Panasonic EY7542 - CORDLESS IMPACT WRENCH User manual

© 2007 Matsushita Electric Works, Ltd. All rights
reserved. Unauthorized copying and distribution is a
violation of law.
Order Number PTD0707U37CE
F16
Cordless Impact Driver
Model No. EY7542
North America
TABLE OF CONTENTS
PAGE PAGE
1 Warning -------------------------------------------------------------- 2
2 Specifications ----------------------------------------------------- 2
3 Troubleshooting Guide ----------------------------------------- 3
4 Disassembly and Assembly Instructions ---------------- 5
5 Wiring Connection Diagram ---------------------------------13
6 Schematic Diagram ---------------------------------------------13
7 Exploded View and Replacement Parts List -----------14

2
1Warning
Caution:
• Pb free solder has a higher melting point that standard solder; Typicall the melting point is 50 - 70°F (30 - 40°C) higher. Please
use a soldering iron with temperature control and adjust it to 750 ± 20°F (400 ± 10°C). In case of using high temperature solder-
ing iron, please be careful not to heat too long.
• Pb free solder will tend to splash when heated too high (about 1100°F / 600°C).
2 Specifications

3
3 Troubleshooting Guide
(Refer to WIRING CONNECTION DIAGRAM)

4

5
4 Disassembly and Assembly Instructions
4.1. Disassembly Instructions
Ref. No. 1A Procedure 1A Removal of the Housings.
1. Loosen the belt hook bolt turning it counterclockwise, using a coin
or a flat blade screwdriver.
2. Take out the belt hook.
3. Remove four screws where tightening fixing cover.
4. Remove eight housing screws.
5. Pull off the fixing cover assembly.
6. Once removing the clutch handle, the out-put shaft may come out.
7. Remove torque click spring and click spring.
8. Then open the housing A and B.

6
Ref. No. 1B Procedure 1A →1B Removal of Motor assembly and Gear hammer block.
1. Unscrew to disconnect the lead wires between switch and motor.
2. Take out the motor assembly with the gear box block from the
housing.
3. Separate the motor assembly from the gear box block.
4. Take out the ring gear from the revolving stand.

7
Ref. No. 1C Procedure 1A →1B →1C Removal of Gear box assembly.
1. Hold the driving carrier as illustrated.
2. Compress the assembly and take out the pin.
3. Take out the driving shaft assembly and the gear case assembly
from the shaft of the driving carrier.
NOTE:
Make sure not to lose the pin and the connect piece.
Ref. No. 1D Procedure 1A →1B →1C →1D Removal of Gear case assembly.
1. Take out the mode change handle.
2. Pull out 2 pins ( 2.5x33.6).
3. After removing pins, the internal parts of the gear case assembly
can be removed one after another.
Thrust plate →clutch gear →planet gear (3pcs) →carrier →thrust
plate
4. Remove the adjusting screw, clutch spring and clutch plate.
5. After removing the clutch plate, 6 pieces of steel balls come off.

8
4.2. Reassembly instructions
Ref. No. 2A Procedure 2A Assembly of Gear case block.
1. Assemble thrust plate, clutch gear, planet gear (3pcs), carrier,
thrust plate and insert pins (2pcs).
2. Reinstall one piece of steel ball into each of 6 holes.
3. Assemble clutch plate and clutch spring.
4. Align the widest protrusion of adjusting screw with the narrower
protrusion of gear case.
5. Turn the adjusting screw into the gear case assembly one rotation
for clockwise direction.
6. Set the mode change handle on the wider protrusion of gear case.
7. Confirm proper position of the mode change handle that both ends
of spring must be put into the grooves of the driving carrier.

9
Ref. No. 2B Procedure 2A →2B Assembly of Gear box assembly.
1. Insert the driving carrier into the hole of gear case assembly and
the driving hammer assembly.
2. Hold the driving carrier as illustrated and confirm if the connect
piece is inside of the driving shaft block.
3. Insert the pin into the shaft of driving carrier holding the bottom of
the gear box assembly by hand.
4. Align the wider groove of revolving stand with the wider protrusion
of gear case.
5. Assemble the ring gear into the revolving stand and set it on the
motor assembly.
6. Place fit the hole of driving carrier and the pins of revolving stand.

10
Ref. No. 2C Procedure 2A →2B →2C Assembly of Switch and Motor assembly.
1. Insert the motor and gear & hammer assembly into the housing.
2. Connect the switch assembly with motor lead wires.
3. Set the motor lead wire (black) is on the upper side of switch
assembly.
4. Confirm to set the motor lead wire (red) under the black lead wire
and confirm if there is no pinching with switch.
5. Place the battery terminal lead wire (black) is over the wire (red)
properly.

11
Ref. No. 2D Procedure 2A →2B →2C →2D Assembly of Housing.
1. Set the hook release lever on the housing.
2. Close the housing A and B.
3. Confirm if the wider protrusion of adjusting screws is placed on
bottom (switch side).
NOTE:
If the adjusting screw does not set correctly, it will make the
wrong clutch force.
4. Set the mode change handle to IMPACT drive mode.
5. Tighten eight housing screws.
6. Place the torque click spring and click spring properly.
7. Apply the grease (WEY6507X5537) all around the anvil and the
bearing part of clutch handle.
8. Confirm if O-ring is attached with the clutch handle.
9. Assemble the slider to the clutch handle. Confirm it has its own
direction.
10. Place the anvil into the clutch handle.
11. Align the wider protrusion of adjusting screw with the wider
groove of the clutch handle.

12
Ref. No. 2E Procedure 2A →2B→2C →2D →2E Assembly of Fixing cover.
1. Place the clutch handle with position 1 on top.
2. Set the fixing cover with mark on top.
3. Tighten four screws.

13
5 Wiring Connection Diagram
6 Schematic Diagram

Model No. : EY7542 Exploded View
7 Exploded View and Replacement Parts List

Model No. : EY7542 Parts List
Safety
Ref.
No. Part No. Part Name & Description Q'ty Remarks
1 WEY7542K3078 HOUSING AB SET 1
2 WEY6507K1167 C-TYPE RING 1
3 WEY6507L0857 THRUST PLATE 1
4 WEY6507L0197 BIT HOLDER SPRING 1
5 WEY6507K3717 BIT HOLDER 1
6 WEY6504S9067 TIGHT SCREW 4 (4*25)
7 WEY6507S0647 FIXING COVER 1
8 WEY7542K3747 CLUTCH HANDLE 1
9 WEY7542L0968 O-RING 1
10 WEY6505L0867 SLIDER 1
11 WEY6507L6977 STEEL BALL 2 (φ3.5)
12 WEY7542L1128 ANVIL 1
13 WEY7542K1128 FIXATION COVER ASSEMBLY 1
14 WEY6631L0887 CONNECT PIECE 1
15 WEY6507L1417 DRIVING SHAFT ASSEMBLY 1
16 WEY6507L0637 ADJUSTING SCREW 1
17 WEY6507L0167 CLUTCH SCREW 1
18 WEY6505L0577 CLUTCH PLATE 1
19 WEY6631L6977 STEEL BALL 6 (φ5), (6PCS/PK)
20 WEY6481L0356 THRUST PIN SET 2 (φ2.5*33.6), (2PCS/PK)
21 WEY6631L1067 GEAR CASE 1
22 WEY6505L0927 THRUST PLATE 1
23 WEY6631L1397 CARRIER 1
24 WEY6505L1346 PLANET GEAR 3 (3PCS/PK)
25 WEY6631L1357 CLUTCH GEAR 1
26 WEY6631L0907 THRUST PLATE 1
27 WEY6505L0917 SP PIN 1
28 WEY6507L1367 CARRIER 1
29 WEY6507L1457 RING GEAR 1
30 WEY7542L0027 MOTOR MOUNTING PLATE 1
31 WEY7440L1187 STATOR 1
32 WEY7542L1467 MOTOR ROTOR ASSEMBLY 1
33 WEY7542L2307 MOTOR BRUSH ASSEMBLY 1
34 WEY7542K2007 SWITCH ASSEMBLY 1
35 WEY7540L2157 BATTERY TERMINAL BLOCK 1
36 WEY6230L6026 SCREW 2 (K3-6)
37 WEY7542L2117 CONTROL PCB 1
38 WEY7440K3958 OPERATION PANEL 1
39 WEY7540L0167 SPRING FOR RELEASE LEVER 1
40 WEY7540H0407 HOOK RELEASE LEVER 1
41 WEY7542K3187 BELT HOOK SET 1
42 WEY7205K0257 BELT HOOK BOLT 1
43 WEY6230K9216 TORX TAPPING SCREW 9 (K3-20)

Model No. : EY7542 Parts List
Safety
Ref.
No. Part No. Part Name & Description Q'ty Remarks
44 WEY7542H3247 F/R SELECTOR HANDLE 1
45 WEY6631L0977 CLICK SPRING 1
46 WEY6505L0187 CLICK SPRING 1
47 WEY7542S3238 SELECT SWITCH COVER 1
48 WEY7542K3257 I/D CHANGE HANDLE 1
49 WEY7542L1458 GEAR BOX BLOCK 1
- WEY7440K7018 TOOL CASE 1 [SH]
- WEY7542K8108 OPERATING INSTRUCTIONS 1 [SH]