Panasonic EY6406 - CORDLES DRILL&DRIVER User manual

ORDER NO. MEW/PTD 9906-64061
Service Manual
Cordless Drill & Driver
EY6406 • EY6407 • EY6431
• Specifications.1
■ Disassembly / Assembly Instructions.4
■ Wiring Connection Diagram.5
• Troubleshooting Guide .6
• Schematic Diagram.7
• Exploded View & Replacement Parts List-8-11
- ■ * ■ - -
CONTENTS
Page
SPECIFICATIONS
MAIN UNIT
Model
EY6406 EY6407
EY6431
Motor
DC Motor 12V
DC Motor 15.6V
No load speed
LOW
400/min (rpm.)
450/min (rpm.)
HIGH
1300/min (rpm.)
1100/min (rpm.) j
Chuck capacity
0.5 ~ $ lOmm (1/32' - 3/8")
<f> 1.0 - <f> 13mm (1/16”--1/2”)
Maximum torque
LOW
22.5Nm (230kgf-cm, 199in-lbs.)
31.9Nm (325kgf-cm,
282in-lbs.)
HIGH
6.3Nm (65kgf-cm, 56in-lb$.)
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 p
8.7in-lbs.) - 6.9Nm (70kgf-
cm, 61 in-lbs.)
Overall lenqth
202mm (7-61/64”)
208mm (8-3/16")
Weight (with battery pack)
1.7kg (3.74lbs.) with
EY9106
1.8kg (3.96lbs.) with
EY9200
2.0kg (4.4lbs.) with
EY9230/EY9136
BATTERY PACK
EY9106
EY9108
EY9200
EY9230
EY9136
Ni-Cd battery
Ni-MH battery
Ni-Cd battery
Battery voltage
IlHJililHgllllilllll 11
15.6V DC (1.2V X 13 cells)
BATTERY CHARGER
Weiqht
0.78kq (1.72lbs.)
Charging time
Approx. 30min. with EY9106/9108/9136 45min. with EY9200/9230
Panasonic
©1999 Matsushita Electric Works, Ltd.
All rights reserved. Unauthorized copying
and distribution is a violation of law.

Model EY6406 • EY6407 • EY6431
^WARNING
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 individuals of potential dangers in attempting to service a product. Products
powered by electricity should be serviced or repaired only by experienced professional technicians. Any attempt to sen/ice or repair the
product or products dealt with in this service information 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
Chuck
Allen wrench
Chuck
Allen wrench
Chuck
Set the clutch handle to position and
'LOW" position.
Turn the lock handle counterclockwise direction
to open the chuck jaws.
Use a screwdriver to turn 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 a hammer to
tighten the chuck, and then loosen the
chuck fastening screw. (See Fig.2)
Insert the alien wrench into the chuck, and turn
counterclockwise direction in the arrow with
holding the unit by the vise to remove the
chuck. (See Fig. 3)
Ref. No. 2A
Procedure 2 A
Removal of the housings.

Model EY6406 • EY6407 • EY6431
Ref. No. 2B
Procedure 2A—2B
Removal or attachment of the 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 2 A—2B-
Removal or attachment of the gear box block.
Planet gear B Thrust plate
Ring gear A _ carrier A
Carrier B \ /**+ a
PlanetgearB _
Pin Planet qe A
\ Carrier
a?<D
Driving block
Fling gear
Clutch Clutch
spring plate
oo n
o o
o_2-
o 3 F
°oo°
Steel ball
(Removal of the gear box block.)
1. Turn 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 direction. (See Fig.8)
4. Start from inserting 6 pins 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 A and B, Ring gear,
and Ring gear A have their own
correct directions for proper
reassembly.
Fig.7
ft
Insert to
driving ^
block.
o.
LT
Fig.8
Lock ring
Driving block
Ffg.9
- 3 -

Model EY6406 • EY6407 • EY6431
Ref. No. 2D Procedure 2A—2B-*2C—2D
Attachment for steel balls.
Reinstalling place 2pcs of steel balls into each of
the 6 holes. (See Fig. 10)
Steel balls
(2 pcs x 6 holes)
Driving block
Fig.10
Ref. No. 2E
Clutch “1
o
Procedure 2A-*2B—2C—2D—2E Attachment for the adjusting screw and the
- clutch handle.
Align the O mark 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 1 on top
Insert the clutch handle with adjusting the tabs
of adjusting screw to the groove of inside clutch
handle.
Clutch handle
OO mark
\ O mark
Projection
Adjusting screw
Driving block
Flg.11

Model EY6406 • EY6407 • EY6431
- 5 -

Model EY6406 • EY6407 • EY6431
TROUBLESHOOTING GUIDE (Refer to WIRING CONNECTION DIAGRAM)

Model EY6406 * EY6407 * EY6431
SCHEMATIC DIAGRAM
Select SW Main SW
\- v - /\ - v -/ \-V-'
Battery Charger Battery Pack Main Unit

Model EY6406 ■ EY6407
EXPLODED VIEW FOR EY 406 • EY6407

Model EY6406 - EY6407
REPLACEMENT PARTS LIST FOR EY6406 • EY6407
Ref.No.
▲ 1
2
Part No. for EY6406
Part No. for EY6407
EY6406K3078
EY6407K3078
EY6481L0177
EY6481L0177
EYTl03L6807
EYTl03L6807 (
EY9795
EY9796 (
EY6406Y3228
EY6406Y3228
EY6406L0638
EY6406L0638
EY6406L0168
EY6406L0168
EY6406L0578
EY6406L0578
EY560B6967
EY560B6967
EY6406L1078
EY6406L1078 1
EY6406Y3238
EY6406Y3238 1
EY6406L2568
EY6406L2568 1
EY6406L0178
EY6406L0178
EY6402Y3247 j
EY6402Y3247
EY6283L0377
EY6283L0377 i
EY6406L1118
EY6406L1118
EY6406L1488
EY6406L1488
EY6406U 348
EY6406L1348
EY6406L0858
EY6406L0858
EY6406L1128
EY6406L1128
EY6406L1468
EY6406L1468
EY6406L1108
EY6406L1108
EY6406L1478
EY6406L1478
EY6406L1358
EY6406L1358
EY6406L0888
EY6406L0888
EY6406L1008
EY6406L1008
EY6230L6027
EY6230L6027 j
EY6406L0028
EY6406L0028
EY6207Y6027
EY6207Y6027
EY6406Y2008
EY6406Y2008
EY6230L0207
EY6230L0207
EY6230K9218
EY6230K9218
EY6406K9038
EY6406K9038
EY6406L1458
EY6406L1458
EY9106
EY9200
EY0230
EY0230
EY9594
EY9594
EY6406K8108
EY6406K8108
Part Name & Descriptions I Per unit I Remarks
sarMU^&i
BATTERY CHARGER
TOOL CASE
-9-

Model EY6431
EXPLODED VIEW FOR EY6431

Model EY6431
REPLACEMENT PARTS LIST FOR EY6431
Ret. No.
NOTE : *A • *
*B * •
_ *C • •
1 Part Ho.
available as an optional accessory
only avaitable as set
avaiIabIe individua11y
~~ 1 Part Name & Descriptions
Per unitI Remarks
EY6431K3078
HOUSING AB SET
EY6481L0177
CLICK SPRING
EYT103L6807
CHUCK FASTENING SCREW 1
EY9796
KEYLESS CHUCK
EY6406Y3228
CLUTCH HANDLE
EY6406L0638
ADJUSTING SCREW
EY6431L0168 j
CLUTCH SPRING
EY6406L0578
CLUTCH PLATE
EY560B6967
STEEL BALL
EY6431L1078
DRIVING BLOCK 1
EY6406Y3238
H/L HANDLE
EY6406L2568
HEAT SINK
EY6406L0178
CLICK SPRING A 1
EY6402Y3247
F/R SELECTOR HANDLE
EY6283L0377
ROLLER PIN
EY6406L1118
CARRIER
EY6406L1488
RING GEAR
EY6406L1348
PLANET GEAR
EY6406L0858
THRUST PLATE
EY6406L1128
CARRIER A
EY6406L1468
RING GEAR A
EY6406L1108
CARRIER B
EY6406L1478
RING GEAR B
EY6406L1358
PLANET GEAR B
EY6406L0888
THRUST PLATE
EY6431L1008
MOTOR
EY6230L6027
SCREW
EY6406L0028
MOTOR MOUNTING PLATE
EY6207Y6027
SCREW
EY6431Y2008
SWITCH BLOCK r
EY6230L0207
DUST PREVENTIVE PLATE
EY6230K9218
TAPPING SCREW
EY6406K9038
TORX TAPPING SCREW
EY6431L1458
GEAR BOX BLOCK
EY9136
BATTERY PACK
EY9230
BATTERY PACK
EY0230
BATTERY CHARGER
EY9594
TOOL CASE
EY6406K8108
OPERATING INSTRUCTIONS i