Koki Holdings NR 3665DA User manual

PRODUCT NAME
36 V Cordless Metal Connector Nailer
Model NR 3665DA
CONTENTS
N
Page
CONFIDENTIAL
Mar. 2021
Overseas Sales Management Dept.
TROUBLESHOOTING GUIDE -------------------------------------------------------------------------------------- 1
1. Troubleshooting and corrective action -------------------------------------------------------------- 1
2. Corrective action when the orange LED blinks --------------------------------------------------- 7
3. Maintenance mode -------------------------------------------------------------------------------------- 8
4. Resetting error mode (when the orange LED is blinking) -------------------------------------- 8
REPAIR GUIDE --------------------------------------------------------------------------------------------------------- 9
1. Precautions on disassembly and reassembly ---------------------------------------------------- 9
• Preparation before disassembly -------------------------------------------------------------------- 9
• Disassembly and reassembly of the magazine section --------------------------------------10
• Disassembly and reassembly of the probe and pushing lever (A) --------------------------12
• Disassembly and reassembly of the output section -------------------------------------------15
• Replacement of the piston ass’y -------------------------------------------------------------------25
• Replacement of sensor ass’y (B) ------------------------------------------------------------------28
• Feeding compressed air -----------------------------------------------------------------------------29
• Checking after reassembly ---------------------------------------------------------------------------31
• Tightening torque --------------------------------------------------------------------------------------31
• Connecting diagram ----------------------------------------------------------------------------------32
STANDARD REPAIR TIME (UNIT) SCHEDULES ------------------------------------------------------------33

-1-
1. Troubleshooting and corrective action
Problem Possible cause
(*: Most common cause) Inspection method Corrective action
1.
Nails
cannot be
driven.
<Nails>
• Magazine is not loaded with
specified nails.
• Magazine is loaded with
abnormal nails (e.g., bent nails,
abnormal collation)
• Check whether the magazine
is correctly loaded with
specified nails.
• Use specified nails.
• Remove abnormal
nails and load the
nailer with proper
nails.
• Worn-out piston tip • Check whether the piston tip
is excessively worn.
• Replace defective
parts. See page 25.
• Piston trouble • Check the piston for any
trouble (e.g., deformation,
burring, break).
• Replace defective
parts. See page 25.
<Magazine section>
• Nail feeder trouble
(deformation, burring, break)
• Worn-out nail rail or magazine
plate
• Check the nail feed section
for any trouble (e.g., burring,
deformation, break,
excessive wear).
• Remove burring.
• Correct the
deformed portion.
• Replace defective
parts.
• Nail guide groove of blade
guide (B) too narrow or wide
• Nail guide groove trouble
(protrusion or burring) of blade
guide (B) and nail support (A)
• Step in the nail shank guide
groove between blade guide
(B), nail support (A), and
magazine
• Nail guide groove of the
magazine too narrow or wide
• Nail guide groove trouble
(deformation or burring) of the
magazine
• Load nails in the nailer and
make sure the nailer works
normally.
• Broken or worn-out nail support
(A) or spring (A)
• Check whether the nail
support (A) moves smoothly.
When checking, disassemble
the magazine referring to
page 10.
• Replace defective
parts.
* Unwanted objects (e.g., dust,
wood dust, adhesives) in the
nail guide groove of blade guide
(B), nail support (A), magazine,
and nail feeder
• Load nails in the nailer and
make sure the nailer works
normally.
• Remove unwanted
objects (e.g., dust,
wood dust,
adhesives).
• Loose bolts of the output
section and the magazine
section
—
• Tighten the bolts at
the specified torque.
• Nail feeding trouble • Check the nail feeder slide
surface for dust.
• Check the nail feeder slide
surface for deformation.
• Check the ribbon spring for
damage.
• Replace defective
parts.
TROUBLESHOOTING GUIDE

-2-
Problem Possible cause
(*: Most common cause) Inspection method Corrective action
1.
Nails
cannot be
driven.
• No compressed air in the
nailer
• Compressed air leak
• Fill up the nailer with
compressed air, leave the
nailer still for one day, and
then check the nailing work.
• Check the sealing surfaces,
X-rings, and O-rings inside
the cylinder, piston, chamber
cover, and chamber base for
flaws, unwanted objects, and
other failures.
• Supply compressed
air.
• Disassemble the
nailer and clean the
chamber, piston,
and their vicinity.
• Replace the sealing
parts.
2.
Nails are
driven but
bent.
*• Worn-out piston tip
*• Broken or worn-out blade
rack
• Check the piston tip for
excessive wear.
• Check the blade rack for
break or wear.
• Replace defective
parts. See page 25.
• Nails are not completely fed
into the injection port.
• Unspecified nails are used.
• Check whether the magazine
is correctly loaded with
specified nails.
• Use specified nails.
• Remove abnormal
nails and load the
nailer with proper
nails.
• Wood material too hard to be
nailed
• Drive nails into soft wood and
check whether the driven
nails are bent.
• This nailer is not for
hard wood.
• Deformed output section • Check the tips of the pushing
lever, blade guide, nail
support, and probe for warp,
deformation and excessive
wear.
• Replace defective
parts.
• Probe is not set at the hole of
the metal connector.
• Set the probe at the hole of
the metal connector surely
and drive nail.
―
3.
Nails
cannot be
driven into
the
workpiece
completely:
the lower
heads
cannot be
made flush
with the
workpiece
surface.
• Worn-out piston tip • Check the piston tip for
excessive wear.
• Replace defective
parts. See page 25.
*• Worn-out piston rack • Check the piston rack for
excessive wear.
• Replace defective
parts. See page 25.
• Wood material too hard to be
nailed
• Drive nails into soft wood and
check whether the nail heads
are lifted.
• This nailer is not for
hard wood.
• Weak thrusting force against
wood to be nailed
• Firmly thrust the nailer
against wood to be nailed
and start nailing. Check
whether the nail heads are
still lifted.
• Follow the nailer
operation guide.
• Deformed output section • Check the nail guide groove
of the pushing lever, blade
guide, nail support, and
probe for any trouble (e.g.,
deformation, excessive wear,
burrs
)
.
• Replace defective
parts.
• Insufficient grease on the
cylinder and piston section
• Check the greasing condition
of the cylinder and piston
section.
• Replenish grease.

-3-
Problem Possible cause
(*: Most common cause) Inspection method Corrective action
3.
Nails cannot
be driven
into the
workpiece
completely:
the lower
heads
cannot be
made flush
with the
workpiece
surface.
• No compressed air in the
nailer
• Compressed air leak
• Fill up the nailer with
compressed air, leave the
nailer still for one day, and
then check the nailing work.
• Check the sealing surfaces,
X-rings, and O-rings inside
the cylinder, piston, chamber
cover, and chamber base for
flaws, unwanted objects, and
other failures.
• Supply compressed
air.
• Disassemble the
nailer and clean the
chamber, piston, and
their vicinity.
• Replace the sealing
parts.
• Probe is not set at the hole
of the metal connector.
• Set the probe at the hole of
the metal connector surely
and drive nail.
―
4.
Nails are
driven out of
hole on the
metal
connector
• Probe is not set at the hole
of the metal connector.
• Set the probe at the hole of
the metal connector surely
and drive nail.
―
• Broken or worn-out probe • Check if the probe is broken
or worn out.
• Replace defective
parts.
• Broken or worn-out nail
support (B) or spring (B) or
urethane shaft
• Check if nail support (B) is
broken or worn out.
• Check whether the nail
support (B) moves smoothly
and the load of spring (B) and
urethane shaft is felt. When
checking, disassemble the
magazine referring to page
10.
• Replace defective
parts.
5.
Nails jam.
*• Abnormal nails are used
(e.g., bent nails, abnormal
collation)
• Nails are not completely fed
into the injection port.
• Check whether the magazine
is correctly loaded with
specified nails.
• Use specified nails.
• Remove abnormal
nails and load the
nailer with proper
nails.
• Worn-out piston tip • Check whether the piston tip
is excessively worn.
• Replace defective
parts. See page 25.
• Wood material too hard to be
nailed
• Drive nails into soft wood and
check whether nails jam.
• This nailer is not for
hard wood.
• Piston slide surface trouble
(e.g., galling, break)
• Check the surfaces on which
the piston slides (blade
guides (A), (B), pushing
levers (A), (B), probe, and
nail support (B)).
• Replace defective
parts.
<Magazine section>
• Nail feeder trouble (e.g.,
deformation, burring, break)
• Check the nail feed section
for any trouble (e.g., burring,
deformation, break,
excessive wear).
• Remove burring.
• Correct the
deformed portion.
• Replace defective
parts.
• Nail guide groove of blade
guide (B) too narrow or wide
• Nail guide groove trouble
(e.g., protrusion, burrs,
excessive wear) of blade
guide (B) or nail support (A)
• Nail guide groove of the
magazine too narrow or wide
• Nail guide section trouble
(e.g., deformation, burrs) of
the magazine
• Load nails in the nailer and
check that the nailer works
normally.
• Remove burring.
• Replace defective
parts.

-4-
Problem Possible cause
(*: Most common cause) Inspection method Corrective action
5.
Nails jam.
• Unwanted objects (e.g., dust,
wood dust, adhesives) in the
nail guide groove of the
magazine and nail feeder
• Load nails in the nailer and
check that the nailer works
normally.
• Remove unwanted
objects (e.g., dust,
wood dust,
adhesives).
• Deformed output section • Check pushing lever (A) and
blade guides (A) and (B) for
deformation, excessive wear,
and burrs.
• Replace defective
parts.
• Misaligned assembly of
blade guide (B) and
magazine
• Set specified nails in the
nailer and lightly push them
against the magazine. Make
sure the nail tips closely
touch the nail guide surface
of blade guide (B).
(See "Disassembly and
reassembly of the magazine
section.")
• Reassemble blade
guide (B). See page
10.
• Loose bolts of the output
section and magazine
section
―
• Tighten the bolts at
the specified torque.
• Broken or worn-out nail
support (A) or spring (A)
• Check whether the nail
support (A) moves smoothly.
When checking, disassemble
the magazine referring to
page 10.
• Replace defective
parts.
• Probe is not set at the hole
of the metal connector.
• Set the probe at the hole of the
metal connector surely and
drive nail.
―
6.
Nailing
started by
single
triggering.
*• Malfunction caused by
unwanted objects (e.g.,
adhesive, dust) near
pushing lever (A), (B), blade
guide (A), or probe, or by
deformation of the lever or
blade guide
• Check that pushing lever (A)
moves smoothly (in a body).
• Clean the pushing
lever and the blade
guide. Then apply oil
to them.
• Replace defective
parts.
• Broken or worn-out pushing
lever spring (B)
• Check the spring for any
trouble.
• Replace defective
parts.

-5-
Problem Possible cause
(*: Most common cause) Inspection method Corrective action
7.
No nailing
operation
without
motor
rotation
sound.
• Dry-fire lockout mechanism is
activated.
• Count the number of
remaining nails. There
should be 6 or more
remaining nails.
• Load nails.
*• Wire-related trouble of
wiring, switch cable (A), and
sensor ass’y (B)
• Check whether the wires
and sensor ass’y (B) are
firmly soldered.
• Check whether the rotor
emits a parching smell.
• Check the conductivity of
the switch and
microswitch by using a
multimeter.
[Checking procedure]
(1) When switch cable (A) is
not defective:
• Set the switch to OFF and
apply tester probes to the
points shown in the figure
below. Make sure the
terminals are not
electrically connected.
• Set the switch to ON and
apply tester probes to the
points shown in the figure
below. Make sure the
terminals are electrically
connected.
(2) When the microswitch is
not defective:
• Set the switch to ON and
apply tester probes to the
points shown in the figure
below. Make sure the
contacts are electrically
connected.
• Set the switch to OFF and
apply tester probes to the
points shown in the figure
below. Make sure the
contacts are not
electrically connected.
• Firmly resolder the
disconnected wires.
• Replace defective parts.
Microswitch
Silicone Apply multimeter probes here.
NOTE: Remove the silicone a little and apply the
multimeter probes to the exposed terminal metal.
Apply multimeter probes here.
(1) (2)

-6-
Problem Possible cause
(*: Most common cause) Inspection method Corrective action
8.
No nailing
operation
with the
orange LED
blinking.
*See page 7.
*• Broken movable part that
disabled nailing work.
• Check the movable part for
any trouble (e.g.,
deformation, break,
excessive wear).
• Replace defective
parts.
• Disconnected wiring and
stator
• Check the wires and sensor
assemblies for breaks or
disconnection.
• Check the conductivity of the
stator.
• Replace defective
parts.
*• Power transmission
failure due to broken
gears
• Check that the gear turns
smoothly. See page 21.
• Check the gear box ass'y for
breaks.
• Replace defective
parts.
• Sensor (C) trouble • Visually check the sensor
wires for breaks.
• Replace defective
parts.
• Excessively charged
compressed air
• Check the LED lighting
pattern.
• Move the piston down
to the bottom dead
point. Discharge the
compressed air. Use
the reduction valve
set to feed
compressed air again.
See pages 29 to 30.
9.
No nailing
operation
with the two
red LEDs
blinking
*• Overheat protector is
activated.
• Cool the nailer body and
check the nailing work. ―
*• Overcool protector is
activated.
• Warm the nailer body and
check the nailing work. ―
10.
No nailing
operation
with the one
red LED
blinking
*• Low battery voltage • Use a fully charged battery
and check the nailing work
again.
• Charge or replace the
battery.
LED blinks in red.

-7-
Power ON*1
Reset the error.
(See page 8.)
Pull the trigger.*3
See No. 4 in the table.
See No. 3 and 6 in the table.
See No. 1, 2, and 5 in the table.
2. Corrective action when the orange LED blinks
No. Orange LED lighting pattern Possible cause Corrective action
1 Power switch is automatically turned off after
about 10 seconds.
• Reversed magnet polarity
of position detector
• Sensor (C) failure or
disconnection
• Failure of one-way clutch
in gear box
• Replace defective parts.
2
Power switch is automatically turned off after
blinking 5 times (about 5 seconds).
• Idle by broken gear • Replace defective parts.
3
Power switch is automatically turned off after
blinking 6 times (about 6 seconds).
• Broken wiring • Replace defective parts.
4
Power switch is automatically turned off after
blinking 7 to 8 times (about 7 to 8 seconds).
• Locked by broken gear
• Locked by worn-out
piston rack
• Locked by broken piston
bumper
• Broken wiring
• Replace defective parts.
5
Power switch is automatically turned off after
about 9 seconds.
• Excessively charged
compressed air
• Deformed or broken
moving parts
• Moving parts are out of
grease.
• Replace defective parts.
• Move the piston down to the
bottom dead point. Discharge
the compressed air. Use the
reduction valve set to feed
compressed air again.
• Replace moving parts.
• Lubricate the moving parts
with grease.
6
Power switch is automatically turned off after
blinking 10 times (about 10 seconds).
• Broken wiring • Replace defective parts.
*1: Do not press the pushing lever and/or pull
the trigger during the process of turning the
power switch ON. Doing so will prevent the
power switch from turning ON.
*2: LED of the information indicator
*3: Press the pushing lever against the wood
before pulling the trigger.
Does the
motor run?
No
Does the orange
LED*2 blink?
Yes
Does the
piston move?
No
Yes
Yes
No

-8-
Fig. 1
Fig. 2
3. Maintenance mode
The maintenance mode is used to move the piston down to the bottom dead point in preparation for feeding
compressed air or overhauling the nailer. To switch to the maintenance mode, hold down both the power
switch and the maintenance switch for at least five seconds.
NOTE: The maintenance switch is hidden under the operation panel. Peel off a part of the operation
panel and hold down the maintenance switch.
Indication: Indicated by the blue LED on the operation panel blinking at intervals of 0.5 second.
Function: Starts the motor when the pushing lever is pressed against wood and the trigger is pulled.
Stops the motor when detecting two motor rotations.
4. Resetting error mode (when the orange LED is blinking)
Error indication: Indicated by the orange battery level indicator blinking at intervals of 0.5 second.
The power indicator turns off automatically 10 seconds later.
To reset the mode: Hold down both the error reset switch and the maintenance switch for at least five
seconds.
NOTE: The error reset switch and maintenance switch are hidden under the
operation panel. Peel off a part of the operation panel and hold down both
the error reset switch and the maintenance switch.
Switched to the full sequential actuation
mode (The blue LED goes on.)
5 seconds later
Push
The orange LED blinks
at intervals of 0.5 sec.
The blue LED blinks at intervals of 0.5 sec.
Push
Error reset switch
Power switch
Maintenance switch
Push
5 seconds later
Push
Maintenance switch

-9-
Fig. 3
The Model NR 3665DA mainly consists of two sections: the output section and the magazine section. The
most essential precautions on disassembly and reassembly of the Model NR 3665DA are described below.
1. Precautions on disassembly and reassembly
[Bold] numbers in the description below correspond to the item numbers in the parts list and exploded
assembly diagram for the Model NR 3665DA.
WARNING: Be sure to remove the battery from the main body before starting repair or maintenance
work. If the switch is activated inadvertently with the battery still mounted on the main
body, the motor may turn unexpectedly and could cause serious injury.
1. Removal of the hook
Remove the Hook [62] by removing the Nylock Hex. Socket Hd. Bolts M4 x 8 [63] for easy disassembly
work, although disassembly can be done without removing the Hook [62].
2. Removal of housing (C)
• When the nailer is enabled to nail, switch to the maintenance mode and move the Piston Ass'y [16]
down to the bottom dead point referring to "Feeding compressed air" on page 29.
• Remove the Tapping Screw (W/Flange) D4 x 20 [47] and remove Housing (C) [48].
• Remove the Charge Cap [8] by using a hexagonal socket wrench.
• Push the Valve Core [10] to release compressed air as shown below.
REPAIR GUIDE
Preparation before disassembly
[10]

-10-
Fig. 4
1. Disassembly
• Remove the Nylock Bolt (W/Flange) M5 [82] that fastens the magazine ass'y to the Housing Ass’y [50]
and two Nylock Bolts M5 x 22 [35] that fasten the magazine ass'y to the Nose [18].
• Remove the three Tapping Screws (W/Flange) D4 x 16 [105], Cap Nut M3 [78], and Step Bolt M3 [103].
• Remove the Magazine Guard [104] from the magazine ass'y and remove Magazine Cover (B) [81] from
Magazine Cover (A) [85]. Then remove Blade Guide (B) [88].
• Remove the Needle Roller D4 [92], Nail Support (B) [93], Spring (B) [94], and Urethane Shaft [95] from
Blade Guide (B) [88].
• Remove the Needle Roller D3 x 22 [87], Nail Support (A) [90], and Spring (A) [89] from Blade Guide (B)
[88].
• Remove the Tapping Screw (W/Flange) D5 x 20 [107] that fastens Magazine Cover (A) [85] to Nail Feeder
(B) [101]. Then remove the Feeder Knob [106] and Ribbon Spring [102].
• Remove Pushing Lever Stopper (A) [96], Pushing Lever Stopper (B) [98], and two Springs [97] from
Magazine Cover (A) [85].
• Remove the Nail Rail [84] from Magazine Cover (B) [81] and remove the Magazine Plate [83].
Disassembly and reassembly of the magazine section
[81]
[92]
[85]
[93]
[87]
[88]
[91]
[98]
[100]
[99]
[94]
[82]
[101]
[96]
[84]
[103]
[78]
[83]
[95]
[102]
[97]
[97]
[104] [105] [106] [107]
[89]
[90]

-11-
Fig. 7
Fig. 5
Fig. 6
2. Reassembly
Reverse the disassembly procedure to reassemble. Note the following points.
• Mount Spring (A) [89] on Nail Support (A) [90]. Insert Nail Support (A) [90] into the groove of Blade Guide
(B) [88] and insert the Needle Roller D3 x 22 [87] into the hole of Blade Guide (B) [88].
• Insert the Urethane Shaft [95] into Spring (B) [94] and insert Spring (B) [94] and Nail Support (B) [93] into
the groove of Blade Guide (B) [88].
NOTE: Be sure to insert the Urethane Shaft [95].
• Insert the black marking side of the Nail Rail [84] into the nail head inlet of Blade Guide (B) [88].
Nail head inlet of
Blade Guide (B) [88]
Protrusion of
Nail Rail [84]
[90]
[89]
[90]
[88]
[95] [94]
[93]
[94] and [95] [88]
[92]

-12-
Fig. 8
Fig. 9
1. Disassembly
• Remove Housing (C) [48] and magazine ass'y referring to page 9 to 10.
• For safety, push the valve core once more and check that compressed air is completely released and the
Piston Ass'y [16] is lowered to the bottom dead point referring to "Feeding compressed air" on page 29.
• Slide the Needle Cover [43] to the side of Pushing Lever (B) [40] and remove the Needle Roller D2.5 [41]
using a tapered tool.
NOTE: Pay attention not to drop the Needle Roller D2.5 [41] in the Housing Ass'y [50].
• Turn the Adjuster [42] and remove Pushing Lever (A) [44], Probe [45], and Needle Roller D3 x 10.4 [46].
• Remove the Needle Cover [43] from the Adjuster [42].
2. Reassembly
Reverse the disassembly procedure to reassemble. Note the following points.
CAUTION: Adjustment of the Adjuster [42] is required when reassembling Pushing Lever (A) [44]. If
adjusted incorrectly, the nailer cannot drive nails or nails cannot be driven into the holes
of the metal connectors properly.
<Adjustment method of the Adjuster [42]>
• Mount the Needle Cover [43] to the Adjuster [42]. Slide the Needle Cover [43] to the side of Pushing Lever
(B) [40] without fitting in the groove.
• Make a gap about 4 mm between Pushing Lever (A) [44] and Adjuster [42] and align the groove of the
Adjuster [42] with the hole of Pushing lever (A) [44] (Fig. 10).
Disassembly and reassembly of the probe and pushing lever (A)
[44]
[42]
[43]
[41]
[44]
[46]
[45]
[43]
[42]
Fig. 10 [42]
[43]
4 mm
[44]
[16]
Align the groove of the Adjuster [42] with
the hole of Pushing Lever (A) [44].

-13-
Fig. 11-1
Fig. 11-2
• Set the lock lever to the lock position to lock the trigger for
safety (Fig. 11-1).
• Mount the battery and adjust the Adjuster [42] according to the following procedure (Figs. 11-2 and 11-3).
Press the Probe [45] against the 5.2 mm groove of the J-409 push lever gauge.
NOTE: Prevent the tip of the Piston Ass'y [16] from contacting the J-409 push lever gauge
(Fig. 12).
Hold down the power switch on the operation panel for 2 seconds and check that the power is turned
on.
When the power is not turned on, make a half turn of the Adjuster [42] to narrow the gap between
Pushing Lever (A) [44] and the Adjuster [42], and repeat the above steps and .
When the power is turned on, hold down the power switch for 2 seconds to turn off the power. Press
the Probe [45] against the 4.5 mm groove of the J-409 push lever gauge.
Hold down the power switch on the operation switch for 2 seconds and check that the power is not
turned on. When the power is turned on, check Sensor Ass'y (B) [39] referring to "Checking the
pushing lever operation (sensor ass’y (B) output)" on page 24.
NOTE: Prevent the tip of the Piston Ass'y [16] from contacting the J-409 push lever gauge (Fig. 12).
1
2
3
1 2
4
5
Lock lever
Yes
Adjustment completed.
Check Sensor Ass’y (B)
[39] referring to page 24.
No
Is the power turned on?
Yes
Press the Probe [45] against the 4.5 mm
groove of the J-409 push lever gauge and
hold down the power switch for 2 seconds.
No
Press the Probe [45] against the 5.2 mm
groove of the J-409 push lever gauge and
hold down the power switch for 2 seconds.
Is the power turned on?
1
2
3
4
Make a half turn of the Adjuster [42] to
narrow the gap between Pushing Lever
(A) [44] and Adjuster [42].
5

-14-
Fig. 12
Fig. 11-3
• Put the Needle Roller D2.5 [41] into the hole of the Adjuster [42] and slide the Needle Cover [43] to the
groove of the Adjuster [42].
NOTE: Pay attention not to drop the Needle Roller D2.5 [41] in the Housing Ass'y [50].
• Check that the Probe [45] and Pushing Lever (A) [44] move smoothly without any catch.
• Check that the Adjuster [42] does not turn.
OK: • Piston Ass’y [16] does not contact
the J-409 push lever gauge.
• Nailer is vertical.
[16] [86]
J-409 push lever gauge
[45]
NG: • Piston Ass’y [16] contacts the
J-409 push lever gauge.
• Nailer is tilted.
J-409 push lever gauge
(Code No. 377657)
J-409 push lever gauge
1
2
Power switch Operation panel
( 4)
( 5)
[42]
[44]
3
The tool is powered on while this LED is lighting.
5.2 mm groove
(4.5 mm groove)
4.5 mm groove 5.2 mm groove

-15-
Fig. 14
1. Removal of the power assembly and wiring
• Housing Ass’y [50] consists of two halves: housing (A) with a metabo HPT logo mark on its surface and
housing (B).
• For safety, push the valve core once more and check that compressed air is completely released.
• Remove the Hex. Socket Hd. Bolt M6 [1] and detach the Top Cover [2].
• Remove the Tapping Screw (W/Flange) D4 x 20 (Black) [47] and housing (F).
• Remove the fourteen Tapping Screws (W/Flange) D4 x 20 (Black) [47] that fasten housings (A) and (B).
• Holding the battery portion of housing (B), gently open and remove the Housing Ass’y [50].
• Remove the Trigger [57] and Spring (T) [56] from housing (A).
• Remove Rubber Cushion (A) [26] from housing (A).
• Disconnect the connectors of Sensor Ass’y (B) [39], Sensor (C) [67], Switch Cable (A) [55], and Wiring
Ass’y [60].
• Remove the two O-rings (I.D 2.5) [54] from Switch Cable (A) [55]. Be careful not to lose the O-rings.
• Carefully lift the Chamber Base Ass’y [11] and Nose [18] to remove the power assembly from housing (A)
and Rotor [80].
• Remove the Gear Box Ass’y [79] and Bumper (B) [66] from the power assembly.
• Firmly hold the stator of the Wiring Ass’y [60] (as the Rotor [80] has strong magnetic force), slowly push
the ball bearing (opposite to the pinion) of the Rotor [80] in direction "A" to separate the Wiring Ass’y [60]
from the Rotor [80] as shown in the figure below.
• Carefully twist housings (D) and (E), and remove them from housing (A).
• Remove the two Tapping Screws (W/Flange) D4 x 20 (Black) [47] and detach housing (E).
• Remove the Wiring Ass’y [60] from housing (A).
• Remove Lever (C) [58] from Lever (A) [64].
• Remove Lever (A) [64] from housing (A).
Fig. 13
Disassembly and reassembly of the output section
Housing (F)
[47]
[47]
A
Stator
[80]

-16-
Fig. 15
2. Disassembly of the power assembly
NOTE: • See pages 25 to 27 for replacement of only the Piston Ass'y [16].
• Put alignment marks on the Chamber Base Ass’y [11] and Cylinder [5] as shown in the figure
below before disassembly to indicate the coupling positions.
[1]
Alignment marks
[2]
[3]
[4]
[5]
[6]
[7]
[8] [9]
[10]
[12]
[13]
[19]
[11]
[20]
[21]
[22]
[23]
[31]
[33]
[24]
[32]
[34]
[35]
[36]
[26]
[27]
[25]
[28]
[29]
[30]
[17]
[18]
[14]
[15]
[14]
[16]
[67]
[71]
[72]
[68]
[69]
[26]
[70]
[38]
[37]
[39]
[40]
[46]
[41]
[42]
[43]
[44]
[45]
[86]

-17-
Fig. 16
Fig. 19
Fig. 17
• Remove the valve core from the Chamber Base Ass’y [11] by using a commercially available valve core
tool. (See Fig. 16.)
• Remove the four Nylock Bolts M6 [12] that fasten the Chamber Base Ass’y [11] and Chamber Cover [4],
and remove the Chamber Base Ass’y [11].
NOTE: If it is difficult to remove the Chamber Base Ass’y [11], temporarily tighten at least two
Nylock Bolts M6 [12] so that the threaded portion can be seen 3.5 mm to 6.5 mm as shown
in Fig. 17. Mount the reduction valve set and feed compressed air to remove the Chamber
Base Ass’y [11].
• Remove the O-ring (I.D 94.5) [7] from the Chamber Base Ass’y [11].
• Push in the Piston Ass'y [16] from Blade Guide (A) [86] side to the Cylinder [5] side to remove it.
• Remove the Hex. Socket Hd. Bolt M5 [71] from the Nose [18].
• Move the Chamber Base Ass’y [11] from the Cylinder [5] contact surface to the Nose [18] side and secure
the Cylinder [5] and Chamber Base Ass’y [11] with tape as shown below.
• Fix the hexagonal portion of the J-400 special socket. Fit the claws of the J-400 special socket in the
notches on the end surface of the Cylinder [5]. Loosen the Special Nut M58 [13] and turn the Nose [18]
to remove it from the Cylinder [5].
Bit type Tip shape
[11]
Temporarily tighten the
Nylock Bolts M6 [12] so that
the threaded portion can be
seen 3.5 to 6.5 mm.
[11] Reduction valve set
Fig. 18
[71]
[18]
Tape

-18-
Fig. 20
• Turn the Special Nut M58 [13] and remove it from the Cylinder [5].
• Remove the Chamber Base Ass’y [11] from the Cylinder [5] being careful not to damage the sealing
surfaces.
• Remove the two O-rings (I.D 55.5) [6] from the Cylinder [5].
• Remove the Slide Ring [14] and X-ring [15] from the Piston Ass'y [16].
• Remove the Piston Bumper [17] from the Nose [18].
• Remove the Retaining Ring D52 [19] from the Nose [18] and pull out the Bearing Holder [20] and Pin
Wheel [28].
NOTE: The Pin Wheel [28] can be removed only after removing the Piston Ass'y [16].
• Remove the Ball Bearing 6000VV [21] and Ball Bearing 6902VV [30] from the Pin Wheel [28].
• Remove the Needle Roller D3 [31] from the Pin Wheel [28] and then remove the Position Detector [23].
• Remove the eight Needle Rollers D4 [33] and one Needle Roller D4.5 [24] from the Pin Wheel [28].
Remove Wheel Spring (A) [32], Wheel Spring (B) [29], and Pin (A) [34].
• Remove Felt (P) [25] from the Pin Wheel [28].
Fit the claws of the J-400 special socket in the
notches on the Cylinder [5] (4 places).
J-400
Repair tool number "J-400"
J-400 special socket (Code No. 372798)
• Apply 0.5 g or more oil to the top and bottom of the Special Nut M58 [13] all around.
• Leave the Special Nut M58 [13] as it is for at least 2 hours.
• Loosen the Special Nut M58 [13].
• If it is hard to loosen, apply additional oil to the Special Nut M58 [13]
and leave it for more than half a day. Then loosen it again.

-19-
Fig. 21
• Remove Pushing Lever (B) [40] and Pushing Lever Spring (B) [37].
• Remove the Special Bolt M6 [38] and Adjuster [42] from Pushing Lever (B) [40].
• Remove the two Nylock Bolts (W/Flange) M4 x 14 [36] and one Nylock Bolt (W/Flange) M4 x 25 [27] from
the Nose [18], then remove Blade Guide (A) [86].
• Remove the Nylock Hex. Socket Hd. Bolt M3 [69] from the Nose [18], then remove Guide Plate (P) [68].
• Cut the two Wire Bands [73] that fix Sensor Ass’y (B) [39] and Sensor (C) [67], then remove Sensor (C)
[67].
• Remove the Roll Pin D2.5 x 8 [72] and Roll Pin D2.5 x 16 [70] that fix Sensor Ass’y (B) [39] referring to
page 28.
NOTE: Sensor (C) [67] can be removed only after removing Blade Guide (A) [86].
3. Reassembly of the power assembly
Reverse the disassembly procedure to reassemble. Note the following points:
• Use the specified tightening torques. (See page 31.)
• Protect the sealing parts (e.g., O-rings, X-rings, valve core, etc.) against contaminants and scratches
during reassembly.
• Always use brand-new seal lock bolts. Never reuse the old bolts.
• Use the alignment marks (made before disassembly) for precise positioning when mounting the Chamber
Base Ass’y [11] on the Cylinder [5].
• Slowly tighten the four Nylock Bolts M6 [12] to fasten the Chamber Base Ass’y [11] and Chamber Cover
[4]. Be careful not to pinch and damage the O-ring (I.D 94.5) [7].
• Impregnate Felt (P) [25] with about 1 g of Molub-Alloy 777-1 grease by hand before reassembly.
• Mount the Pin Wheel [28] to the Position Detector [23] so that the end surface side of Pin (A) [34] is
aligned with the notch of the Position Detector [23] as shown in Fig. 21.
NOTE: If the Position Detector [23] is not precisely located, an error (causing the orange LED of
the battery indicator to blink) may occur.
• Remove dust from between the Pin Wheel [28] and Needle Roller D3 [31] and apply about 1.5 g of Molub-
Alloy 777-1 grease to the Needle Roller D3 [31], eight Needle Rollers D4 [33], and Needle Roller D4.5
[24] evenly.
• Apply about 1.0 g of Isoflex Topas NB52 grease to the X-ring [15] and Slide Ring [14] of the Piston Ass'y
[16] evenly.
Pay special attention to the position of
the Position Detector [23].
If the Position Detector [23] is
misaligned, the standby position of the
piston is also misaligned. (See page 27.)
[28]
[23]
Notch
Notch