Panasonic EY6780 User manual

ORDER NO. MEW/PTD 9411-6780
Service Manual
Cordless Off-set Drill & Driver
EY 6 7 8 0
SPEC I FI CAT 1ONS
DRILL/DRIVER
Motor voltage : 9.6V DC
No load speed : 120 ~ 800 min -1 (RPM)
Maximum torque : 5.9Nm (60kg-cm, 521n.lbs.)
Maximum clutch torque : 4.4Nm (45kg-cm, 391n.lbs.)
at 21 positions
Overall length : 213mm (8-22/32°)
Mass (Weight) : 1.5kg (3.31bs.)
(with battery pack)
BATTERY PACK EY9086 (Compact Type)
Storage battery : Nl-Cd battery
Battery voltage : 9.6V DC ( 1.2V x 8 cells)
Battery Capacity : 120OnAh
BATTERY PACK EY9182
Storage battery : Ni-Cd battery
Battery voltage : 9.6V DC ( 1.2V x 8 cells)
Battery Capacity : 1600mAh
BATTERY CHARGER
Input : 120, 230, 240V AC separately available
Mass (Weight) : 0.66kg (1.451bs.)
Charging time : 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 (75irm)
CONTENTS
Page Page
• Specifications . 1 - Troubleshooting .. 7-8
- Disassembly & Assembly Instructions. 2-5* Exploded View.. 9
• Wiring Connection Diagram/Schmatlc Diagram •••• 6 ■ Replacement Parts List .10
© 1994 Matsushita Electric Works, Ltd.
All rights reserved. Unauthorized copying and
distribution is a violation of law.
Panasonic

Model EY6780
A WARNING
This service literature Is designed for experienced repair technicians only and 1$ not designed for
use by the general public. It does not contain warnings or cautions to advise non-technlcal Indi¬
viduals of potential dangers In attempting to service a product. 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. 1 Procedure 1A
Removal of the housings.
1. R emove 8 housing screws.
Hint : Remove the 2 lead wires from the switch may
help to do efficient work.
Ref. No. 2 Procedure 1A
Removal or attachment of the motor.
Gear case block
Motor
Motor Gear case block
Radiating
plate
Bit holder
Bit holder
[IJ \ Revolving mechanism
Clutch handle
Switch
Black
Thrust pin \ R ;* olv1ng
i. >* \ mechanism
ite Clutch handle
(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 In the
direction of the arrow.
(Attachment for the motor.)
3. A djust the tabs of gear box block to the
groove of motor In the counter-direction of
the arrow.
- 2 -

Model EY6780
Removal of the revolving mechanism.
Bit holder
/ Bit holder spring
Gear case B / /
\ Gear /Steel ball/
Gear case block \ case A / (02) /Holder collars
/ \ ^1 ^ ffwm l f C * ” type ring
D F “ flu /Bit holder
0 f ° ==il Steel ball(02)
T V Bit holder bolck
\ Revolving mechanism
Clutch handle
1. R emove the C-type ring at the top of the
bit holder with snap ring pliers.
* C-type ring are lively and could be lost,
handle accordingly.
* Be careful not to lose 2 pieces of steel
balls{02) and 2 holder 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 4 screws for gear case A.
2. Disassemble the lock pin AB and the lock
lever.
* Be careful not to lose 2 springs attached to
the gear case A.
3. Take out the output shaft block from the
gear case B.
* Make sure to attach the O-ring with output
shaft.
4. Make sure when assembling, the lock pin AB
have their own directions.
- 3 -

Model EY6780
Ref. (to. 3B Procedure 1A - ♦ 2 -* 3B
Removal of the driving block.
Gear case block
Thrust pin /
Thrust pin
/ Gear case B
Clutch handle
Clutch case
/ C-type spring
/ jl -
Insert
Hammer
Bushing
Bushing j Qea r g
Clutch handle
1. When removing the 2 thrust 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 (05).
(Removal of the bushing.)
2. Remove the C-type spring from the bushing.
3. Set and knock the jig to remove the bushing
out rcm the clutch case.
(Attachment for the bushing.)
4. Set the bushing to the clutch case from the
side of gear case B. Knock the jig until
the bushing Is 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.

Model EY6780
Ref. No. 6 Procedure lA-*2-*3-*4-*-5 Attachment for the adjusting screw and
Clutch handle
1. Align the O n«rk of adjusting screw with 4. Adjust the tabs of click plate to the
'A' part of the clutch case. projection of adjusting screw.
2. Turn the adjusting screw Into driving block 5. Set the clutch handle with position 7 toward
about one rotation for clockwise direction. A part of the clutch case.
3. Align the OO mark of adjusting screw with 6. Insert the clutch handle with adjusting the
'A* part of the clutch case. tabs of adjusting screw and of click plate to
the groove of Inside clutch handle.
Ref. No. 7 Procedure IB Removal or attachment of the battery charger.
(Removal of the battery charger.) (Attachment for the battery charger.)
1. Remove 4 housing screws. 2. Reassemble the module block (power cord,
power transformer, and module) to housing A,
be certain that LED appears through the hole
In 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 It Is approx. 3V DC.

Model EY6780
WIRING CONNECTION, DIAGRAM
■ Main unit
Motor
SCHEMATIC DIAGRAM
EY6780EQK
EY6780CQK
Battery Charter Battery rack
Main Unit
Battery Charoar Battery Pack
Hein Unit
- 6 **

Model EY6780
TROUBLESHOOTING GUIDE ( Refer to WIRING CONNECTION DIAGRAM )
< TROUBLE > < CHECK > < REMEOY >
<CHECK BATTERY PACK.>
If no less than 9.6V DC Is available across
the (+) and (-) terminals, the battery pack
is OK.
Note: The battery pack Is sold separately
as shown In REPLACEMENT PARTS LIST. 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 9.6V DC or the usable time
is extremely short.
- the battery leaks. Check battery for
leaks and terminals for corrosion.
OK
CCHECK 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) Wien the switch handle Is depressed all
the way :
• There should be OQ between ® -
and between @ ® ; when the switch
lever Is set to the forward side.
• There should be OQ between ® -
and between (g) - ® ; when the switch
lever is set to the reverse side.
OK
( to be continued )
Contacts In the switch
block are defective.
Replace the switch.
Does not
operate.
- 7 -

Does not speed-
control or does
not brake.
■ EY0202
Does not charge.
- 8 -

Model EY6780
- 9 -

Model EY6780
REPLACEMENT PARTS LIST
Note :
*A ••• available as an optional accessory *C available Individually
*B ••• only available as set
Ref No.
Parts No.
Parts Name & Descriptions
Per set Remarks
1
EY670OK3O70
HOUSING AB SET
1
2
EY6401LQ177
CLICK SPRING
1
3
EY670OK3117 GEAR CASE B
1
4
EY670OLO337 BUSHING
1
5
EY60OOBO447
C-TYPE RING
1
6
EY670OL3227 CLUTCH CASE
1
7
EY670OLO577
CLUTCH PLATE
1
0
EY6780L0457
CLICK PLATE
1
9
EY670OLO167
SPRING FOR CLUTCH
1
10
EY6283L0637
ADJUSTING SCREU
1
11
EY670OH3237 CLUTCH HANDLE
1
12
EY678OL1407
CLUTCH CASE BLOCK
1
13
EY670OLO5O7
LOCK PIN A
1
14
EY6780L0597 LOCK PIN B
1
15
EY670OYO360
LOCK LEVER
2
16
EY670OL4537
OUTPUT SHAFT BLOCK
1
17
1 EY6780L0977
O-RING
1
10
1 EY6780L0177
SPRING FOR LOCK LEVER
2
*B
17
’ EY670OK31O7 GEAR CASE A
1
20
EY670QK6977
STEEL BALL
10
*B
21
EY67B0L0837
HOLDER COLLAER
2
*B
22
EY670QK3717 BIT HOLDER
1
23 i EY6780L0197
HOLDER SPRING
1
24 EY6780KQ187
C-TYPE SPRING
1
25 . EY574B9037
TAPPING SCREW
4 *C
26 EY6401LO357
THRUST PIN SET
2 *B
21 EY560B6967
STEEL BALL
12
*b
28
EY670OL1127 DRIVING SHAFT
1
29 EY560B1457
RING GEAR A
1
30
EY6780L1357 PLANET GEAR A 3
*B
31
EY62OOBO057
THRUST PLATE
1
32
EY670QL1377
TRANSMISSION GEAR
1
33
EY560B1367
PLANET GEAR B SET
3
*B
34
EY6401L1467
RING GEAR B
1
35
EY6401LO007
THRUST PLATE
1
36
EY6780L1008
MOTOR
1
37
EYT104LOO27
MOTOR MOUNTING PLATE
1
30
EYT184L6077
SCREU FOR MOTOR
2
*C
39
EY6780L2947 LEAD WIRE SET
1
40
EY6780L6027 TAPPING SCREU
1
41
EYT184L2567
RADIATING PLATE (W/SCREU)
1
42
EY670OY2OO0
SWITCH BLOCK
1
43
EY67B0L6037
SCREU
2
*C
44
EY6401LO2O7
DUST PREVENTIVE PLATE
1
45
EY6401H3247
SELECTOR HANDLE
1
46
EY563B9217
TAPPING SCREW
8
*C
47
EY502B7957
PHILLIPS BIT #2
1
*A
48
EY9O06
BATTERY PACK
1
49
EY9182
BATTERY PACK
1
*A
50
EY0202
BATTERY CHARGER
1
*A
51
EY678OL7067
JIG FOR BUSHING
1
—
EY9592
TOOL CASE
1
*A
(7>'JA) Printed in Japan.
- 10 -