Panasonic EY6405-X8 User manual

1 SCHEMATIC DIAGRAM 2
2 WIRING CONNECTION DIAGRAM 2
3 DISASSEMBLY/ASSEMBLY INSTRUCTIONS 3
©2002 Matsushita Electric Works Ltd. All rights
reserved. Unauthorized copying and distribution is a
violation of law.
EY6405-X8
EY6409-X8
EY6432-X8
4 TROUBLESHOOTING GUIDE 7
5 EXPLODED VIEW 9
6 REPLACEMENT PARTS LIST 10
Cordless Drill & Driver
SPECIFICATIONS
CONTENTS
Page Page
ORDER NO.PTD0207X34C8

1 SCHEMATIC DIAGRAM
2 WIRING CONNECTION DIAGRAM
2.1. EY6405/EY6409
2.2. EY6432
2
EY6405-X8 / EY6409-X8 / EY6432-X8

■HOW TO DISASSEMBLE KEYLESS CHUCK.
3 DISASSEMBLY/ASSEMBLY INSTRUCTIONS
Ref. No. 1A Procedure 1A Removal of the Keyless Drill Chuck.
Fig.1
Fig.2
Fig.3
1. Set the clutch handle to position and select "LOW"
position.
2. Turn the lock collar counterclockwise direction to open the chuck
jaws.
3. Use a screwdriver to turn 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
allen wrench into the chuck and lightly tap in the clockwise
direction with a hammer to tighten the chuck, and then loosen
the chuck fastening screw. (See Fig.2)
4. Insert the allen wrench into the chuck, and turn counterclockwise
direction in the arrow with holding the unit by the vise to remove
the chuck. (See Fig.3)
3
EY6405-X8 / EY6409-X8 / EY6432-X8

■HOW TO DISASSEMBLE MAIN UNIT.
Ref. No. 2A Procedure 2A Removal of the Housing.
1. Remove eight housing screws.
(See or Fig.4 or Fig.5)
EY6405/EY6409 EY6432
Fig.4 Fig.5
Ref. No. 2B Procedure 2A →
→→
→2B Removal or attachment of the Motor.
Fig.6
(Removal)
1. Take out 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)
3. Motor mounting base and the positioning rib of gear case should
be set. (See Fig.6)
4
EY6405-X8 / EY6409-X8 / EY6432-X8

Ref. No. 2C Procedure 2A →
→→
→2B →
→→
→2C Removal or attachment of the Gear Box Block.
(Removal)
1. Turn the thrust plate to remove.
2. The internal parts of gear box block can be removed one after
another. (See Fig. 7)
(Attachment)
3. If the lock ring comes out, reassemble in the correct direction.
(See Fig. 8)
4. Start from inserting 6 pins 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 A and B, Ring Gear, and Ring Gear A have
their own correct directions for proper reassembly.
5
EY6405-X8 / EY6409-X8 / EY6432-X8

Ref.No.2D Procedure 2A →
→→
→2B →
→→
→2C →
→→
→2D Assembly of the Adjusting Screw and the Clutch
Handle.
1. Align the mark of adjusting screw with the center of upper
projection of clutch case.
2.Turn the adjusting screw into the driving block about one rotation
for clockwise direction.
3. Align the mark of adjusting screw with the center of
upper projection of clutch case.
4. Set the clutch handle with position 1 on top.
5. Insert the clutch handle with adjusting the tabs of adjusting
screw to the groove of inside clutch handle.
Fig.11
6
EY6405-X8 / EY6409-X8 / EY6432-X8

(Refer to WIRING CONNECTION DIAGRAM)
4 TROUBLESHOOTING GUIDE
< TROUBLE > < CHECK > < REMEDY >
Does not operate. <CHECK BATTERY PACK.> NO Replace battery pack.
→If no less than 12V or 15.6 V DC is available across the (+) and (-) terminals, →
the battery pack is OK.
NOTE: The battery pack is sold separately as an optional accessory.
See the nearest sales dealer for details. The battery pack has a
limited life.
The pack should be replaced if;
-after being charged for the rated charging time the battery voltage
is less than 12V/15.6V DC or the usable time is extremely short.
-the battery leaks. Check battery for leaks and terminals for
corrosion.
↓OK
<CHECK TERMINAL CONNECTIONS BETWEEN MAIN UNIT NO repair contacts.
AND BATTERY PACK.> →
Check for proper terminal contacts.
↓OK
<CHECK SWITCH BLOCK.> NO Contacts in switch block
(See .WIRING CONNECTION DIAGRAM.) →are defective.
Check continuity between following terminals. Replace switch & FET
*Inspection of the forward / reverse selection switch. block.
When switch handle is depressed all the way:
-There should be 0Ωbetween - , and between - ;
when switch lever is set to forward side.
-There should be 0Ωbetween - , and between - ;
when switch lever is set to reverse side.
*Inspection of the brake.
When switch handle is not depressed:
-There should be 0Ωbetween - .
↓OK
<CHECK MOTOR.> NO Replace motor.
The motor normally operates with its white (+) and black (-) lead wires →
connected to 12V DC for EY6405/EY6409 or 15.6V DC for EY6432.
7
EY6405-X8 / EY6409-X8 / EY6432-X8

< TROUBLE > < CHECK > < REMEDY >
Does not speed- <CHECK FET.> NO Repair the contact
control or does not Even if FET block is defective, it can not be replaced individually. or replace switch
brake. →Replace whole switch block. →& FET block.
Remove the FET circuit block and check the lead wire terminals.
These terminals are open normally when there is an open circuit ( Ω)
between the green and yellow lead wires, and between the blue and
yellow lead wires.
NOTE:
*FET is sensitive against static electricity.
** The resistance value will vary dependent upon the measurement
range of the tester.
↓OK
<CHECK SWITCH BLOCK.> NO Replace switch & FET
→block.
8
EY6405-X8 / EY6409-X8 / EY6432-X8

5 EXPLODED VIEW
9
EY6405-X8 / EY6409-X8 / EY6432-X8

6 REPLACEMENT PARTS LIST
6.1. EY6405 REPLACEMENT PARTS LIST
NOTE:
*B=only available as set
*C=available individually
Ref.No. Part No. Part Name & Description Remarks Per Unit
1WEY6405K3079 HOUSING AB SET for EUROPE 1
1WEY6405K3080 HOUSING AB SET for OCEANIA 1
2WEY6481L0177 CLICK SPRING 1
3WEYT103L6807 CHUCK FASTENING SCREW 1
4WEY6406K7918 KEYLESS CHUCK 1
5WEY6406Y3228 CLUTCH HANDLE 1
6WEY6406L0638 ADJUSTING SCREW 1
7WEY6406L0168 CLUTCH SPRING 1
8WEY6406L0578 CLUTCH PLATE 1
9WEY560B6967 STEEL BALL *B (12pcs/PK) 12
10 WEY6406L1078 DRIVING BLOCK 1
11 WEY6406Y3238 H/L CHANGE HANDLE 1
12 WEY6406L2568 HEAT SINK 1
13 WEY6406L0178 CLICK SPRING A 1
14 WEY6405Y3248 F/R SELECTOR HANDLE 1
15 WEY6283L0377 ROLLER PIN *B (6pcs/PK) 6
16 WEY6406L1118 CARRIER 1
17 WEY6406L1488 RING GEAR 1
18 WEY6406L1348 PLANET GEAR *B (3pcs/PK) 6
19 WEY6406L0858 THRUST PLATE 1
20 WEY6406L1128 CARRIER A 1
21 WEY6406L1468 RING GEAR A 1
22 WEY6406L1108 CARRIER B 1
23 WEY6406L1478 RING GEAR B 1
24 WEY6406L1358 PLANET GEAR B *B (3pcs/PK) 3
25 WEY6406L0888 THRUST PLATE 1
26 WEY6405L1008 DC MOTOR 1
27 WEY6230L6027 SCREW *C K3*6 3
28 WEY6406L0028 MOTOR MOUNTING PLATE 1
29 WEY6207Y6027 SCREW *C K3*5 2
30 WEY6405Y2008 SWITCH 1
31 WEY6230L0207 DUST PREVENTIVE PLATE 1
32 WEY6230K9218 TAPPING SCREW *C K3*20 8
33 WEY6406K9038 TORX TAPPING SCREW *C K3*12 4
34 WEY6406L1458 GEAR BOX BLOCK 1
-WEY9596K7018 TOOL CASE 1
-WEY6405K8109 OPERATING INSTRUCTIONS 1
**Battery Pack is available as an optional accessory. See the nearest sales dealer for details.
***For replacement parts of charger, see the charger service manual.
Charger complete set is available as an optional accessory. See the nearest sales dealer for details.
10
EY6405-X8 / EY6409-X8 / EY6432-X8

6.2. EY6409 REPLACEMENT PARTS LIST
NOTE:
*B=only available as set
*C=available individually
Ref.No. Part No. Part Name & Description Remarks Per Unit
1WEY6409K3079 HOUSING AB SET for EUROPE 1
1WEY6409K3080 HOUSING AB SET for OCEANIA 1
2WEY6481L0177 CLICK SPRING 1
3WEYT103L6807 CHUCK FASTENING SCREW 1
4WEY6407K7918 KEYLESS CHUCK 1
5WEY6406Y3228 CLUTCH HANDLE 1
6WEY6406L0638 ADJUSTING SCREW 1
7WEY6406L0168 CLUTCH SPRING 1
8WEY6406L0578 CLUTCH PLATE 1
9WEY560B6967 STEEL BALL *B (12pcs/PK) 12
10 WEY6406L1078 DRIVING BLOCK 1
11 WEY6406Y3238 H/L CHANGE HANDLE 1
12 WEY6406L2568 HEAT SINK 1
13 WEY6406L0178 CLICK SPRING A 1
14 WEY6405Y3248 F/R SELECTOR HANDLE 1
15 WEY6283L0377 ROLLER PIN *B (6pcs/PK) 6
16 WEY6406L1118 CARRIER 1
17 WEY6406L1488 RING GEAR 1
18 WEY6406L1348 PLANET GEAR *B (3pcs/PK) 6
19 WEY6406L0858 THRUST PLATE 1
20 WEY6406L1128 CARRIER A 1
21 WEY6406L1468 RING GEAR A 1
22 WEY6406L1108 CARRIER B 1
23 WEY6406L1478 RING GEAR B 1
24 WEY6406L1358 PLANET GEAR B *B (3pcs/PK) 3
25 WEY6406L0888 THRUST PLATE 1
26 WEY6405L1008 DC MOTOR 1
27 WEY6230L6027 SCREW *C K3*6 3
28 WEY6406L0028 MOTOR MOUNTING PLATE 1
29 WEY6207Y6027 SCREW *C K3*5 2
30 WEY6405Y2008 SWITCH 1
31 WEY6230L0207 DUST PREVENTIVE PLATE 1
32 WEY6230K9218 TAPPING SCREW *C K3*20 8
33 WEY6406K9038 TORX TAPPING SCREW *C K3*12 4
34 WEY6406L1458 GEAR BOX BLOCK 1
-WEY9596K7018 TOOL CASE 1
-WEY6405K8109 OPERATING INSTRUCTIONS 1
**Battery Pack is available as an optional accessory. See the nearest sales dealer for details.
***For replacement parts of charger, see the charger service manual.
Charger complete set is available as an optional accessory. See the nearest sales dealer for details.
11
EY6405-X8 / EY6409-X8 / EY6432-X8

6.3. EY6432 REPLACEMENT PARTS LIST
NOTE:
*B=only available as set
*C=available individually
Ref.No. Part No. Part Name & Description Remarks Per Unit
1WEY6432K3079 HOUSING AB SET for EUROPE 1
1WEY6432K3080 HOUSING AB SET for OCEANIA 1
2WEY6481L0177 CLICK SPRING 1
3WEYT103L6807 CHUCK FASTENING SCREW 1
4WEY6407K7918 KEYLESS CHUCK 1
5WEY6406Y3228 CLUTCH HANDLE 1
6WEY6406L0638 ADJUSTING SCREW 1
7WEY6431L0168 CLUTCH SPRING 1
8WEY6406L0578 CLUTCH PLATE 1
9WEY560B6967 STEEL BALL *B (12pcs/PK) 12
10 WEY6431L1078 DRIVING BLOCK 1
11 WEY6406Y3238 H/L CHANGE HANDLE 1
12 WEY6406L2568 HEAT SINK 1
13 WEY6406L0178 CLICK SPRING A 1
14 WEY6405Y3248 F/R SELECTOR HANDLE 1
15 WEY6283L0377 ROLLER PIN *B (6pcs/PK) 6
16 WEY6406L1118 CARRIER 1
17 WEY6406L1488 RING GEAR 1
18 WEY6406L1348 PLANET GEAR *B (3pcs/PK) 6
19 WEY6406L0858 THRUST PLATE 1
20 WEY6406L1128 CARRIER A 1
21 WEY6406L1468 RING GEAR A 1
22 WEY6406L1108 CARRIER B 1
23 WEY6406L1478 RING GEAR B 1
24 WEY6406L1358 PLANET GEAR B *B (3pcs/PK) 3
25 WEY6406L0888 THRUST PLATE 1
26 WEY6432L1008 DC MOTOR 1
27 WEY6230L6027 SCREW *C K3*6 3
28 WEY6406L0028 MOTOR MOUNTING PLATE 1
29 WEY6207Y6027 SCREW *C K3*5 2
30 WEY6432Y2008 SWITCH 1
31 WEY6230L0207 DUST PREVENTIVE PLATE 1
32 WEY6230K9218 TAPPING SCREW *C K3*20 8
33 WEY6406K9038 TORX TAPPING SCREW *C K3*12 4
34 WEY6431L1458 GEAR BOX BLOCK 1
-WEY9596K7018 TOOL CASE 1
-WEY6405K8109 OPERATING INSTRUCTIONS 1
**Battery Pack is available as an optional accessory. See the nearest sales dealer for details.
***For replacement parts of charger, see the charger service manual.
Charger complete set is available as an optional accessory. See the nearest sales dealer for details.
12
EY6405-X8 / EY6409-X8 / EY6432-X8