Panasonic EY6406 - CORDLES DRILL&DRIVER Bedienungsanleitung

ORDER NO. MEW/PTD 9906-64061

Service Manual

Cordless Drill &Driver

EY6406•EY6407 •EY6431

CONTENTS

specifications

Disassembly /Assembly Instnjctions —

Wiring Connection Diagram

Troubleshooting Guide •

Schematic Diagram

Exploded View &Replacement Parts List

Page

'8-11

SPECIFICATIONS

MAIN UNIT

Model EY6406 EY6407 EY6431

Motor DC Motor 12V

No load speed LOW 400/min (rpm.)

HIGH 1300/mln (rpm.)

Chuck capacity ^0.5 ~^10mm (1/32"~ 3/8")

Maximum torque

DC Motor 15.6V

450/mln (rpm.)

1100/min (rpm.)

^1.0 13mm (1/16"- 1/2")

LOW 22.5Nm (230kgf-cm, 199ln-lbs.)

HIGH 6.3Nm (65kgf-cm. 56in-lbs.)

31 .9Nm (325kgf-cm,

2e2in-lbs.)

8.8Nm (90kgf'Cm, 78in -lbs.)

Clutch torque Approx. I.ONm (lOkgf-cm, 8.7in-lbs.)

5.4Nm (55kgf-cm. 47.7in-lbs.)

Approx. I.ONm (10kgf-cm,

8.7in-lbs.) -6.9Nm (70kg1-

cm. 61in-lbs.)

Overall length 202mm (7-61/64")

Weight (with battery pack) 1.7kg (3.74lbs.) with

208mm (8-3/1 6")

1.8kg (3.96lbs.) with

EY9200 2.0kg (4.4lbs.) with

EY9230/EY9136

BATTERY PACK EY9106 EY9108 EY9200 EY9230 EY9136

Storage battery Ni-Cd battery Ni-MH battery Ni-Cd battery

Battery voltage 12V DC (1.2V X10 cells) !15.6V DC (1.2V X13 cells)

BATTERY CHARGER

Weight a78kq (1.72lbs.)

Charging time Approx. 30min. with EY9106/91 08/91 36 45min. with EY9200/9230

and distribution is aviolation of law.

Model EY6406 •EY6407 •EY6431

AWARNING

This service literature is designed for experienced repair technicians only and is not designed for use by the general public. It does rwt

contain warnings or cautions to advise non-technical individuals of potential dangers in attempting to service aproduct. Products

powered by electricity should be serviced or repaired only by experienced professional technicians. Any attempt to service or repair the

product or products dealt with in this service infonnation by anyone else could result in serious injury or death.

DISASSEMBLY /ASSEMBLY INSTRUCTIONS

Ref. No. 1A Procedure 1A Removal of the keyless drill chuck.

Lock handle

Screwdriver

Flg.1

Chuck

Allen wrench Flg.2

Chuck

Fig.3

Allen wrench Chuck

Set the clutch handle to position QB^ and

"LOW" position.

Turn the lock handle counterclockwise direction

to open the chuck jaws.

Use ascrewdriver to tun^ the chuck fastening

screw Inside the chuck clockwise direction of the

arrow, and remove the screw. (See Fig. 1)

NOTE :If the chuck fastening screw will not

come loose, insert the alien wrench

into the chuck and lightly tap in the

clockwise direction with ahammer to

tighten the chuck, and then loosen the

chuck fastening screw. (See Fig.2)

Insert the alien wrench into the chuck, and tum

counterclockwise direction in the arrow with

holding the unit by the vise to remove the

chuck, (See Fig. 3)

Ref. No. 2A Procedure 2A Removal of the housings.

<EY6406-6407> 1.Remove 8housing screws. (See Fig.4-5)

Screw

Flg.5

-2-

Model EY6406 •EY6407 •EY6431

Ref.No. 2B Procedure 2A-*2B Removal or attachment of the motor.

Motor Gear box bl ck

Black

White

(Removal of the motor.)

1.Remove the motor with the gear box block from

housing.

2. Separate the motor from the gear box block by

twisting the motor to unlock tabs.

(Attachment for the motor.)

3. Motor mounting base and the positioning rib of

gear case should be set. (See Fig. 6)

Fig.6

Ref.No. 2C Procedure 2A-^2B-*- 3Removal or attachment of the gear box block.

Planet gear BThrust plate

Ring gear ACarrier A

Carrier B\/sSs. /s^ •

™1?D Planet gear B

Igear d

'Pin Planet ge A

Carrier f1

Driving block

(Removal of the gear box block.)

1.Tum the thrust plate to remove.

2. The internal parts of gear box block can be

removed one after another.(See Fig. 7)

(Attachment for the gear box block.)

3. If the lock ring comes out, reassemble in the

correct directton. (See Ffg.8)

4. Start from inserting 6pins into the driving block

as shown in the Fig. 9.

5. Assemble the other parts In reverse order as

shown in the Fig. 7.

NOTE :Carrier, Carrier Aand B, Ring gear,

and Ring gear Ahave their own

connect directions for proper

reassembly.

Clutch Clutch

spring plate Flg.7

Insert to .

driving ^

bkx:k.

Fig.S

Lock ring

Driving block

Fig.9

-3-

Model EY6406 •EY6407 •EY6431

Ref.No. 2D Procedure 2A—2B-^2C-*2D Attachment for steel balls.

1.Reinstalling place 2pcs of steel balls Into each of

the 6holes. (See Fig. 10}

Steel balls

(2 pes X6holes)

Drivinq block

Fig.10

Ret. No. 2E Procedure 2A-^2B—2C-*2D—2E Attachment for the adjusting screw and the

clutch handle.

Clutch "1

Align the Omark of adjusting screw with the

center of upper projection of clutch case.

Turn the adjusting screw into driving block about

one rotation for clockwise direction.

Align the OO mark of adjusting screw with the

center of upper projection of clutch case.

Set the clutch handle with position 1on top

Insert the clutch handle with adjusting the tabs

of adjusting screw to the groove of Inside clutch

handle.

00 mark

Omark

Adjusting screw Driving block

Fig.11

.4.

Model EY6406 •EY6407 •EY6431

WIRING CONNECTION DIAGRAM

EY6406/EY6407

-5-

Model EY6406 •EY6407 •EY6431

TROUBLESHOOTING GUIDE (Refer to WIRING CONNECTION DIAGRAM)

<TROUBLE

Does not operate.

Does not speed-

control or does not

brake.

If no less than 12 VDC for EY9106/EY91oe/EY9200 or

15.6V DC for EY9230/EY9136 is available across the (+)

and (-) tern^inals, the battery pack is OK.

Note: The battery pack is sold separately as shown

In REPLACEMENT PARTS LIST. The battery

pack has alimited life. The pack should be

replaced if

after being charged for the rated charging

time the battery voltage is less than 12 V

DC/1 5.6V DC or the usable time is

extremely short.

the battery leaks. Check battery for leaks

and terminals for corrosion.

The motor normally operates with its white (+) arKi black

(-) lead wires connected to 12 VDC for EY6406/EY6407

or 15.6V DC for EY6431.

(See WIRING CONNECTION DIAGRAM,)

With touching (+) terminal of Volt-Ohm meter, check

continuity between following terminals.

*Inspection of the brake.

(a) When the switch handle is not depressed :

-There should be OQ between ®-(§) .

without depressing the switch handle.

•Inspection of the forward /reverse selection switch.

(b) When the switch handle is depressed all the way :

There should be 0Qbetween ®-@,

and between @-©;when the switch

lever is set to the fonA/ard side.

*There should be 00 between ®-,

and between (§) -@;when the switch

lever is set to the reverse side.

NO <REMEDY >

Replace battery

pack.

<CHECK TERMINAL CONNECTIONS BETWEEN

MAIN UNIT AND BATTERY PACK.>

Check for proper terminal contacts.

NO Repair the

contacts.

NO Repair the motor.

NO Contacts in the

switch block are

defective.

Replace the

switch &FET

block.

Remove the FET circuit block and check the lead wire

terminals. These terminals are open normally when there

is an open circuit between the g;een and yellow

lead wires, and between the blue and yellow lead wires.

1NO Repair the

contacts,

<CHECK SWITCH BLOCK >NO Replace the

switch &FET

bk>ck.

-6-

Model EY6406 •EY6407 *EY6431

SCHf'.MATIC DIAGRAM

Power

source

+o-

-o-

KO-

5+0-

Battery Charger

—

Select SW Main SW

octsjv

Battery Pack —^y/—

Main Unit

-7-

Model EY6406 •EY6407

EXPLODED VIEW FOR EY )406 •EY6407

-8-

Model EY6406 EY6407

REPLACEMENT PARTS LIST FOR EY6406 •EY6407

NOTE :*A *••available as an optional accessory

*B •* * only available as set

*C ••*aval lable individual ly

Part No. for EY6406 Part No. for EY6407 Part Name &Descr ipt ions 1Per uni tRemarks

EY6406K3078 EY6407K3078 HOUSING AB SET 1

9EY6481L0177 EY6481L0177 CLICK SPRING 1

EYT103L6807 EYT103L6807 CHUCK FASTENING SCREW 1

AAEY9795 EY9796 KEYLESS CHUCK 1*A

EY6406Y3228 EY6406Y3228 CLUTCH HANDLE 1

ADEY6406L0638 EY6406L0638 ADJUSTING SCREW 1

EY6406L0168 EY6406L0168 CLUTCH SPRING 1

4li^ 0EY6406L0578 EY6406L0578 CLUTCH PLATE 1

QEY560B6967 EY560B6967 STEEL BALL 12 *B ^5

in EY6406L1078 EY6406L1078 DRIVING BLOCK 1

EY6406Y3238 EY6406Y3238 H/L HANDLE 1

EY6406L2568 EY6406L2568 HEAT SINK 1

EY6406L0178 EY6406L0178 CLICK SPRING A1

EY6402Y3247 EY6402Y3247 F/R SELECTOR HANDLE 1

1c;

13EY6283L0377 EY6283L0377 ROLLER PIN 6*B <^ 3.1 75*7.

Ifi EY6406L1118 EY6406L1118 CARRIER 1

17 EY6406L1488 EY6406L1488 RING GEAR 1

IP EY6406L1348 EY6406L1348 PLANET GEAR 6*B (3PCS/PK)

1Q EY6406L0858 EY6406L0858 THRUST PLATE 1

90 EY6406L1128 EY6406Llt28 CARRIER A1

EY6406L1468 EY6406L1488 RING GEAR A1

99 EY6406L1108 EY6406L1108 CARRIER B1

9^ EY6406L1478 EY6406L1478 RING GEAR B1

EY6406L1358 EY6406L1358 PLANET GEAR B3*B

EY6406L0888 EY6406L0888 THRUST PLATE 1

26 EY6406L1008 EY6406L1008 MOTOR 1

27 EY6230L6027 EY6230L6027 SCREW 3*C iK3-6

28 EY6406L0028 EY6406LaO28 MOTOR MOUNTING PUTE 1

29 EY6207Y6027 EY6207Y6027 SCREW 2*C iK3-5

30 EY6406Y2008 EY6406Y2008 SWITCH BLOCK 1

31 EY6230LG207 EY6230LQ207 DUST PREVENTIVE PLATE 1

A32 EY6230K9218 EY6230K9218 TAPPING SCREW 8*C iK3-20

A33 EY6406K9038 EY6406K9038 TORX TAPPING SCREW 4*C iK3-12

34 EY6406L1458 EY6406L1458 GEAR BOX BLOCK 1

35 EY9106 EY9200 BAHERY PACK *A

36 EY0230 EYO230 BATTERY CHARGER 1*Ai

-EY9594 EY9594 TOOL CASE 1*Aj

EY6406K8108 EY6406K8108 OPERATING INSTRUCTIONS 11!

-9-

-10-

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