ORDER NO. PTD0108U32C1
F16
Cordless Multi Drill & Driver
EY6535-U1
SPECIFICATIONS
© 2001 Matsushita Electric Works Ltd. All rights
reserved. Unauthorized copying and distribution is a
violation of law.
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EY6535-U1
3 DISASSEMBLY INSTRUCTIONS
IHOW TO DISASSEMBLE THE MAIN UNIT.
Ref. No. 1A
Procedure 1A
Removal of Fixation Cover and Housing.
1. Remove 4 screws tightened with the fixation
cover and take it out.
2. Remove clutch handle, slider and anvil.
3. Remove 7 housing screws.
4. Remove the click springs and separate
housing A and B.
Ref. No. 1B
Procedure 1A → 1B
Disassembly of Motor and Gear Box
Block.
1. Remove the motor assembly with the gear box
block from the housing.
2. Separate the motor assembly from the gear
box block by twisting the motor to unlock tabs.
3
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EY6535-U1
Ref. No. 1C
Procedure 1A → 1B → 1C
Removal of Motor Mounting Base.
1. To remove the ring gear, unhook right and left
side of the projections using a flat screwdriver.
2. After removing the ring gear, the internal parts
can be remove one after another.
3. Loosen 3 screws tightened with the motor
mounting base.
Ref. No. 1D
Procedure 1A → 1B → 1D
Removal of Gear Box Assembly.
1. Hold the driving carrier as illustrated.
Compress the assembly and remove the pin.
2. 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.
4
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EY6535-U1
Ref.No.1E
Procedure 1A → 1B → 1D → 1E
Removal of Gear Case Assembly.
1. Take out the mode change handle.
2. Pull out 2 pins (
2.5×33.6).
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 adjusting screw, clutch spring, and
clutch plate.
5. After removing the clutch plate, 6 pieces of
steel ball come off.
5
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EY6535-U1
4 ASSEMBLY 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.
6
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EY6535-U1
Ref.No.2B
Procedure 2A→2B
Assembly of Motor Mounting Base.
NOTE :
After loosening these screws, please replace
them with new screws. The old screws have
an adhesive that can not be reapplied. New
screws are identified with blue adhesive.
1. Tighten 3 screws of the motor mounting base.
2. Assemble planet gears and pins with the
revolving stand and insert them into the motor
mounting base.
3. The ring gear has its own correct direction.
Confirm the direction when the ring gear is
inserted into the motor mounting base.
4. Adjust the protrusion parts of ring gear with
the groove parts of motor mounting base.
7
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EY6535-U1
Ref.No.2C
Procedure 2A→2B→2C
Assembly of Gear Box Assembly.
1. Fit the driving carrier into the hole of the gear
case assembly and the driving shaft assembly.
2. Confirm the connect piece is inside of the
driving shaft block.
3. Insert the pin into the shaft of the driving
carrier holding the bottom of the gear box
assembly (driving carrier) by hand.
4. Align the wider protrusion of motor mounting
base with the wider protrusion of gear case.
Ref.No.2D
Procedure 2A→2B→2C→2D
Assembly of Motor and Switch.
1. Fit terminal of lead wire (black) parallel to the
heat sink.
Caution:
Be careful that the heat sink and the terminal
do not touch, otherwise these are
shortcuircuit.
8
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EY6535-U1
Ref.No.2E
Procedure 2A→2B→2C→2D→2E
Assembly of Housing.
1. Confirm proper position of the click springs
and the position in each housing A and B.
2. Check that the widest protrusion (6mm) of
adjusting screw is in the middle and the mode
change handle is set to the IMPACT position.
3. Set anvil and slider, has its own correct
direction. Confirm the direction when assembling.
4. Set the clutch handle with position 1 on top.
5. When setting fixation cover, align
mark on
top.
6. Tighten 4 screws.
9
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EY6535-U1
5 TROUBLESHOOTING GUIDE
(Refer to WIRING CONNECTION DIAGRAM)
< TROUBLE >
Does not operate.
< CHECK >
<CHECK BATTERY PACK.>
If no less than 15.6 V DC is available across the (+) and (-) terminals,
the battery pack is OK.
< REMEDY >
NO Replace battery pack.
→
→
The battery pack is sold separately as an optional accessory.
See the nearest sales dealer for details. The battery pack has a
limited life.
NOTE:
The pack should be replaced if;
- after being charged for the rated charging time the battery voltage
is less than 15.6V DC or the usable time is extremely short.
- the battery leaks. Check battery for leaks and terminals for
corrosion.
↓OK
<CHECK TERMINAL CONNECTIONS BETWEEN MAIN UNIT
AND BATTERY PACK.>
NO Clean and repair
→
contacts.
Check for proper terminal contacts.
↓OK
<CHECK SWITCH BLOCK.>
NO Contacts in switch block
See WIRING CONNECTION DIAGRAM.
Check continuity between following terminals.
Inspection of the forward / reverse selection switch.
When switch handle is depressed all the way:
→
are defective.
Replace switch & FET
block.
*
- There should be 0Ω between
when switch lever is set to forward side.
- There should be 0Ω between , and between
when switch lever is set to reverse side.
Inspection of the brake.
-
, and between
-
;
;
-
-
*
When switch handle is not depressed:
- There should be 0Ω between
-
.
↓OK
<CHECK MOTOR.>
NO Replace motor.
The motor normally operates with its white (+) and black (-) lead wires
connected to 15.6V DC.
→
10
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EY6535-U1
< TROUBLE >
< CHECK >
< REMEDY >
No speed-control.
<CHECK FET.>
Even if FET block is defective, it can not be replaced individually. Replace
whole switch block.
NO Replace switch & FET
→
→
block.
Shortcircuit (G: gate) and (S: source), and measure between it and (D:
drain) with switch block.
NOTE:
*
FET is sensitive against static electricity.
** The resistance value will vary dependent upon the measurement
range of the tester.
↓OK
<CHECK SWITCH BLOCK.>
NO Replace switch & FET
block.
→
Weakness of
vibration.
<CHECK ANVIL.>
NO Replace anvil.
→
→
Check wear condition. If no less than 1mm from the corner at (A) side or
0.5mm from the corner at (B) side, anvil is OK.
↓OK
<CHECK HAMMER BLOCK.>
Check whether hammer block rotates smoothly when moving shaft of
hammer.
NO Replace driving shaft
→
assembly.
↓OK
<CHECK MOTOR.>
Measure no load rotation whether it is more than 1,900rpm with full charged
battery pack.
NO Replace motor.
→
11
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EY6535-U1
6 EXPLODED VIEW
12
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EY6535-U1
7 REPLACEMENT PARTS LIST
NOTE:
*A = available as an optional accessory
*B = only available as set
*C = available individually
Ref. No.
1
Part No.
Part Name & Description
HOUSING AB SET
Remarks
Per Unit
WEY6535K3078
1
2
3
EY6481L0177
WEY6535K9158
CLICK SPRING
SCREW
1
4
*C
4×25
4
5
WEY6535S0648
WEY6535K3748
WEY6535L0868
WEY6535L1128
WEY6535L0888
WEY6535L1418
WEY6535L0638
WEY6535L0168
WEY6535L0578
WEY6535L6968
WEY6535L1068
FIXATION COVER
CLUTCH HANDLE
SLIDER
1
1
1
1
1
1
1
1
1
6
1
6
7
POWER SHAFT
8
CONNECT PIECE
DRIVING SHAFT ASSEMBLY
ADJUSTING SCREW
CLUTCH SPRING
CLUTCH PLATE
STEEL BALL
9
10
11
12
13
14
*B
*B
5 ,(6PCS/PACK)
GEAR CASE
15
16
EY6481L0357
WEY6535L0928
THRUST PIN 2.5*33.6
THRUST PLATE
2.5×33.6,(2PCS/PACK)
2
1
17
18
19
20
21
22
23
WEY6535L1648
WEY6505L1347
WEY6535L1358
WEY6535L0908
WEY6535L0918
WEY6535L1368
WEY6505L1457
CARRIER
1
3
1
1
1
1
1
PLANET GEAR
CLUTCH GEAR
THRUST PLATE
PIN
*B
(3PCS/PACK)
1×5.5
DRIVING CARRIER
RING GEAR
24
25
26
27
WEY6505L1377
WEY6535L1388
WEY6505L0367
WEY6505L9007
PLANET GEAR A
REVOLVING STAND
PIN
*B
(2PCS/PACK)
2
1
2
3
*C
*B
5×9.4
SCREW
K3×6, (3PCS/PACK)
28
29
30
WEY6535L0028
WEY6535L1008
WEY6535Y2008
MOTOR MOUNTING BASE
DC MOTOR
1
1
1
SWITCH
31
32
33
EY6230L6037
EY6230L0207
WEY6535L0188
SEMS SCREW
*C
*B
M3×5
2
1
2
DUST PREVENTIVE PLATE
CLICK SPRING
(2PCS/PACK)
34
35
36
37
-
EY6402Y3247
WEY6535X3248
WEY6535K3238
WEY6930K9218
WEY6535K8108
SELECTOR HANDLE
D/I INDICATION COVER
D/I CHANGE HANDLE
SCREW
1
1
1
7
1
*C
3×20
OPERATING INSTRUCTIONS
** Battery Pack, Keyless Chuck, Quick Change Chuck and Tool Case are available as an optional accessory. " See the nearest
sales dealer for details.
*** For replacement parts of charger, see the charger service manual.
13
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