Panasonic EY7880 - 28.8V ROTARY HAMMER User manual

© 2007 Matsushita Electric Works, Ltd. All rights
reserved. Unauthorized copying and distribution is a
violation of law.
Order Number PTD0709X41CE
Cordless Rotary Hammer
Model No. EY7880
Europe
Oceania
TABLE OF CONTENTS
PAGE PAGE
1 Warning -------------------------------------------------------------- 2
2 Specifications ----------------------------------------------------- 2
3 Troubleshooting Guide ----------------------------------------- 3
4 Disassembly and Assembly Instructions ---------------- 7
5 Wiring Connection Diagram ---------------------------------13
6 Schematic Diagram ---------------------------------------------14
7 Exploded View and Replacement Parts List -----------15

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

6
3.1. Trial Operation (After Checking Troubleshooting Guide.)

7
4 Disassembly and Assembly Instructions
4.1. How to Disassemble the Main Unit.
Ref. No. 1A Procedure 1A Removal of the chuck handle.
1. Set the hammering/drilling switching lever to the position .
2. Loosen the support handle and take it out from the unit.
3. Pluck the chuck cover depressing the chuck handle.
NOTE:
If it is hardly to take out, use the slotted-head screwdriver.
4. Remove the chuck handle.
5. Take out a steel ball pushing the chuck spring with the chuck
spring plate.
6. Remove the chuck spring plate and the chuck spring.
Ref. No. 1B Procedure 1A →1B Removal of the housing.
1. Remove 14 housing screws.

8
Ref. No. 1C Procedure 1A →1B →1C Removal of the switch.
1. Loosen two screws to remove the lead wires from motor assembly.
NOTE:
Do not lose the nut.
2. Take out the switch from the housing.
3. Take out the LED cover.
For assembling
NOTE:
Do not push the area where marked the arrow in order to prevent the
breakage.
Ref. No. 1D Procedure 1A →1B →1C →1D Removal of the motor assembly.
1. Hitch the brush spring to the frame by something like a forceps and
take the motor brush assembly with the switch out from the motor
assembly.
2. Take out the rotor and the current plate from the motor case.
For assembling
NOTE:
Make sure to return the spring into the groove of the motor brush.
Make sure to set the motor case faced the printing side up.
Close the housing and try to apply the DC28.8V and check if the
motor rotates or not.

9
Ref. No. 1C Procedure 1A →1B →1C →1D →1E Removal of the power shaft assembly.
1. Remove the piston applying power spring.
2. Take out the power shaft assembly.
3. Remove the snap ring.
4. Slide the jig (plate) into between the washer and the gear case and
hold it by a vise.
5. Tap the top of spindle block with a plastic hammer to take out the spin-
dle and clutch block assembly.
6. Take out the snap ring on the rear side of the bearing.
7. Take out two pins by using absorption force about 30N magnet from
the clutch block.
8. Take out four steel balls and remove the spindle & piston assembly.
9. Remove the striker with the O-ring and the O-ring. And take out the
bearing.
10. Take out the piston block. And take out the piston and the universal
coupling.
11. Remove the intermediate shaft assembly.

10
4.2. How to Reassemble the Main Unit.
Ref. No. 2A Procedure 2A Assembly of gear case assembly.
1. Set the jig (bearing cap) into the clutch case and hold it with a vise in
order to take out the bearing.
2. Assemble the bearing with the spindle assembly.
3. Set the snap ring.
NOTE:
It has own direction for reassembly. Place the rounded face of snap
ring to the clutch case side.
4. Fit O-ring onto the bearing.
5. Place the thrust plate on the end of intermediate shaft assembly.
6. Insert the reciprocation bearing shaft into the hole of universal cou-
pling. Make sure two thrust plates should be set both side of reciproca-
tion bearing shaft one of each.
7. Assemble the intermediate shaft assembly into the gear case from the
motor side first.
NOTE:
Apply grease especially for the connection area between reciproca-
tion bearing and universal coupling. In addition, hammer O-ring,
inside of piston and cylinder for output shaft block also need to
apply.
Air compressed by the piston drives hammer. Take care to protect
the piston and hammer from contamination by dust.

11
Ref. No. 2B Procedure 2A →2B Assembly of gear case assembly.
1. Assemble the chuck spring and the chuck spring plate.
2. Insert a ball pushing down the chuck spring.
3. Inject an adhesive such as Cemedine SX720WH and wipe off to
bury the gap between the gear case A and B in order to prevent the
leakage of grease inside of gear box.
NOTE:
Make sure an adhesive is completely dried before assembling
the driving block into the houshing.

12
Ref. No. 2C Procedure 2A →2B →2C Assembly of driving block into housing.
1. Set the H/D handle to HAMMER mode.
2. Set the H/S handle in between HIGH and SOFT model.
3. Insert the gear case assembly into the housing.
4. Connect the switch assembly with motor lead wires.

13
5 Wiring Connection Diagram

14
6 Schematic Diagram

Model No. : EY7880 Exploded View for EY7880
7 Exploded View and Replacement Parts List

Model No. : EY7880 Parts List
Safety
Ref.
No. Part No. Part Name & Description Q'ty Remarks
1 WEY7880K3079 HOUSING AB SET 1 (for EUROPE)
1 WEY7880K3070 HOUSING AB SET 1 (for OCEANIA)
2 WEY6813H3116 CHUCK COVER 1
3 WEY6813K3126 CHUCK HANDLE 1
4 WEY6813L0426 BALL GUIDE 1
5 WEY6813L0436 CHUCK SPRING STRIKE PLATE 1
6 WEY6813L0916 CHUCK SPRING 1
7 WEY7880L4307 SPINDLE ASSEMBLY 1
8 WEY6813L0477 SNAP RING 1
9 WEY6813L0366 O RING 1 (φ35)
10 WEY6813L4957 BEARING 1
11 WEY7880L0057 SPINDLE 1
12 WEY6813L1916 STEEL BALL 1 (φ7)
13 WEY6813L1926 STEEL BALL 4 (φ5), (4PCS/PK)
14 WEY6813L0317 O RING 1
15 WEY6813L0327 O RING 1
16 WEY6813L1237 STRIKER 1
17 WEY7880L0337 O RING 1 (φ3.2)
18 WEY6813L0907 PIN 4 (φ5×4), (4PCS/PK)
19 WEY6813L0067 CYLINDER 1
20 WEY6813L1397 POWER GEAR 1
21 WEY6813L0927 CLUTCH SPRING 1
22 WEY6813L0207 THRUST PLATE 1
23 WEY6813L0217 SNAP RING 1 (φ30)
24 WEY6812L0386 BEARING 1
25 WEY7880L1247 PISTON ASSEMBLY 1
26 WEY7880L4627 HAMMER 1
27 WEY6812L0976 O RING 1
28 WEY7880L1987 PISTON 1
29 WEY6812L0846 THRUST PLATE 2 (2PCS/PK)
30 WEY7880L1257 UNIVERSAL COUPLING 1
31 WEY7880L0017 GEAR CASE A 1
32 WEY7880L0027 GEAR CASE B 1
33 WEY7880L0897 SCREW AND NUT SET 1SET
34 WEY7880L0177 SPRING 1 (φ3.5)
35 WEY7880L0987 GASKET AB SET 1
36 WEY6930K9037 SCREW 4 (K3-20)
37 WEY6813L4076 INTERMEDIATE SHAFT ASSEMBLY 1
38 WEY6502L0857 THRUST PLATE 1
39 WEY7880L0857 C-TYPE THRUST PLATE 1
40 WEY7880L1467 MOTOR ROTOR ASSEMBLY 1
41 WEY6813L0356 O RING 1
42 WEY6813L0446 CURRENT PLATE 1

Model No. : EY7880 Parts List
Safety
Ref.
No. Part No. Part Name & Description Q'ty Remarks
43 WEY7880L4987 MOTOR CASE ASSEMBLY 1
44 WEY7880L4637 MOTOR BRUSH ASSEMBLY 1
45 WEY6261B6026 SCREW 2 (K3-6)
46 WEY7880H4617 H/S HANDLE 1
47 WEY7880H4607 H/D HANDLE 1
48 WEY7880L0387 O RING 2 (φ15.6)
49 WEY6813L1406 CLICK SPRING 2 (2PCS/PK)
50 WEY7880B6967 STEEL BALL 2 (φ4)
51 WEY7880L0377 O RING 2
52 WEY6813L0456 SNAP RING 2 (2PCS/PK)
53 WEY7880L0257 LOCK LEVER 1
54 WEY7880L0507 PIN 1 (3*34)
55 WEY7880L0167 PLATE SPRING 1
56 WEY7880L0187 SPRING 1 (φ4.8)
57 WEY7880L0287 PIN 1 (3.5-60)
58 WEY7880L3147 F/R HANDLE 1
59 WEY6813K4626 AUXILIARY HANDLE 1
60 WEY6813H3927 GRIP 1
61 WEY6813K4636 SUPPORT HANDLE 1
62 WEY6813H7726 DEPTH GAUGE 1
63 WEY7880L4157 SWITCH ASSEMBLY 1
64 WEY7880L2157 BATTERY TERMINAL BASE 1
65 WEY7880L3137 TRIGGER COVER 1
66 WEY7880L3957 LED COVER 1
67 WEY7880L2117 MAIN PCB ASSEMBLY 1
68 WEY3503K6206 TORX TAPPING SCREW 14 (K4-20)
69 WEY7880L3417 SHOULDER STRAP 1
70 WEY7880L0208 FERRITE CORE 1
71 WEY6812T7916 BIT GREASE 1 [SH]
- WEY9635K7018 TOOL CASE 1 [SH]
- WEY7880K8109 OPERATING INSTRUCTIONS 1 [SH]