Panasonic EY6535 - CORDLESS User manual

IMPORTANT
This manual contains safety information. Read manual completely before first using
this product and save this manual for future use.
SAVE THESE INSTRUCTIONS
MULTI Drill & Driver
Operating Instructions
Model No. : EY6535
EY6535.book

—2 —
GENERAL SAFETY RULES-
FOR ALL BATTERY
OPERATED TOOLS
SAVE THESE INSTRUCTIONS
Work Area
1) Keep your work area clean and well
lit.
Cluttered benches and dark areas invite
accidents.
2) Do not operate power tools in explo-
sive atmospheres, such as in the
presence of flammable liquids,
gases, or dust.
Power tools create sparks which may
ignite the dust or fumes.
3) Keep bystanders, children, and visi-
tors away while operating a power
tool.
Distractions can cause you to lose con-
trol. Make sure that no one is beneath,
or on the other side of the area when
you are working.
Electrical Safety
4) A battery operated tool with integral
batteries or a separate battery pack
must be recharged only with the
specified charger for the battery.
A charger that may be suitable for one
type of battery may create a risk of fire
when used with another battery.
5) Use battery operated tool only with
specifically designated battery pack.
Use of any other batteries may create a
risk of fire.
Personal Safety
6) Stay alert, watch what you are doing,
and use common sense when operat-
ing a power tool. Do not use tool
while tired or under the influence of
drugs, alcohol, or medication.
A moment of inattention while operating
power tools may result in serious per-
sonal injury.
7) Dress properly. Do not wear loose
clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves
away from moving parts.
Loose clothes, jewelry, or long hair can
be caught in moving parts.
8) Avoid accidental starting. Be sure
switch is in the locked or off position
before inserting battery pack.
Carrying tools with your finger on the
switch or inserting the battery pack into
a tool with the switch on invites acci-
dents.
9) Remove adjusting keys or wrenches
before turning the tool on.
A wrench or a key that is left attached to
a rotating part of the tool may result in
personal injury.
10) Do not overreach. Keep proper foot-
ing and balance at all times.
Proper footing and balance enable bet-
ter control of the tool in unexpected situ-
ations.
11) Use safety equipment. Always wear
eye protection.
Dust mask, non-skid safety shoes, hard
hat, or hearing protection must be used
for appropriate conditions.
Tool use and care
12) Use clamps or other practical way to
secure and support the workpiece to
a stable platform.
Holding the work by hand or against
your body is unstable and may lead to
loss of control.
13) Do not force tool. Use the correct tool
for your application.
The correct tool will do the job better
and safer at the rate for which it is
designed.
14) Do not use tool if switch does not
turn it on or off.
WARNING!
Read and understand all instructions.
• Failure to follow all instructions listed
below, may result in electric shock, fire
and/or serious personal injury.
EY6535.book 2

—3 —
A tool that cannot be controlled with the
switch is dangerous and must be
repaired.
15) Disconnect battery pack from tool or
place the switch in the locked or off
position before making any adjust-
ments, changing accessories, or
storing the tool.
Such preventive safety measures
reduce the risk of starting the tool acci-
dentally.
16) Store idle tools out of reach of chil-
dren and other untrained persons.
Tools are dangerous in the hands of
untrained users.
17) When battery pack is not in use, keep
it away from other metal objects like:
paper clips, coins, keys, nails,
screws, or other small metal objects
that can make a connection from one
terminal to another.
Shorting the battery terminals together
may cause sparks, burns or a fire.
18) Maintain tools with care. Keep cutting
tools sharp and clean.
Properly maintained tools with sharp
cutting edge are less likely to bind and
are easier to control.
19) Check for misalignment or binding of
moving parts, breakage of parts, and
any other condition that may affect
the tool’s operations. If damaged,
have the tool serviced before using.
Many accidents are caused by poorly
maintained tools.
20) Use only accessories that are recom-
mended by the manufacturer for your
model.
Accessories that may be suitable for
one tool may create a risk of injury when
used on another tool.
Service
21) Tool service must be performed only
by qualified repair personnel.
Service or maintenance performed by
unqualified personnel may result in a
risk of injury.
22) When servicing a tool, use only iden-
tical replacement parts. Follow
instructions in the Maintenance sec-
tion of this manual.
Use of unauthorized parts or failure to
follow Maintenance Instructions may
create a risk of shock or injury.
SPECIFIC SAFETY RULES
1) Hold tool by insulated gripping sur-
faces when performing an operation
where the cutting tool may contact
hidden wiring.
Contact with a “live” wire will make
exposed metal parts of the tool “live”
and shock the operator.
Symbol Meaning
VVolts
Direct Current
n0no load speed
.../min revolutions or
reciprocation per minutes
Rotation only
WARNING!
Some dust created by power sanding,
sawing, grinding, drilling, and other con-
struction activities contains chemicals
known to the State of California to cause
cancer, birth defects or other reproduc-
tive harm. Some examples of these
chemicals are:
• Lead from lead-based paints
• Crystalline silica from bricks and
cement and other masonry products
• Arsenic and chromium from chemically-
treated lumber.
To reduce your exposure to these chemi-
cals:
work in a well ventilated area, and work
with approved safety equipment, such as
dust masks that are specially designed
to filter our microscopic particles.
EY6535.book 3

—4 —
FOR BATTERY CHARGER
& BATTERY PACK
1) SAVE THESE IN-
STRUCTIONS -This
manual contains important safety and
operating instructions for battery
charger EY0230.
2) Before using battery charger, read all
instructions and cautionary markings on
(1) battery charger, (2) battery pack.
3) CAUTION -To reduce the risk of
injury, charge only Battery Pack as
shown below.
EY9103, EY9101, EY9001, EY9006,
EY9180, EY9080, EY9182, EY9086,
EY9065, EY9066, EY9106, EY9107,
EY9136, EY9230, EY9200, EY9108,
EY9168
Other types of batteries may burst caus-
ing personal injury and damage.
4) Do not expose charger to rain or snow.
5) To reduce risk of damaging the electric
plug and cord, pull by plug rather than
cord when disconnecting charger.
6) Make sure cord is located so that it will
not be stepped on, tripped over, or oth-
erwise subjected to damage or stress.
7) An extension cord should not be used
unless absolutely necessary.
Use of improper extension cord could
result in a risk of fire and electric shock.
If extension cord must be used, make
sure:
a. that pins on plug of extension cord
are the same number, size and
shape as those of plug on charger.
b. that extension cord is properly wired
and in good electrical condition.
c. that wire size is large enough for
ampere rating of charger as specified
below.
8) Do not operate charger with damaged
cord or plug—replace them immediately.
9) Do not operate charger if it has received
a sharp blow, been dropped, or other-
wise damaged in any way; take it to a
qualified serviceman.
10)Do not disassemble charger; take it to a
qualified serviceman when service or
repair is required. Incorrect reassembly
may result in a risk of electric shock or
fire.
11) To reduce the risk of electric shock,
unplug charger from outlet before
attempting any maintenance or clean-
ing.
12) The charger and battery pack are spe-
cifically designed to work together. Do
not attempt to charge any other cordless
tool or battery pack with this charger.
13) Do not attempt to charge the battery
pack with any other charger.
14) Do not attempt to disassemble the bat-
tery pack housing.
15) Do not store the tool and battery pack in
locations where the temperature may
reach or exceed 122°F (50°C) (such as
in a metal tool shed, or a car in the sum-
mer), which can lead to deterioration of
the storage battery.
16)Do not charge battery pack when the
temperature is BELOW 32°F (0°C) or
ABOVE 104°F (40°C). This is very
important in order to maintain optimal
condition of the battery pack.
17) Do not incinerate the battery pack. It can
explode in a fire.
18)Avoid dangerous environment. Do not
use charger in damp or wet locations.
RECOMMENDED MINIMUM AWG SIZE OF
EXTENSION CORDS FOR
BATTERY CHARGERS
AC Input Rating. Amperes AWG Size of Cord
Equal to or
greater than
But less
than
Length of Cord, Feet
25 50 100 150
0 2 18 18 18 16
EY6535.book 4

—5 —
19)The charger is designed to operate on
standard household electrical power
only. Do not attempt to use it on any
other voltage!
20)Do not abuse cord. Never carry charger
by cord or yank it to disconnect from
outlet. Keep cord away from heat, oil
and sharp edges.
21)Charge the battery pack in a well venti-
lated place, do not cover the charger
and battery pack with a cloth, etc., while
charging.
22) Use of an attachment not recommended
may result in a risk of fire, electric shock,
or injury to persons.
23) Do not short the battery pack. A battery
short can cause a large current flow,
over heating and create the risk of fire or
personal injury.
24) NOTE: If the supply cord of this appli-
ance is damaged, it must only be
replaced by a repair shop authorized by
the manufacturer, because special pur-
pose tools are required.
25) TO REDUCE THE RISK OF ELECTRIC
SHOCK, THIS APPLIANCE HAS A
POLARIZED PLUG (ONE BLADE IS
WIDER THAN THE OTHER).
This plug will fit in a polarized outlet only
one way. If the plug does not fit fully in
the outlet, reverse the plug. If it still does
not fit, contact a qualified electrician to
install the proper outlet. Do not change
the plug in any way.
EY6535.book 5

—6 —
FUNCTIONAL DESCRIPTION
(A)
Square drive (Ball detent)
(
B
)
Clutch handle
(C)
Reversing lever / Switch lock
( D)
Variable speed control trigger
( E )
Mode Selector switch (Drill driver with
clutch function / Impact)
( F )
Bit holder
(
G
)
Battery pack (EY9230)
(
H
)
Battery pack release button
( I )
Battery charger (EY0230)
( J )
Keyless drill chuck
(
K
)
Quick change chuck
(A)
(G)
(H)
(F)
(E)
(B)
(D)
(C)
(I)
(J)
(K)
EY6535.book 6

—7 —
ASSEMBLY
Selecting Mode
Select appropriate mode (Drill driver mode or
Impact mode) sliding the Mode selector switch.
Note: When selecting the mode, disconnect bat-
tery pack from tool or place Reversing lever in the
center position.(switch lock)
Do not operate Mode selector switch until the
rotation of the spindle comes to a complete
stop.
Select Mode Applications & work material Original Options Accessories in the market
Drill Driver Drilling
Wood
Metal
13mm(1/2") keyless
EY9X003E
Wood/metal
Hole saw
Driving
Wood screw
Metal screw
(+)(-) head
Torx head
Impact Wood screw
Metal screw
Tech screw
Plastic anchor
Quick change chuck for
6.35mm (1/4")
Hexagonal shank bits
(Quick release type)
EY9HX110E
(+)(-) head
Torx head
Fastening
Coach screw (Lag bolt)
Bolt nut
Concrete anchor
Hexagonal socket
Drill driver mode
with clutch function
Impact mode
Attaching or Detaching Original Options and Accessories
Keep the body above freezing point (0°C 32°F) when attach or detach original options and accessories
to the square drive on the body. The cushion rubber in the square drive to push up the ball may get
hard under freezing point. This requires extra force in detaching and attaching accessories.
EY6535.book 7

—8 —
Using Keyless drill chuck
(EY9X003E)
CAUTION: • Use keyless drill chuck ONLY in
Drill Driver Mode of EY6535.
This chuck is not designed to be
used in IMPACT MODE.
It can be damaged and its life will
be reduced. Moreover, the chuck
and its metal parts, such as the
push button, front parts, and bit
may become very hot. To prevent
skin burns, use work gloves and/or
allow heated parts to cool down
before handling.
•Make sure the work environment is
safe. When retracting drill from
work material, Keyless drill chuck
may detach if subjected to 100kg
or more of pull force. Detachment
will be sudden. Use care and avoid
excessive force when retracting
drill from work material.
1. Attaching Keyless drill chuck
Attach the chuck by sliding the female detent
on the bottom of the chuck to the square drive
on the body.
Make sure the chuck is firmly connected to the body
2. Inserting the bit
Insert the bit, and turn the lock collar clock-
wise(looking from the front) holding the sleeve
until jaws close firmly.
3. Removing the bit
Turn the lock collar counterclockwise (looking
from the front).
Then remove the bit.
CAUTION: If the drill bit becomes too tight to
remove, hold two lock collars with
pipe wrenches and turn them in
opposite directions.
4. Detaching Keyless drill chuck
To detach the chuck, PUSH the button to
release the chuck from the square drive.
CAUTION: Drill bit blade is sharp. Make sure to
remove the drill bit before you set
and detach the keyless drill chuck.
1
2
2
1
PUSH
EY6535.book 8

—9 —
Using Quick change chuck
(EY9HX110)
This Quick change chuck is
designed to be used with Pana-
sonic EY6535.
Top collar : To insert or to
remove bit.
Bottom collar: To attach or to
detach Quick
change chuck.
Use 6.35mm (1/4") hexagonal bits.
To ensure proper securement of the bit, use only
hexagonal bits with 9.25mm (3/8") detent.
CAUTION: Make sure the work environment is
safe. When retracting bit from work
material, Quick change chuck may
detach if subjected to 50kg or more
of pull force. Detachment will be sud-
den. Use care and avoid excessive
force when retracting bit from work
material.
1. Attaching Quick change chuck
Attach the Quick change chuck by pulling the
bottom collar forward and sliding the female
detent on the bottom of the chuck to the
square drive on the body.
Release the bottom collar to make sure the
Quick change chuck is firmly connected to the
body.
2. Inserting the bit
Pull the top collar of the Quick change chuck
forward, then insert the bit.
Release the bottom collar to make sure the bit
is firmly connected to the chuck.
3. Removing the bit
Pull the top collar of the Quick change chuck
forward, then pull the bit.
CAUTION: lmpact mechanism creates heat.
Square drive and accessory may
become very hot and may cause skin
burns. To prevent skin burns, use
work gloves and/or allow heated
parts to cool down before handling.
4. Detaching Quick change chuck
Pull the bottom collar of the Quick change
chuck forward to detach it.
Attaching or removing battery
pack
1. To connect the battery pack:
Insert the battery pack. It snaps into place to
indicate proper connection.
2. To remove the battery pack:
Press the two buttons on the sides of the bat-
tery pack. Slide the battery pack out of the tool
body.
OPERATION
Switch Operation
1. The speed increases with the amount of
depression of the trigger. When beginning
work, depress the trigger slightly to start the
rotation slowly.
2. A feedback electronic controller is used to
give a strong torque even in low speed.
3. The brake operates when the trigger is
released and the motor stops immediately.
Reversing Lever Operation
(Forward ( ), Switch lock, Reverse ( ))
CAUTION: Do not operate reversing lever until
rotation of the spindle comes to a
complete stop. Shifting during rota-
tion of the chuck may damage the
tool.
1. For reverse rotation, set the lever to reverse.
Check the direction of rotation before use.
Top collar
Bottom collar
6.35mm (1/4") 9.25mm (3/8")
1
2
Top Collar
1
2
EY6535.book 9

—10 —
2. After use, set the lever to its center position
(switch lock).
Clutch Torque Setting
Adjust the torque to one of the 18 possible set-
tings or " " position required to do the job.
CAUTION: Test the setting before actual opera-
tion. Set the scale at this mark ( ).
CAUTION: To eliminate excessive temperature
increase of the tool surface, do not
operate the tool continuously, that is
consecutively replacing the battery
packs.
•Do not close up vent holes on the
sides of the body during operation.
Otherwise, the machine function is
adversely affected to cause a fail-
ure
•Impact mechanism creates heat.
Square drive and accessory
become very hot. They may cause
burns.
•Do not strain the tool(motor).
This may cause damage to the
unit.
•Keep body or skin away from
exhaust vent to avoid risk of being
burned by hot air.
•When operating with a Ni-MH bat-
tery pack, make sure the work
place is well-ventilated.
For Appropriate use of Battery pack
Ni-MH Battery pack EY9230
• Charge the Ni-MH battery fully before storage
in order to ensure a longer service life.
• The ambient temperature range is between
0°C (32°F) and 40°C (104°F).
If the battery pack is used when the battery
temperature is below 0°C (32°F), the tool may
fail to function properly. In that case, charge
the battery until charging is completed for
appropriate functioning of the battery.
Battery Pack Life
The rechargeable batteries have a limited life. If
operation time becomes extremely short after
recharging, replace the battery pack with a new
one.
Note: Use under extremely hot or cold conditions
will reduce operating capacity per charge.
Charging
Note: When you charge the battery pack for the
first time, or after prolonged storage,
charge it for about 24 hours to bring the
batteries up to full capacity.
Battery charger (EY0230)
1. Plug the charger into the AC outlet.
2. Insert the battery pack firmly into the charger.
3. During charging, the charging lamp will be lit.
When charging is completed, an internal elec-
tronic switch will automatically be triggered to
prevent overcharging.
• Charging will not start if the battery pack is
warm (for example, immediately after
heavy-duty operation).
The orange standby lamp will be lit until the
battery cools down. Charging will then
begin automatically.
4. When charging is completed, the charging
lamp will start flashing rapidly.
1
2
Battery pack
Battery charger
To AC outlet
EY6535.book 10

—11 —
5. If the battery pack is too cold, or if the battery
pack has not been used for a long time, the
charging lamp starts flashing slowly to indi-
cate protective charging. Protective charging
takes longer to fully charge the battery pack,
than the standard charging time. (Max. charg-
ing time is approx. 90 minutes).
• If a fully charged battery pack is inserted
into the charger again, the charging lamp
may light up and then flash slowly. After
several minutes, the charging lamp may
flash quickly to indicate the charging is
completed.
6. If the charging lamp does not light immedi-
ately after the charger is plugged in, or if after
the standard charging time the lamp does not
go off, consult an authorized servicer.
Note: • Before charging a cold battery pack
(below 5°C (41°F)) in a warm place,
leave the battery pack at the place and
wait for more than one hour to warm up
the battery to the level of the ambient
temperature. (Battery pack may not be
fully charged.)
•Cool down the charger when charging
more than two battery packs consecu-
tively.
•Do not insert your fingers or any metallic
objects into charger contact opening.
CAUTION: • Do not use power source from an
engine generator.
•Do not cover vent holes on the
charger and the battery pack.
LAMP INDICATIONS OF THE EY0230
MAINTENANCE
Use only dry, soft cloth for wiping the unit. Do not use a damp cloth, thinner, benzine, or other volatile
solvents for cleaning.
BATTERY RECYCLING
ATTENTION:
A nickel metal hydride battery that is recyclable powers the product you have purchased.
Please call 1-800-8-BATTERY for information on how to recycle this battery.
Flashing
Lit
Flashing quickly
Flashing slowly
Lit
Flashing
Charger is plugged into a wall outlet.
Ready to charge.
Now charging
Charging is completed
Protective charging
Battery pack is warm. Charging will begin
when temperature of battery pack drops.
Charging is not possible. Clogged with
dust or malfunction of the battery pack.
EY6535.book 11

—12 —
TIGHTENING TORQUE
• The power required for tightening a bolt will vary, according to bolt material and size, as well as the
material being bolted. Choose the length of tightening time accordingly.
Reference values are provided below.
(They may vary according to tightening conditions.)
FACTORS AFFECTING TIGHTENING TORQUE
The tightening torque is affected by a wide variety of factors including the followings. After tightening,
always check the torque with a torque wrench.
1) Voltage
When the battery pack becomes nearly discharged, the voltage decreases and the tightening
torque drops.
Bolt Tightening Conditions
M6, M8, M10, M12, M14 x 25 mm (1") Standard bolt
(Bolt size : Millimeters)
1300
(1100)
kgf-cm
(in-lbs)
M14
400
(350)
600
(500)
800
(700)
1000
(850)
0.1 0.25 0.5
Tightening time (Sec.)
123
1200
(1000)
Tightening torque
200
(170)
M8
M6
M10
M12
Washer
Washer
Spring washer
Steel plate
thickness 10 mm (3/8")
Bolt
Nut
Tightening conditions
*The following bolts are used.
Standard bolt: Strength type 4.8
High tensile type 12.9
Explanation of the strength type
4.8
Bolt tensile strength 60 kgf/mm2
(85,000psi)
Bolt yield point
(80% of tensile strength)
48 kgf/mm2(68,000psi)
EY6535.book 12

—13 —
2) Tightening time
Longer tightening time results in increased
tightening torque. Excessive tightening, how-
ever, adds no value and reduces the life of
the tool.
3) Different bolt diameters
The size of the bolt diameter affects the tight-
ening torque.
Generally, as the bolt diameter increases,
tightening torque rises
4) Tightening conditions
• Tightening torque will vary, even with the
same bolt, according to grade, length, and
torque coefficient (the fixed coefficient indi-
cated by the manufacturer upon produc-
tion).
• Tightening torque will vary , even with the
same bolting material (e.g. steel), accord-
ing to the surface finish.
• Torque is greatly reduced when the bolt
and nut start turning together.
5) Socket play
• Torque is lowered as the six-sided configu-
ration of the socket of the wrong size is
used to tighten a bolt.
6) Switch (Variable speed control trigger)
Torque is lowered if the unit is used with the
switch not fully pulled out.
7) Effect of Connecting Adaptor
The tightening torque will be lowered through
the use of a universal joint or a connecting
adaptor.
EY6535.book 13

—14 —
ACCESSORIES
Use only bits suitable for size of drill’s chuck.
Use Panasonicoriginal Optional Keyless drill chuck (EY9X003E) and Quick change chuck (EY9HX110E)
for maximum performance.
SPECIFICATIONS
MAIN UNIT
KEYLESS DRILL CHUCK
BATTERY PACK
BATTERY CHARGER
Note: This chart may include models that are not available in your area.
Please refer to the catalogue.
CAUTION: This Panasonic Multi Drill & Driver is designed to use only battery pack type EY9230,
EY9136. Use with other battery pack type may damage the tool and the battery, and may
result in the risk of fire and personal injury.
Model EY6535
Drill driver Mode Impact mode
(Caution: Do not use Keyless drill chuck for impact mode)
Maximun
recommen
ded
capacities
Drilling Wood drilling ø 27 mm (1 - 1/16") Not feasible
Metal drilling ø 13 mm (1/2")
Screw
driving
Machine screw M5 Not feasible
Wood screw ø 6.8 mm (17/64")
Tech screw ø
6 mm (15/64")
Coach screw (Lag bolt) ø10 mm (3/8")
Bolt Fastening Not feasible Standard Bolt: M12
High Tensile Bolt: M10
No load speed 0 - 650 /min (rpm) 0 - 2200 /min (rpm)
Clutch Torque
Approx.
1.0 Nm (10 kgf-cm, 8.7 in-lbs.) -
5.4 Nm (55 kgf-cm, 47.7 in-lbs.)
-
Impact per minute - 0 - 3300 /min (ipm)
Motor DC Motor 15.6V
Square drive 12.7 mm (1/2") square drive with ball detent
Weight (with battery pack) 2.2 kg ( 4.8 lbs.)
Overall length 216 mm ( 8 - 1/2")
Model EY9X003E
Chuck Capacity 1.6 mm - 13 mm (1/16" - 1/2")
Model EY9230
Storage battery Ni-MH Battery
Battery voltage 15.6V DC (1.2V x 13 cells)
Model EY0230
Electrical Rating See the name plate on the bottom of the charger.
Weight 0.78 kg (1.72 lbs)
Charging time
15.6 V 12 V 9.6 V 7.2 V Standard charging time
-
EY9001
EY9006
EY9080
EY9086
EY9065
EY9066 Approx. 20 min.
-
EY9101
EY9103
EY9180
EY9182
- Approx. 25 min.
EY9136
EY9106
EY9107
EY9108
- EY9168 Approx. 30 min.
EY9230 EY9200
-- Approx. 45 min.
EY6535.book 14

—15 —
— MEMO —
EY6535.book

PANASONIC CONSUMER ELECTRONICS COMPANY
One Panasonic Way, Secaucus, New Jersey 07094
Printed in Japan
EY981065351 H1306
30-DAY QUALITY
SATISFACTION GUARANTEE:
If you are dissatisfied with any Panasonic
Cordless Power Tool for any reason, sim-
ply return it to the place of purchase with
a dated proof of purchase, in the original
packaging, with all accessories, parts
and instructions, within 30 days of the
date of purchase, for a full refund, or call
Panasonic at 201-392-6655. Abuse or
misapplication of any power tool voids the
guarantee.
EY6535.book 16