNT " (USA), the Model NT 65GB is equipped with a FULL SEQUENTIAL ACTUATION MECHANISM. FULL SEQUENTIAL ACTUATION MECHANISM First, press the pushing lever against the wood, and then pull the trigger to drive the nail. After nailing once, nailing will not be possible again until you release the trigger and press the lever again. -2-

6 5-3. Nail Selection The Model NT 65GB utilizes small-head, T-shaped nails (finish nails) collated by adhesive. Applicable nails are shown below. CAUTION: Ensure that nails are as specified in Fig. 1. The use of other nails will cause the clogging of nails and subsequent nail damage. NT 65GB 16 Gauge finish nails (Angle: 20 ) 2.8 mm (.110 ) Min. Max. 32 mm (1-1/4 ) 1.3 mm (.051 ) 1.4 mm (.055 ) 1.65 mm (.065 ) 65 mm (2-1/2 ) Fig. 1 Nail dimensions 5-4. Nail Driving Force In contrast to a pneumatic nailer, a gas nailer s output energy is not optional. However, output energy can be altered by such environmental conditions as ambient temperature, humidity and altitude, which affect combustion. Fig. 2 below compares the output energy range of the Model NT 65M2 and other pneumatic nailers, with that of the Model NT 65GB Gas Finish Nailer. The output energy of the Model NT 65GB changes within an operating range of 5.4 kg/cm 2 (76.8 psi) to 5.8 kg/cm 2 (82.5 psi) due to the conversion to air pressure of the Model NT 65M2. Always select suitable nails and workpieces according to the output energy of this nailer. Required nailing energy [J] [lt-lb] Nailer output energy [J] [lt-lb] NT 65M2 Required nailing energy Hand Wood Nailer output energy NT 65GB Size of nail 38 mm (1-1/2 ) (in 2 ) (mm 2 ) Nail: d x L 45 mm (1-3/4 ) 50 mm (2 ) 65 mm (2-1/2 ) L d (psi) (kg/cm 2 ) (bar) Air pressure setting of NT 65M2 to drive nail flush Fig. 2 Required nailing energy and nailer output energy -3-

7 6. COMPARISON WITH SIMILAR PRODUCTS Maker Model HITACHI NT 65GB P Item Weight (tool, battery, fuel cell) 1.8 kg (4.0 lbs.) 2.3 kg (5.1 lbs.) Dimensions (L x H x W) 268 x 282 x 85 mm 273 x 292 x 90 mm (10-5/8 x 11-1/8 x 3-3/8 ) (10-3/4 x 11-1/2 x 3-1/2 ) Applicable nails Dia. 1.4 to 1.65 mm (0.055 to 0.065") 2.9 to 3.3 mm (0.113 to 0.131") (Clip head) Length 25 to 65 mm (1 to 2-1/2") 20 to 65 mm (3/4 to 2-1/2") Nail capacity 100 nails (2 strip) 100 nails (2 strips) Magazine type Rear loading Rear loading Feeder 2-action nail feeding 2-action nail feeding No-nail driving prevention mechanism Driving depth adjusting mechanism Provided Tools not required Provided Tools not required Jam release Single-touch operation Single-touch operation by hand by hand Hook Attachable on either right or left sides Fixed on left side Handle grip Rubber Rubber Driving method Single action Single action Driving speed 2 to 3 pcs./sec. 2 to 3 pcs./sec. Battery voltage 3.6 V 6 V Charging time 1 hour 2 hour Driving times on a fully Approx. 2,000 pcs. Approx. 4,000 pcs. charge battery Fuel cell dimensions ø31.5 x 80 mm ø31.5 x 80 mm Fuel cell service life 1,200 nails 1,200 nails HITACHI P USA EU <Compatible with Paslode fuel cell> Can size diameter (mm) Height (mm) Contents 18 g 20 g 18 g Fuel cell service life (nails/cell) 1,200 1,200 1,000 Ambient temperature 0 to 40 * (degrees Celsius) - -7 to 49 (+5 to 40) Max. temperature for storage (degrees Celsius) Part no. for USA /1 cell for EU /1 cell - - *1: Because of gas restriction for aerosol standard -4-

8 7. PRECAUTIONS ON SALES PROMOTION In the interest of promoting the safest and most efficient use of the Model NT 65GB Gas Finish Nailer by all of our customers, it is very important when concluding a sale that the salesperson carefully ensure that the buyer seriously recognizes the importance of the Handling Instructions, and fully understands the precautions listed on the Warning Label attached to each tool Handling Instructions Although every effort is made in each step of design, manufacture, and inspection to provide protection against safety hazards, the dangers inherent in the use of any pneumatic tool cannot be completely eliminated. Accordingly, the Handling instructions list general precautions and suggestions on the use of precautions tools, and specific precautions and suggestions on use of the pneumatic nailer, in order to enhance the safe, efficient use of the tool by the customer. Salespersons must be thoroughly familiar with the Handling Instructions to be able to offer appropriate guidance to customers during sales promotion activities Warning Label Each Model NT 65GB unit is provided with a Warning Label (illustrated below) that lists basic safety precautions on use of the tool. Carefully ensure that customers fully understand and follow these precautions before using the tool. [For the USA and Canada] -5-

9 [For Europe] Fuel cell [For the USA and Canada] OK Befestigung D Krefeld, Germany ( PATENT PENDING Contents: Compressed flammable liquefied gas Made in Germany 18 g/30 ml 50 C max. (120F) DANGER - EXTREMELY FLAMMABLE CONTENTS UNDER PRESSURE. Keep away from temperatures over 50 C < 120 F >(for ex., sun radiation). Do not damage, puncture or burn even after use. KEEP OUT OF THE REACH OF CHILDREN. IN USE, MAY FORM FLAMMABLE/EXPLOSIVE VAPOR-AIR MIXTURE. Do not use near flames or spray on heated surface. Keep away from ignition sources. Use only outside or in well-ventilated rooms. Keep container in well-ventilated place. No smoking. KEEP AWAY FROM SKIN AND EYES and DO NOT BREATHE GAS, for SKIN AND EYE IRRITANT and VAPOR HARMFUL. DO NOT REFILL. [For EU] OK Befestigung D Krefeld, Germany ( PATENT PENDING e < 50 Made in Germany 18 g/30 ml DANGER - EXTREMELY FLAMMABLE Contents under pressure, keep away from temperatures over 50 C < 120 F > (for ex., sun radiation). Do not use near flames or spray on heated surfaces. Use only outside or in well ventilated rooms. Throw away only at designated areas. Keep out of the reach of children. Do not damage, puncture or burn even after use. In use, may form flammable/explosive vapor - air mixture. Keep container in a well ventilated place. Do not breathe gas. Keep away from ignition sources. No smoking. Do not refill. -6-

10 7-3. Related Laws and Regulations As nailers and staplers are designed to instantaneously drive nails and staples, there is an everpresent danger of misfiring and possibly serious injury. Accordingly, close attention to handling is absolutely necessary at all times. Carefully ensure that the customer is fully aware of the precautions listed in the Handling Instructions provided with each unit. While there are no specific safety regulations, there are related items in various general safety regulations with which salespersons should be familiar, in order to properly advise the customer. Please check your national and/or local regulations for applicable items. Some applicable items are outlined below. For the USA: OSHA ANSI SNT Eye and face protection Power-operated hand tools Portable, Compressed-Air-Actuated, Fastener Driving Tools-Safety Requirements for For Europe: EN EN EN EN EN Hand-held-non-electric power tools Hand-held-motor-operated electric tools Household and similar electrical appliances Electromagnetic compatibility Electromagnetic compatibility (EMC) -7-

11 Cautions on handling the fuel cell: First Aid: If contents are inhaled, move to an area with fresh air. Contact a doctor if symptoms persist. If contents come in contact with skin, wash affected area with soap and warm water, then apply skin cream. If contents come in contact with eyes, flush open eyes with water. Contact a doctor if irritation continues. How to discharge gases from the canister: (1) Separate the metering valve from the canister. (2) Push the extended stem vertically to discharge remaining fuel gas. (3) After remaining fuel gas has been discharged, forcibly push down the stem vertically to puncture the cap of the canister, and thus discharge remaining propellant gas. Puncturing the cap will discharge remaining propellant gas. Carton box, small Storage To Retailers: Flammable contents. Container under pressure. Store in well-ventilated area. Do not store above 50 C (120 F) (e.g., exposed to direct sunlight). Do not display in shop windows. Do not store in passages, entry halls, near doors/exits or in attics. Do not store together with pyrotechnical goods. The quantity stored in sales rooms should not exceed daily sales. Storerooms must not occupy more than 20 m 2 of floor space. A fire extinguisher of 6 kg (class A, B, or C) must be available. Packages should be stacked so as not to fall to the ground. Do not expose to an open flame or sparks. Do not puncture or open the fuel cell. Keep out of the reach of children. Carton box, large Transportation Shipment per mail is not allowed. - Transportation of small quantities for own use in private car is allowed without shipping papers and emergency card. - Observe the temperature limit of 50 C (120 F). - Goods must be accompanied by a transport emergency card for road; class 2.1, UN No UN No.: United Nation IMDG (International Maritime Dangerous Goods) -8-

12 8. MECHANISM AND PRINCIPLE OF OPERATION 8-1. Mechanism The Model NT 65GB is a gas nailer that drives nails into workpieces with the aid of fuel combustion energy. The basic construction of the Model NT 65GB is the same as that of the Model NR 90GC2. Its principle of operation is completely different from that of a pneumatic nailer, except for the magazine section. The Model NT 65GB is equipped with a fuel cell and a battery to output combustion energy, in addition to such electric components as electric circuits, a motor, and electric switches. As illustrated in Fig. 3, the Model NT 65GB can generally be divided into three sections the output section, head section, and handle section. The following describes the features of the main parts. Output section (Housing section): This section outputs fuel combustion energy. The piston reciprocates to drive nails in the same manner as a pneumatic nailer. The piston reciprocates in the cylinder. There is a driving unit under the piston. The combustion chamber is encased in a chamber and burns fuel to output combustion energy. The combustion energy output is then applied to the top of the piston, thereby driving the piston downward to drive nails at the driving unit The nails are fed from the magazine unit located in the handle section. Head section (Cylinder head section): This section is at the top of the combustion chamber in the output section. There is a fan to stir fuel and fuel is fed from the fuel cell to the combustion chamber in this section. The fan is mounted to the motor. The motor is held in the motor mount and secured to the center of the cylinder head through the spring. This spring absorbs shock to the motor. There is a spark plug beside the fan. The top cover at the top of the main body covers the filter. The cell lever feeds fuel from the fuel cell to the combustion chamber. Its rotation is supported. Handle section: This section consists of a magazine unit to feed nails to the driving unit, battery holder, handle unit, fuel cell holder, and related electrical wiring. The magazine unit features a construction similar to that of a pneumatic nailer. There is a controller behind the magazine unit to control electric signals. The handle unit contains a trigger and a spark switch. The electrical wiring connects the battery, trigger switch, and fan switch. Each time the controller receives a switch signal, the motor in the head section rotates and the spark plug discharges. -9-

13 Head section (Cylinder head section) Motor mount Filter Cover [1A] Filter Mesh [2] Top Cover [4A] Motor Actuator [56] Handle section Cylinder Head [7A] Spark Plug (A) [5] Motor spring Fan [11] Combustion chamber Chamber [16] Spark switch Battery [58] Piston [27] Cylinder Ass'y (A) [104A] Output section Housing [30A] Piston Bumper [28] Lock Lever [36A] Guide Plate [38] Trigger [71] Pushing Lever (A) [82] Nail Feeder (B) [91] Fig

14 8-2. Principle of Operation (1) Before nailing Fuel is not charged into the nailer in the initial state. The combustion chamber is released to the atmosphere (Fig. 4). (2) When nailing 1) Push up Pushing Lever (A) [82].. The nailer then starts operation in the following order (Fig. 5). (a) The Pushing Lever Arm [77] on the Chamber [16] pushes the Trigger Stopper [75] to turn on the fan switch. The Fan [11] in the combustion chamber then rotates. (b) The Chamber Head [14] and the Chamber [16] surface are sealed by the Piston Ring (B) [17] simultaneously. Thus the combustion chamber is cut off from the atmosphere. (c) The protrusion of the Chamber Head [14] pushes up the tip of the Actuator [56] to rotate it. The Actuator [56] thus pushes the back of the fuel cell to spray fuel into the combustion chamber. Combustion chamber Fan [11] Chamber [16] Cylinder Ass'y (A) [104A] Pushing Lever (A) [82] Piston Ring (B) [17] Fan [11] Piston Ring (B) [17] Fig. 4 Fuel cell Trigger [71] Actuator [56] Chamber Head [14] Fan switch Chamber [16] Pushing Lever Arm [77] Trigger Stopper [75] Pushing Lever (A) [82] -11- Fig. 5

15 2) Holding down the Trigger [71] makes the spark switch turn on. The spark plug in the combustion chamber then discharges (Fig. 6). The fuel thus burns and a sudden expansion occurs. The Piston [27] is then lowered to drive nails (Fig. 7). When the Piston [27] passes the hole of Cylinder Ass'y (A) [104A], combustion gas is partially released into the atmosphere through the Reed Valve [50]. Because the Reed Valve [50] is a non-return valve, no air enters Cylinder Ass'y (A) [104A]. When the Piston [27] contacts the Piston Bumper [28], the combustion of fuel is almost completed. (3) During return Piston Ring (B) [17] seals the Chamber [16] to cut off the atmosphere (Fig. 7). Because combustion gas is partially released into the atmosphere through the Reed Valve [50], the pressure at the upper portion of the Piston [27] becomes lower than the atmospheric pressure. The Piston [27] is returned to its initial position by the difference in pressure between the upper and lower portions of the Piston [27]. Spark Plug (A) [5] Combustion chamber Piston [27] Hole of Cylinder Ass'y (A) [104A] Piston Bumper [28] Fig. 6 Spark switch Trigger [71] Hole of Cylinder Ass'y (A) [104A] Piston [27] -12- Fig. 7

16 (4) Discharge and cooling When you stop pressing Pushing Lever (A) [82], the Chamber [16] is placed in its initial state and the sealing by Piston Ring (B) [17] is released. When the Fan [11] rotates, air passes through the Filter Mesh [2], enters the combustion chamber, and is then discharged outside, in order to discharge gas and cool the combustion chamber (Fig. 8). Piston Ring (B) [17] Chamber [16] Filter Mesh [2] Fan [11] Pushing Lever (A) [82] Fig

17 (5) Full sequential action mechanism Press Pushing Lever (A) [82] against the workpiece and move the Chamber [16] to the uppermost position. The nailer will then operate only when you hold down the Trigger [71]. The nailer will not operate if you press Pushing Lever (A) [82] insufficiently or press it after holding down the Trigger [71]. Chamber [16] Tip of Trigger Stopper [75] Spark switch When holding down the Trigger [71] after pressing Pushing Lever (A) [82] The convex portion of the Pushing Lever Arm [77] pushes up the Trigger Stopper [75] and moves when the Chamber [16] reaches the uppermost position. The tip of the Trigger Stopper [75] does not prevent the Trigger [71] from rotating (Fig. 9). Holding down the Trigger [71] turns on the spark switch and drives nails. When pressing the Pushing Lever (A) [82] after depressing the Trigger [71] When depressing the Trigger [71], the tip of the Trigger Stopper [75] prevents the Trigger [71] from rotating. Thus the spark switch is not turned on. The convex portion of the Pushing Lever Arm [77] Pushing Lever (A) [82] Fig. 9 Trigger [71] Tip of Trigger Stopper [75] Spark switch Chamber [16] Trigger [71] Pushing Lever (A) [82] -14- Fig. 10

18 9. TROUBLESHOOTING GUIDE 9-1. Problems Caused by Improper Handling The table below lists the problems that may occur. Note that improper handling causes these problems, not any nailer abnormality. Therefore, please instruct the customers to use the nailer properly according to the table. Improper handling Problem Cause Corrective action The Trigger [71] is The Piston [27] is pressed insufficiently. lowered. Pushing Lever (A) [82]is pressed while the Trigger [71] is being slightly held down. No combustion occurs. No nail is driven. No combustion occurs. The spark switch is not turned on. Return the Piston [27] to the uppermost position with a flat-blade screwdriver. Press Pushing Lever (A) [82] securely for about 0.5 second after combustion. Press Pushing Lever (A) [82] without holding down the Trigger [71], and then hold down the Trigger [71]. The Battery [58] is not set or set improperly. The nailer is used while the battery indicator light is red (Fig. 11). The nailer is used with a clogged Filter Mesh [2]. The fuel cell is not set or set improperly. The metering valve of the fuel cell is set improperly. Pushing Lever (A) [82] is pressed insufficiently. The fuel cell lacks fuel. The nailer does not start. Output is decreased. Output is decreased. The nailer generates heat. No combustion occurs. No combustion occurs. No combustion occurs. No combustion occurs. No electricity is sent. Set the Battery [58] properly in the nailer. The number of Charge the Battery [58]. revolutions of the Fan [11] is low. Discharge and Clean the Filter Mesh [2] cooling are (Fig. 12). insufficient. No fuel is fed. Set the fuel cell properly (Fig. 13). No fuel is fed. Set the metering valve of the fuel cell properly No fuel is fed. The switch of the Fan [11] is not turned on. No fuel is fed. (Fig. 14). Press Pushing Lever (A) [82] securely. Use a new fuel cell. Filter Cover [1A] Filter Mesh [2] (Clean Filter Mesh [2] with an air gun.) Top Cover [4A] Battery indicator light Fig. 11 Fig

19 Insert the stem of the fuel cell into the hole on the adapter. To attach the metering valve to a fuel cell: (1) Separate the metering valve and cap from the gas cartridge. Adapter [20] Stem Fuel cell (2) Press the front side of the metering valve forward (stem side) and downward. (3) Press the rear of the metering valve downward until it seals. Fig. 13 Fig. 14 <Checking the fuel cell> Problem Possible cause Inspection method Corrective action Fuel is not sprayed. Fuel is leaking. There is no fuel. Fuel is sprayed but no combustion occurs. Fuel is sprayed but no combustion occurs. The bag in the fuel cell is damaged. Insufficient sealing of the cup and stem in the metering valve. The nailer is left under a high temperature condition. The nailer is left in direct sunlight or nails are driven continuously. <Excessively high concentration of gas> The nailer is left under a low temperature condition. 0 C or lower temperature <Low concentration of gas> The oxygen content of air is low at such places as highlands at an altitude of 1,500 meters or more. <Excessively high concentration of gas> The metering valve is not set properly. Press the stem five or more times with the fuel cell held upright to check whether fuel is being sprayed. Fuel is not sprayed when the fuel cell is held upright, but is sprayed when the fuel cell is held horizontally. Check whether fuel is leaking by holding down the stem. The main body is hot due to combustion heat. The sprayed fuel is in a liquid state. A large amount of fuel is sprayed Set the metering valve properly (and rotate the valve to secure it in place). Replace the metering valve with a new one. Replace the fuel cell with a new one. Replace the fuel cell with a new one. Replace the metering valve with a new one. Allow the main body and fuel cell to cool down. Replace the fuel cell with a new one. Warm up the fuel cell. Instruct the customers on such necessary measures as putting the fuel cell in a pocket or wrapping it in a thermal insulating material. Use the nailer where the altitude is less than 1,500 meters.

20 9-2. Troubleshooting and Corrective Action (1) Troubleshooting and correction action for gas nailers The mechanism used by a gas nailer to produce output is completely different from that used by a pneumatic nailer. The table below lists the troubleshooting and correction action to take for gas nailers. Problem Possible cause Inspection method Corrective action No combustion occurs. <Combustion section> The Piston [27] is lowered. Check the position of the Piston [27]. Return the Piston [27] to the uppermost position with a flat-blade screwdriver. Hold down Pushing Lever (A) [82]securely until nailing operation is completed. The outside air temperature and altitude exceed specifications. No fuel is fed. Pushing Lever (A) [82] cannot be pushed up. <Electric section> The battery indicator light does not go on. The motor does not rotate. Check the outside air temperature and altitude. Check that the fuel cell is set properly. lack of fuel in the fuel cell. The metering valve is not set properly to the fuel cell. The Actuator [56] is deformed. The Adapter [20] is damaged. Pushing Lever (A) [82] is deformed. The Pushing Lever Arm [77] is deformed. Piston Ring (B) [17] is pinched. Low voltage Outside air temperature range: 0 C to 40 C Altitude: Less than 1,500 m (5,000 feet) Set the fuel cell properly (Fig. 13). Replace the fuel cell. Set the metering valve to the fuel cell properly (Fig. 14). Replace the Actuator [56]. Replace Adapter [20]. Replace Pushing Lever (A) [82]. Replace the Pushing Lever Arm [77]. Mount Piston Ring (B) [17] properly. Charge the battery. The Battery [58] is not set Set the Battery [58] properly. properly. Replace the Battery [58]. The Battery [58] is faulty. Charge the Battery [58]. The battery indicator light Connect properly (Fig. 15). goes on in red. Connect properly (Fig. 16). Connection failure between Replace Internal Wire (A) Internal Wire (A) [60A] and [60A]. the Controller [95]. Replace Internal Wire (A) Connection failure between [60A]. Internal Wire (A) [60A] and Replace the Pushing Lever the motor. Arm [77]. Break in Internal Wire (A) Replace the Motor Ass'y [60A]. [25B]. The fan switch is faulty. The Pushing Lever Arm [77] is deformed. The motor is damaged. -17-

21 Connection between Internal Wire (A) [60A] and the Controller [95] Controller [95] Fig. 15 Support (B) [59] with adhesive Fig

22 <Continued> Problem Possible cause Inspection method Corrective action No combustion occurs. No nail is driven though nails are set properly and combustion is normal. Output is low. The nailer is overheated. Abnormal noise is heard during fan rotation. * A rubbing noise may be heard in some rare cases, but there is no problem in operation. <Electric section> Continued No spark occurs. (Check for sparking according to 9-3, Checking for Sparking and Corrective Action.") <Combustion section> The Piston [27] does not return completely. Discharge and cooling are insufficient. The outside air temperature and altitude exceed specifications. Discharge and cooling are insufficient. The operating speed is too fast. Discharge and cooling are insufficient. The Battery [58] is not set properly. The Battery [58] is faulty. The battery indicator light goes on in red. Connection failure between Internal Wire (A) [60A] and the Controller [95]. The spark plug cable is disconnected from Spark Plug (A) [5]. Faulty insulation of the spark plug cable wire Break in Internal Wire (A) [60A]. The spark switch is faulty. Spark Plug (A) [5] is stained. The wire near the Trigger [71] is pinched. The Pushing Lever Arm [77] is deformed. Check the position of the Piston [27]. Piston Ring (B) [17] is worn. The Reed Valve [50] is deformed. The cylinder is stained inside. Piston Ring (A) [26] is damaged. The Filter Mesh [2] is clogged. Check the outside air temperature and altitude. The Filter Mesh [2] is clogged. Check that the Motor Ass'y [25B], Fan [11] and Nut M3 [8] are mounted properly. Set the Battery [58] properly. Replace the Battery [58]. Charge the Battery [58]. Connect properly (Fig. 15). Connect properly (Fig. 16). Replace the Controller [95]. Replace Internal Wire (A) [60A]. Replace Internal Wire (A) [60A]. Clean Spark Plug (A) [5] (Fig. 17). Position the wire correctly (Fig. 15). Replace the Pushing Lever Arm [77]. Return the Piston [27] to the uppermost position with a flat-blade screwdriver. Hold down Pushing Lever (A) [82] securely until nailing operation is completed. Replace Piston Ring (B) [17]. Replace the Reed Valve [50]. Clean inside the cylinder. Replace Piston Ring (A) [26]. Clean the Filter Mesh [2] (Fig. 12). Outside air temperature range: 0 C to 40 C Altitude: Less than 1,500 m (5,000 feet) Clean the Filter Mesh [2] (Fig. 12). Do not use the nailer at high speed. Speed: 1 nail/sec. Continuous operation: 1,000 nails/h Mount each part properly. -19-

23 Spark Plug (A) [5] Clean this area in particular. Fan [11] Fig

24 (2) Troubleshooting and corrective action for general-purpose nailers Problem Possible cause Inspection method Corrective action 1) Nails cannot be driven. <Nails> The magazine is not loaded with specified genuine nails. The magazine is loaded with abnormal nails (e.g., bent nails, large or small head nails, abnormal collation). Clogging due to nails or collating band. Collating band is deformed or torn. Check whether the magazine is loaded normally with the specified nails. Use the specified nails. Remove any abnormal nails and load the magazine with normal nails. <Magazine> The magazine is abnormal (deformed or damaged). Nail Feeder (A) [92] is abnormal (deformed or damaged). The Ribbon Spring [90] is abnormal (deformed or damaged). The Nail Rail [97] is abnormal (deformed, burrs, damaged or fatigued). Adhesive fragments are on the nail rail or it needs oil. Foreign matter is found on the guide face of Nail Feeder (A) [92]. <Nose> The nail inlet groove of the nose is abnormal (deformed, burrs or damaged). Adhesive fragments are in the nail inlet groove. Check whether the nail feeder operates smoothly in the magazine. Check whether nails (one strip) move smoothly in the magazine. Check whether nails (one strip) are fed smoothly into the nail injection port of the nose. Repair or replace the defective part. Remove the adhesive fragments and apply grease (ATTOLUB No.2) to the nail feeder, Ribbon Spring [90] and nail rail. Repair or replace the defective part. Remove the adhesive fragments. -21-

25 Problem Possible cause Inspection method Corrective action 1) Nails cannot be driven. (Continued) Replace the piston bumper. 2) Nails are bent when being driven. 3) Head of a nail driven into a workpiece protrudes from the wood surface. 4) Nails clog the mechanism. <Output section> The piston bumper is abnormal (dislocated, deformed or damaged). Piston Ring (B) [17] of the cylinder is abnormal (dislocated, deformed or damaged). The driver blade is abnormal (deformed, burrs, damaged or fatigued). For short nails, the adjuster is raised too high. Nails are not fully fed into the injection port. Unspecified nails are used. The driver blade is worn. The workpiece is very hard. Nail Feeder (A) [92] is abnormal (worn or damaged). The adjuster is improperly adjusted. The workpiece is very hard. The driver blade is worn. Unspecified nails are used. <Improper nail feed> See <Magazine> in item 1). Driver blade worn. Nail Feeder (A) [92] is abnormal (worn or damaged). Pull the nail feeder backward and perform idle driving. Check whether the driver blade has returned. While operating the nailer without nails, check whether driving operation is performed. After operating the nailer without nails, check whether the driver blade is kept in the down position. Check whether the adjuster is raised too high. See item 1). Check whether the driver blade tip is abnormally worn. Drive a nail into a soft wood workpiece and check whether the nail is bent. Check Nail Feeder (A) [92] for any abnormal condition. Turn the adjuster to the lowest position and drive a nail. Drive a nail into a soft wood workpiece and check whether the head protrudes from the wood surface. Operate the nailer without nails and check whether the driver blade projects from the tip of the nose. Check whether the nails are the specified ones. Check whether the nails move smoothly after being loaded, and then check whether the nail feeder operates smoothly. Check whether the tip of the driver blade is worn. Check Nail Feeder (A) [92] for any abnormal condition. Reassemble or replace. Repair or replace. Turn the adjuster to a lower position, in order to reduce pressure. See item 1). Replace the driver blade. Do not use unspecified workpieces. Replace Nail Feeder (A) [92]. Adjust the adjuster to the proper position. Do not use unspecified workpieces. Replace the driver blade. Use specified nails. See <Magazine> in item 1). Replace the part. Replace Nail Feeder (A) [92]. -22-

26 9-3. Checking for Sparking and Corrective Action The following five items are the main causes of no combustion. 1. The fuel cell is abnormal. (Replace the fuel cell with a new one.) 2. The battery is abnormal. (Check the battery.) 3. The Chamber [16] is improperly sealed. (Check Piston Ring (B) [17], and how much Pushing Lever (A) [82] has been moved.) 4. The Piston [27] is not in the uppermost position. (Check the position of the Piston [27].) 5. No sparking occurs. It is difficult to check the cause of item 5 above ( No sparking occurs"). The following explains how to determine the cause of no sparking. (Disassemble the nailer according to Chapter 10, DISASSEMBLY AND REASSEMBLY.") Remove the fuel cell, then set nails, and finally the battery. (1) Remove the Nylock Hex. Socket Hd. Bolt M4 x 12 [6], and then remove the Cylinder Head [7A] from the Housing [30A]. (2) Put the Fan [11] on the Cylinder Head [7A] and check that the Fan [11] does not contact nearby components. (3) Push up Pushing Lever (A) [82] to rotate the motor. (4) Hold down the Trigger [71]. If sparking does not occur from the spark plug (Fig. 18) as a result of the operation above, check and take corrective action as follows: (Disassemble and reassemble the nailer according to Chapter 10, DISASSEMBLY AND REASSEMBLY.") Checking and corrective action 1. Check for stains on Spark Plug (A) [5]. Clean Spark Plug (A) [5]. 2. Faulty insulation of the spark plug cable (Sparking occurs from the spark plug cable.) Disconnect the spark plug cable from Spark Plug (A) [5] and check the spark plug cable. If the spark plug cable is abnormal (discharged from the cable due to scratches), replace the Controller [95]. 3. Faulty insulation of Spark Plug (A) [5] Replace Spark Plug (A) [5]. 4. Check whether the trigger switch wire in the handle section is pinched. 5. Pushing Lever Arm [77] is faulty. Replace Pushing Lever Arm [77]. 6. The Trigger [71] is faulty. Replace the Trigger [71]. 7. No sparking occurs even if the switch in the handle section is directly turned on. Replace Internal Wire (A) [60A]. Cylinder Head [7A] Spark Plug (A) [5] Check whether sparking occurs in this area. Fig

27 9-4. Regrinding the Driver Blade The tip of the driver blade should be ground as shown in Fig. 19. When grinding with a grinder, gradually grind the tip while cooling the ground area with water to prevent it from being excessively heated. Excessive grinding will rapidly reduce the service life of the driver blade. In such a case, replace the driver blade. 7 Driver blade Slant Grinding surface Fig DISASSEMBLY AND REASSEMBLY This chapter describes the specific items necessary for disassembly and reassembly. [Bold] numbers in the descriptions below correspond to item numbers in the Parts List and exploded view assembly diagram. CAUTION: Before disassembly or reassembly, be sure to remove all nails, the fuel cell, and the battery. Be sure to tighten the screw of the head securely before driving nails General Precautions on Disassembly and Reassembly Apply grease (Attolub No. 2) on the sliding surface of Pushing Lever (A) [82] and the screw part of the Adjuster [80]. Apply oil (Gas Nailer Lubricant) (Code No or ) to the areas shown in Fig. 20. Oil required: Hitachi Gas Nailer Lubricant 8 oz. (250 cc) oil feeder (Code No or ) Use the cleaner (Code No ) to clean such inner parts. Pull out and insert the roll pin on a stable worktable, and be careful not to deform or damage the roll pin by applying exceeding force to it. Tightening torque for each part. Bolt and others Tightening torque N m (kgf cm, ft-lb) Hex. Socket Set Screw M4 x 5 [21] 1.4 ± 0.2 (14 ± 2, 1 ± 0.15) Seal Lock Hex. Socket Hd. Bolt M4 x 8 [46] Seal Lock Hex. Socket Hd. Bolt M4 x 10 [74] 3.4 ± 0.5 (35 ± 5, 2.5 ± 0.4) Seal Lock Hex. Socket Hd. Bolt M4 x 12 [33] Hex. Socket Hd. Bolt M4 x 16 [13] 4.5 ± 0.5 (45 ± 5, 3.4 ± 0.4) Nylock Hex. Socket Hd. Bolt M4 x 12 [6] Hex. Shoulder Bolt M4 x 32 [41] Hex. Shoulder Bolt M5 [24] 3.4 ± 0.5 (35 ± 5, 2.5 ± 0.4) Hex. Socket Hd. Bolt (W/Flange) M5 x 10 [3] Truss Hd. Screw M4 x 25 (Black) [67A] 1.8 ± 0.4 (18 ± 4, 1.3 ± 0.3) Tapping Screw (W/Flange) D4 x 12 (Black) [96] Tapping Screw (W/Flange) D4 x 16 (Black) [39] 1.5 ± 0.5 (15 ± 5, 1.1 ± 0.4) Tapping Screw (W/Flange) D4 x 20 (Black) [57] Machine Screw M5 x 15 (Black) [88] 1.8 ± 0.4 (18 ± 4, 1.3 ± 0.3) Nut M3 [8] 0.4 ± 0.05 (4 ± 0.5, 0.3 ± 0.04) Nylon Nut M5 [44] 6.4 ± 0.5 (65 ± 5, 4.7 ± 0.4) Shaft Cover [23B] 1.8 ± 0.4 (18 ± 4, 1.3 ± 0.3) Spark Plug (A) [5] 1.0 ± 0.2 (10 ± 2, 0.7 ± 0.1) Tapping Screw (W/Flange) D3 x 10 (Black) [103] 0.8 ± 0.2 (8 ± 2, 0.6 ± 0.1) Machine Screw M4 x 10 [62] 1.3 ± 0.2 (13 ± 2, 0.9 ± 0.1) -24-

28 Oil application areas Piston Ring (B) [17] Thoroughly apply oil. Mount Sleeve Thoroughly apply oil. Cylinder Ass'y (A) [104A] Apply oil to the diagonally shaded areas. Inside. Outside: O-ring groove Cylinder Head [7A] Apply oil to the diagonally shaded areas. Outside: Piston ring groove Shaft Rubber Washer [22] Thoroughly apply oil. Piston Ring (B) [17] Thoroughly apply oil. Piston Ring (A) [26] Thoroughly apply oil. Chamber ass'y Apply oil to the diagonally shaded areas. Inside: Piston ring sliding portions (2 places) Piston [27] Apply oil to the diagonally shaded areas. Outside: Piston ring groove Inside Fig

29 10-2. Disconnecting and Reconnecting Wiring between the Cylinder Head Section and Handle Section The Model NT 65GB consists of three sections the cylinder head section, housing section, and handle section. The wiring between the cylinder head section and handle section must be disconnected before disassembling and reassembling each section. See Sections 10-3, 10-4, and 10-5 for how to disassemble and reassemble each section Cylinder head section Spark plug cable (One thick red cable) Four bolts Two bolts Housing section bolt Handle section Wiring connected to the motor. A connector is provided. (One thin red wire and one thin black wire) Fig. 21 [Tools required] Hex. bar wrench (4 mm) Phillips screwdriver (a) Disassembly (See Fig. 22.) Remove the Filter Cover [1A] and Filter Mesh [2], and then remove the Hex. Socket Hd. Bolt (W/Flange) M5 x 10 [3] and Hex. Shoulder Bolt M5 [24] to remove the Top Cover [4A]. Disconnect the red cable from Spark Plug (A) [5]. Be sure to hold the black rubber cap at disconnection to prevent the cable from being damaged. Do not yank the cable. If it is difficult to disconnect the rubber cap from Spark Plug (A) [5], fit the tip of a Phillips screwdriver or similar tool into the root of the rubber cap s cable outlet, and then pry off the rubber cap. Remove the Machine Screw M4 x 10 [62] and Support (B) [59], and then remove the wiring connector connected to the motor. Remove the Nylock Hex. Socket Hd. Bolt M4 x 12 [6], and then remove the cylinder head from the housing. -26-

30 Filter Cover [1A] Hex. Socket Hd. Bolt (W/Flange) M5 x 10 [3] Filter Mesh [2] Top Cover [4A] Nylock Hex. Socket Hd. Bolt M4 x 12 [6] Hex. Shoulder Bolt M5 [24] Packing [19] Adapter [20] Cylinder Head [7A] Fig

31 Spark plug cable Spark Plug (A) [5] Wiring connected to the motor Connector of the motor Packing [19] Machine Screw M4 x 10 [62] Support (B) [59] Fig. 23 (b) Reassembly Conduct reassembly by reversing the disassembly procedure. Note the following points: When mounting the cylinder head section to the main body, align the core Cylinder Ass'y (A) [104A] with the core of the cylinder head section, and then tighten the Nylock Hex. Socket Hd. Bolt M4 x 12 [6]. Perform wiring as shown in Fig. 23. Push in the Adapter [20] until it contacts the Cylinder Head [7A]. -28-

32 10-3. Disassembly and Reassembly of the Cylinder Head Section (1) Disassembly and reassembly of the Cylinder Head [7A] and related parts [Tools required] Hex. bar wrench (3 mm (0.118 ) Spanner (5.5 mm (0.217")) x 2 Socket wrench (8 mm (0.314")) Spanner (7 mm (0.276")) (a) Disassembly (See Fig. 24.) Remove Piston Ring (B) [17]. Remove the Nut M3 [8], Spring Washer M3 [9] and Washer M3 [10] to remove the Fan [11]. Use a hex. bar wrench to remove the Hex. Socket Set Screw M4 x 5 [21], and then remove the Motor Ass'y [25B] and mount sleeve. Use a socket wrench to remove Spark Plug (A) [5]. Remove the Shaft Cover [23B] with a spanner (7mm) and remove the Shaft Rubber Washer [22]. CAUTION: Do not deform the Fan [11]. Motor Ass'y [25B] O-Ring (S-12) [105] Mount sleeve Spark Plug (A) [5] Nylock Hex. Socket Hd. Bolt M4 x 12 [6] Packing [19] Adapter [20] Cylinder Head [7A] Hex. Socket Set Screw M4 x 5 [21] Shaft Rubber Washer [22] Shaft Cover [23B] Piston Ring (B) [17] Nut M3 [8] Spring Washer M3 [9] Washer M3 [10] Fan [11] Washer M3 [10] Spring Washer M3 [9] Nut M3 [8] Fig

33 (b) Reassembly Conduct reassembly by reversing the disassembly procedure. Note the following points: Attach the Shaft Rubber Washer [22] to the Cylinder Head [7A], and apply the specified oil (Code No or ). Apply the designated oil (Code No or ) Piston Ring (B) [17] and the mount sleeve. Set the mount sleeve with the uneven surface facing outward. Place the end of the mount sleeve to face direction A as illustrated in Fig. 25. Match the center of the upper and lower ends of the motor spring to the center of the motor mount ( UP direction in the figure) as illustrated in Fig. 26. Set the Cylinder Head [7A] and Motor Ass'y [25B] as shown in Fig. 26, and then secure in place by tightening the Hex. Socket Set Screw M4 x 5 [21]. At this time, lightly press the motor mount in direction "A" to prevent the motor mount from floating. Spark Plug (A) [5] Cylinder Head [7A] Ends of the mount sleeve Mount sleeve <Motor mount> Fig. 25 UP Upper end Lower end Upper end Lower end Motor spring Motor mount B Motor mount Cylinder Head [7A] Fig

34 10-4. Disassembly and Reassembly of the Housing Section (1) Disassembly and reassembly of the housing section and handle section (See Fig. 27.) [Tool required] Hex. bar wrench (3 mm) (a) Disassembly Remove the cylinder head section from the main body. (Fig. 27) Removing the Hex. Shoulder Bolt M4 x 32 [41] allows you to disassemble both the housing section and handle section. Hex. Shoulder Bolt M4 x 32 [41] <Handle section> <Housing section> Fig. 27 (b) Reassembly Disassembly procedures should be followed in the reverse order. Note the following points. Check that each lever protruded from the handle section fits in each hole on the side of the handle of the housing section (Fig. 28). Convex portion of Handle (A) [68A] and Handle (B) [40A] Convex portion of Handle (B) [40A] Convex portion of Handle (A) [68A] Trigger Stopper [75] Fig

35 (2) Disassembly and reassembly of the housing section (See Fig. 29.) [Tools required] Hex. bar wrench (3 mm (0.118")) Spanner (8 mm) or slender hd. pliers Roll pin puller (3 mm (0.118")) Phillips screwdriver Retaining ring puller for C-type holes Small flat-blade screwdriver (a) Disassembly Turn the Adjuster [80] and remove Pushing Lever (A) [82]. Then remove the Seal Lock Hex. Socket Hd. Bolt M4 x 12 [33] and the entire blade guide ass y. Remove the entire chamber ass y and cylinder ass y, and then detach the push lever arm ass y from the housing. Removing the Seal Lock Hex. Socket Hd. Bolt M4 x 10 [74] allows you to separate the components into the chamber ass y, cylinder ass y, and push lever arm ass y. (b) Reassembly Conduct reassembly by reversing the disassembly procedure. Note the following points: Apply oil along the inner circumference of the chamber ass y (on sliding surfaces of the cylinder and cylinder head), and along the outer circumference of the cylinder ass y (piston ring) as described in Section Install the Chamber Spring [73] at the protrusion of the push lever arm ass y, and then set it into the spring installation groove of the cylinder ass y. Carefully install the bent portion of the push lever arm ass y into the upper portion of the Chamber Stop Rubber [43], as the Chamber Spring [73] is easily removed. -32-

36 Hex. Socket Hd. Bolt M4 x 16 [13] Chamber Head [14] Chamber Spring [73] Gasket [15] Chamber [16] Seal Lock Hex. Socket Hd. Bolt M4 x 10 [74] Pushing Lever Arm [77] Nylon Nut M5 [44] Pushing Lever Piece [78A] O-Ring (S-8) [79] Piston Ring (B) [17] Retaining Ring For D40 Hole [18] Adjuster [80] Ratchet Spring [81] Piston Ring (A) [26] Piston [27] Piston Bumper [28] Pin [31] Blade Guide [32] Lock Lever Cover [34] Lock Lever [36A] Cylinder [42A] Seal Lock Hex. Socket Hd. Bolt M4 x 12 [33] Pushing Lever (A) [82] Chamber Stop Rubber [43] Housing [30A] Fig

37 Firmly insert the Chamber Spring [73] into the spring insertion part of the Pushing Lever Arm [77]. Secure the Pushing Lever Arm [77] to the Chamber [16] by tightening the Seal Lock Hex. Socket Hd. Bolt M4 x 10 [74], so that the contact surface of the Pushing Lever Arm [77] contacts the upper side of the Chamber Stop Rubber [43], thereby preventing removal of the Chamber Spring [73] from the Cylinder [42A] with support provided by the Pushing Lever Arm [77]. Chamber [16] Seal Lock Hex. Socket Hd. Bolt M4 x 10 [74] Cylinder [42A] Chamber Spring [73] Spring mounting portion of the Pushing Lever Arm [77] Chamber Stop Rubber [43] Pushing Lever Arm [77] Contact surface Pushing Lever Arm [77] Fig

38 (3) Disassembly and reassembly of the cylinder ass'y (a) Disassembly Use the retaining ring puller for C-type holes to remove the Retaining Ring For D40 Hole [18]. Insert a finger into the outlet of Cylinder Ass'y (A) [104A] and push the tip of the Piston [27]straight up. Then remove the Piston [27] from Cylinder Ass'y (A) [104A]. Remove the two Piston Ring (A) [26] from the Piston [27], while being careful not to deform the rings. Remove the Piston Bumper [28] by inserting the roll pin puller or similar tool into the screw hole of Cylinder Ass'y (A) [104A], or into the opening at the end of the Piston [27], and then striking it with a hammer (Fig. 32). Remove the Seal Lock Hex. Socket Hd. Bolt M4 x 8 [46], and then remove the exhaust port components, starting with the Buffer Cover [48] and Muffler [49]. Buffer Cover [48] Reed Valve [50] Buffer Plate [51] Cylinder [42A] Seal Lock Hex. Socket Hd. Bolt M4 x 8 [46] Conical Spring H8 [47] Muffler [49] O-Ring [52] Mesh [53] Fig

39 Cylinder Ass'y (A) [104A] Piston Bumper [28] Roll pin puller Roll pin puller Piston [27] Direction of exhaust Push in here. Fig

40 (b) Reassembly Conduct reassembly by reversing the disassembly procedure. Note the following points: Set the Muffler [49] at the concave section between the claws of the Buffer Cover [48]. Drop the Piston Bumper [28] into Cylinder Ass'y (A) [104A] by facing its stepped side inward and using the handle of a hammer to push it in until it passes through the stopper portion. You feel a click when the Piston Bumper [28] passes through the stopper portion (Fig. 33). Apply designated oil to the inside of Cylinder Ass'y (A) [104A] and the piston ring groove on the outside of Cylinder Ass'y (A) [104A] as described in Section Mount the two Piston Ring (A) [26] to the Piston [27], and be careful not to deform the rings. Be careful about the following when mounting the Piston [27] to Cylinder Ass'y (A) [104A]. (1) Position each split of the two Piston Ring (A) [26] at an angle of 90 degrees relative to the exhaust port aligning both splits at 180 degree opposite positions (Fig. 34). (2) Confirm that the tip of the driver blade can be seen in the outlet. The Piston [27] cannot be mounted if the tip of the driver blade contacts the Piston Bumper [28] or the bottom of the cylinder. (3) Face the grooved side of the driver blade toward the direction shown in Fig. 34. Buffer Cover [48] Claws Muffler [49] Handle of a hammer Cylinder Ass'y (A) [104A] Stopper portion Piston Bumper [28] Fig