Panasonic EY6780 User manual

ORDER NO. MEW/PTD 9411-6780
Service Manual
Cordless Off-set Drill &Driver
EY 6780
SPECIF! CAT IONS
DRILL/DRIVER
Motor voltage
No load speed
Maximum torque
Maximum clutch torque
Overall length
Mass (Weight)
(with battery pack)
9.6V DC
120— 800 min"1(RPM)
5.9Nm (60kg-cm, 52in.lbs.)
4.4Nm (45kg-cm, 391n.lbs.)
at 21 positions
213mm (8-22/32°)
1.5kg (3.31bs.)
BATTERY PACK EY9086 (Compact Type)
Storage battery
Battery voltage
Battery Capacity
BATTERY PACK EY9182
Storage battery
Battery voltage
Battery Capacity
BATTERY CHARGER
Input
Mass (Weight)
Charging time
N1-Cd battery
9.6V DC (1.2V X8cells)
1200mAh
Ni-Cd battery
9.6V DC (1.2V x8cells)
1600mAh
120, 230, 240V AC separately available
0.66kg (1.451bs.)
Approx. 15 min. (with compact type battery pack)
Approx. 20 min. (with high capacity type battery pack)
STANDARD EQUIPMENT
Battery charger ,Battery pack ,Phillips bit #2 (75mm)
CONTENTS
Specifications ••
Disassembly &Assembly Instructions
Wiring Connection Diagram/Schmatic Diagram
Page Page
1Troubleshooting 7-8
2-5•Exploded View 9
6Replacement Parts List 10
Panasonic C1994 Matsushita Electric Works, Ltd.
All rights reserved. Unauthorized copying and
distribution is aviolation of law.

Model EY6780
AWARNIhG
This service literature Is designed for experienced repair technicians only and Is not designed for
use by the general public. It does not contain warnings or cautions to advise non-technical Indi-
viduals of potential dangers in attempting to service aproduct. Products powered by electricity
should be serviced or repaired only by experienced professional technicians. Any atteapt to service
or repair the product or products dealt with In this service Inforaatlon by anyone else could result
in serious injury or death.
DISASSEMBLY /ASSEMBLY INSTRUCTIONS
Ref. No. 1Procedure 1A Removal of the housings.
1. Remove 8housing screws.
Hint :Remove the 2lead wires from the switch may
help to do efficient work.
Ref. No. 2Procedure 1A -• 2Removal or attachment of the motor.
Gear case block
Motor
Radiating
plate
Motor Gear case block
9Bit holder If
Revolving mechanism
Clutch handle
Switch Black
L11 si
Bit holder
-1r-j,u=f^
^P1"\Revolving
*1t*Clutch handle mechanism
(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 1n the
direction of the arrow.
(Attachment for the motor.
)
3. Adjust the tabs of gear box block to the
groove of motor 1n the counter-direction of
the arrow.
-2-

Model EY6780
Ref. No. 3A Procedure 1A ~* 2-* 3A Removal of the revolving mechanism.
Bit holder
!
|
1. Remove the C-type ring at the top of the *Otype ring are lively and could be lost,
bit holder with snap ring pliers. handle accordingly.
*Be careful not to lose 2pieces of steel
balls(#2) and 2holder collars.
Ref. No. 4A Procedure 1A 2—3A —4A Removal of the gear case block.
Output shaft block
0-ring
Lock pin B
Lock lever
Gear case B
Lock pin A
Lock lever
1. Remove 4screws for gear case A.
2. Disassemble the lock pin AB and the lock
lever.
*Be careful not to lose 2springs attached to
the gear case A.
3. Take out the output shaft block from the
gear case B.
*Make sure to attach the 0-ring with output
shaft.
4. Make sure when assembling, the lock pin AB
have their own directions.
-3-

Model EY6780
Ref. No. 3B Procedure 1A —> 2—> 3B Removal of the driving block.
Gear case block
Clutch handle
1. When removing the 2thrust pins, the driving
shaft, the ring gear and the planet gear etc.
remove one after another.
*Be careful not to lose the 12 pieces of steel
balls ($5).
(Removal of the bushing.
)
2. Remove the C-type spring from the bushing.
3. Set and knock the J1g to remove the bushing
out rem the clutch case.
(Attachment for the bushing.
)
4. Set the bushing to the clutch case from the
side of gear case B. Knock the J1g until
the bushing 1s Inserted completely.
5. Set the C-type spring to the bushing.
*Be careful not to break or deform the gear
case rib when knocking the bushing.
-4-

Model EY6780
Ref. No. 6Procedure 1A —2-*3-*4-»5 Attachment for the adjusting screw and
the clutch handle.
Clutch
Acting screwcl1ck ^
OO mark
Clutch handleOmark
1. Al 1gn the Omark of adjusting screw with
'A' part of the clutch case.
2. Turn the adjusting screw Into driving block
about one rotation for clockwise direction.
3. Al 1gn the OO mark of actjusting screw with
'A' part of the clutch case.
4. Adjust the tabs of click plate to the
projection of adjusting screw.
5. Set the clutch handle with position 7toward
Apart of the clutch case.
6. Insert the clutch handle with adjusting the
tabs of adjusting screw and of click plate to
the groove of inside clutch handle.
Ref. No. 7Procedure IB Removal or attachment of the battery charger.
(Removal of the battery charger.
)
1. Remove 4housing screws.
(Attachment for the battery charger.
)
2. Reassemble the module block (power cord,
power transformer, and module) to housing A,
be certain that LED appears through the hole
1n housing A.
3. Set the bushing for power cord to the
housing A.
NOTE :Avoid pinching lead wires, dress Into
housing recess and around screw posts
etc.
4. After assembly, test for proper voltage.
Measure the battery terminals between (S) and
£-).
It is OK, if 1t 1s approx. 3V DC.
-5-

Model EY6780
WIRING CONNECTION, DIAGRAM
Main unit
Motor
Cushion
fet
Motor terminal (+)
Battery terminal (
Cushion
terminal (-)
Switch handle
Battery terminal {-)
SCHEMATIC DIAGRAM
EY6780EQK
EY6780CQK
r
Pomr
sourc*
L-
TT? 1.
ri n
m—'„te
(-)?—(
L..
i. .-
S.
3
Niurr Chtrgsr B*tmy P«e* Main Unit
Ponr
tourco
S+
B+
B-
S+
»1 [.
L.
FET
Biturr Chtroar tottery Pack lUin Unit
-6-

Model EY6780
TROUBLESHOOT ING GU IDE (Refer to WIRING CONNECTION DIAGRAM )
<TROUBLE ><CHECK ><REMEDY >
Does not
operate.
<CHECK BATTERY PAOO
If no less than 9.6V DC 1s available across
the (+) and (-) terminals, the battery pack
is OK.
Note: The battery pack 1s sold separately
as shown 1n 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 1s
less than 9.6V DC or the usable time
1s extremely short.
-the battery leaks. Check battery for
leaks and terminals for corrosion.
OK
<CHECK TERMINAL CONNECTIONS BETWEEN
MAIN UNIT AND BATTERY PAOO
Check for proper terminal contacts.
OK
<CHECK MOTOR. >
The motor normally operates with Its white
(M+) and black (M-) lead wires connected to
9.6V DC.
OK
<CHECK SWITCH BLOCK.
>
(See WIRING CONNECTION DIAGRAM. )
With touching (+) terminal of Volt-Ohm meter,
check continuity between following terminals.
*Inspection of the forward /reverse
selection switch,
(a) When the switch handle is depressed all
the way :
•There should be OQ between ®-(§),
and between ©-@;when the switch
lever 1s set to the forward side.
•There should be OQ between ©-®,
and between (f) -(f) ;when the switch
lever is set to the reverse side.
OK
NO
Replace battery pack.
NO
-Repair the contacts.
NO
Replace the motor.
NO
Contacts 1n the switch
block are defective.
Replace the switch.
(to be continued )
-7-

Does not speed-
control or does
not brake.
<CHECK SWITCH BLOCK.
>
FET block could be damaged.
NO
Replace the switch &FET
block.
EY0202
Does not charge. <CHECK POWER C0RD.>
Check continuity.
NO
Replace power cord.
OK
NOTE: Loose connection are possible.
Check for loose capacitor.
If so, resolder.
Check for loose choke (coil).
If so, resolder.
<CHECK MODULE.
>
Check the lamp Indication of the battery
charger.
NO
Replace module 1n the
charger.
Charging lamp —
Red
Flashing Charger is plugged into power
source. Ready to charge.
Lit Now charging.
Charging 1s completed.
L_ ..—•Flashing
quickly
ILit Battery pack 1s warm. Charging
Standby lamp —will begin when temperature of
Orange battery pack drops.
—•••• Flashing Charging is not possible.
Clogged with dust or malfunction
of the battery pack drops.
Possibly foreign matter 1n the charger's battery pack socket,
or amalfunction of the battery pack.
-8-

Model EY6780
EXPLODED VIEW
-9-

Model EY6780
REPLACEMENT PARTS LIST
Note :*A ••• available as an optional accessory
*B ••• only available as set
*C ... available Individually
Ref No. Parts No. Parts Name &Descriptions jPer set Remarks
ltTo roUlsoU /a MUU3 1INL3 HO 9C 1
<£ CYUR1 Ifl 1"77 nirj^ qpi? iKin
•3
JCVi*"7Ank"31 1"7
CIO rOUIsnJ 11fPCAD fACC D
L3C.HK I.HDC D
** LIO ruULUJO
r
DUjn lin la
C, tIOOUUDU4H fP—TYPF P
T
\- 1I~C rs 11xLj
/_
OCIO fOULOZZ fLI_U 1^.n '.HOC
—y
frvL*>oni nc*7*7
ETo /OULUb r
r
C\ 1ITPLI PI ATP
oEY67QQLU457 /•i Ift/ oi ATC
LL 1LJ\ rLH 1c
o
Tcvi7oni r»4 /~7 cio roULUlo
/
cdo iMr cnD niittm
4O
10 EY6ZQ3LQ63
/
An ii ict iMr cr DCli
1
1
EY6780H3237 CLUTCH HANDLE 7
12 EY6780L1487 CLUTCH CASE BLOLK. 7
13 EY6780L0507 LOCK PIN A
14 EY6780L05°7 LOCK PIN B
15 EY6780Y0368 1API/ 1CI l|~Q
LOCK LEVER *B
16 c\s /7ort Iv. e77 EYo7H0L4b37 OUlrUI bnAr 1oLULIs
47
17 r— \/ /-inni 0077
EY67BDLUV77 0—K1Nb
4O
18 f-w /"inni fl 477
EY67QUL0177 caoiwr cad ir\cv \euro
SrKIiNb rUK LULIs LcvtK D
4Q
17 EY6 /BUK31 U/uLAK LnbC A
ZC CVi 7Qni/ /o7~>
EY6 /oUK6v //CTCCI DAI 1
31CCU BALL 1n0
O4
Zl f-v /inni na"7
EY67B0L0B37 uni nco roi iacq
HULUtK LULLAcK *B
zz EY67QQK371
7
aI1HULUtK
22 EY67B0L01t7 HOLDER SrRlNb
24 EY6780K0187 C-TYPc SPRING
25 EY574B°037 TAPPING SCREW WL
26 EY6481L0357 T1 ini lTnILI cPT
THRUST PIN SET •7
27 EY560B6t67 f-> TT f~ f-1DAI 1
STEEL BALL 1zD
28 EY6780L1 127 DRIVING SHAFT
2*7 EY560B1 457 RING GEAR A
7n
30 EY67BUL13b
/
QI AMC TrCAQ A
rLANc 1GEAR A*R
D
T4
31 EY6ZUUBUob rTUQI ICT Dt ATC
IHRUbl rLA 1
c
3Z rvi 7001 17 7 7
EY67BQL13
/
fTDAMCMICCIflM <ZC AO
IKAlNon Itso 1UIN bcAK
33 tYboUol3o rDl AMCT CPAD QCPT
rLANc 1bcAK BSC
1
D
"3/. cT6-sC3 1L1 *o rOIMC CPAP n
35 tT6401LUOO fTUDI ICT PI ATP
1MKUo 1rLA 1
C
7/.
36 EY6 raULlUuo no iuk
7*7
37 EYT lo4LUUZ rMftTrtD M(*\\ IMT 1PI ATP
nU IUK nUUNIiiNb rLH 1t
7Q
38 CVT 4O/1V("17 7
EYT184L6077 bCKEW PUK rlU 1UR
3t tY67BDLZt47 ICaniii nr rr-T
LEAD WIRE be 1
40 r— v/Torn /n77
EY678QL60Z7 TAODiKir crotrii
1Arr INb SLKeW
/ 4
41 CV T 4O/. 1/7 EYT 1B4LZ&6 /DARIATIMC OI ATCT /I.I /CP* PPI.I \
RAUlAllNb rLA 1CvW/bLKcW;
/. 7
4Z EY67BUYZuuo CI 1iTru QI C\CY
bw 11LH oLULN
*7
43 EY67SUL6U3
/
croci i
bLKcw L
44 EY64Q1L0ZU 7ni ICT DDCUCMT IUP PI ATP
UUb IrKfcvciNllve rLA lc
45 EY6481H3247 SELECTOR HANDLE
46 EY563B7217 TAPPING SCREW *c
47 EY502B7957 PHILLIPS BIT «2 *A
46 EY9086 BATTERY PACK
4? EY°182 BATTERY PACK *A
50 EY0202 BATTERY CHARGER *A
51 EY6780L78o7 JIG FOR BUSHING
EY9592 TOOL CASE *A
(jm) Printed in Japan.
-10 -