Panasonic EY6406 - CORDLES DRILL&DRIVER User manual

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
1
4
5
6
7
'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
Panasonic ©1999 Matsushita Electric Works, Ltd.
All rights reserved. tJnauthorized copying
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)
<EY6431>
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
ft
Insert to .
driving ^
bkx:k.
B
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.
<CHECK >
<CHECK BATTERY PACK.>
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.
OK
<CHECK SWITCH BLOCK.>
(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.
OK
NO <REMEDY >
Replace battery
pack.
OK
<CHECK TERMINAL CONNECTIONS BETWEEN
MAIN UNIT AND BATTERY PACK.>
Check for proper terminal contacts.
OK
NO Repair the
contacts.
NO Repair the motor.
NO Contacts in the
switch block are
defective.
Replace the
switch &FET
block.
<CHECK FET CIRCUIT 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,
OK
<CHECK SWITCH BLOCK >NO Replace the
switch &FET
bk>ck.
-6-

Model EY6406 •EY6407 *EY6431
SCHf'.MATIC DIAGRAM
r
Power
source
+o-
-o-
-o-
KO-
5+0-
Battery Charger
s+
—
o
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
1
1
EY6406Y3238 EY6406Y3238 H/L HANDLE 1
A1
Z
EY6406L2568 EY6406L2568 HEAT SINK 1
A1
J
EY6406L0178 EY6406L0178 CLICK SPRING A1
EY6402Y3247 EY6402Y3247 F/R SELECTOR HANDLE 1
1c;
13EY6283L0377 EY6283L0377 ROLLER PIN 6*B <^ 3.1 75*7.
2
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-

Model EY6431
REPLACEMENT PARTS LIST FOR EY6431
NOTE :*A •••available as an optional accessory
*B ** * only aval table as set
*C •• ' available individually
Ref .No. Part No. 1Part Name &Descriptions 1Per unit Remarks
1EY6431K3078 HOUSING AB SET 1
2EY6481L0177 CLICK SPRING 1
3EYT103L6807 CHUCK FASTENING SCREW 1
A4EY9796 KEYLESS CHUCK 1*Ai
ASEY6406Y3228 CLUTCH HANDLE 1
AEY6406L0638 ADJUSTING SCREW 1
A7EY6431L0168 CLUTCH SPRING 1
A8EY6406L0578 CLUTCH PUTE 1
gEY560B6967 STEEL BALL 12
A10 EY6431L1078 DRIVING BLOCK 1
A1
1
EY6406Y3238 H/L HANDLE 1
A12 EY6406L2568 HEAT SINK 1
A13 EY6406L0178 CLICK SPRING A1
A14 EY6402Y3247 F/R SELECTOR HANDLE 1
15 EY6283L0377 ROLLER PIN *BU3.175*7.2
A16 EY6406L1118 CARRIER 1
A17 EY6406L1488 RING GEAR 1
A18 EY6406L1348 PLANET GEAR *Bi(3PCS/PK)
A19 EY6406L0858 THRUST PUTE 1
A20 EY6406L1128 CARRIER A1
A21 EY6406L1468 RING GEAR A1
A22
^A EY6406L1108 CARRIER B1
A23 EY6406L1478 RING GEAR B1
A24 EY6406L1358 PLANET GEAR B3*Bi
A25 EY6406L0888 THRUST PLATE 1
A26 EY6431L1008 MOTOR 1
27 EY6230L6027 SCREW 3*CiK3-6
A28 EY6406L0028 MOTOR MOUNTING PUTE 1
29 EY6207Y6027 SCREW 2*C iK3-5
A30 EY6431Y2008 SWITCH BLOCK 1
31 EY6230L0207 DUST PREVENTIVE PUTE 1
A32 EY6230K9218 TAPPING SCREW 8*C [K3-20
A33 EY6406K9038 TORX TAPPING SCREW 4*CIK3-12
A34 EY6431L1458 GEAR BOX BLOCK 1
A35 EY9136 BAHERY PACK 1*Ai
A35 EY9230 BATTERY PACK 1*Ai
A36 EY0230 BAHERY CHARGER 1
EY9594 TOOL CASE 1[*Ai
AEY6406K8108 OPERATING INSTRUCTIONS 1ii
-11 -