Panasonic Impact Driver EY7542 User Manual

Order Number PTD0707U37CE

F16

Cordless Impact Driver

Model No. EY7542

North America

TABLE OF CONTENTS

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

reserved. Unauthorized copying and distribution is a

violation of law.

3 Troubleshooting Guide

(Refer to WIRING CONNECTION DIAGRAM)

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.

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.

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.

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.

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.

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.

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.

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

3. Tighten four screws.

mark on top.

5 Wiring Connection Diagram

6 Schematic Diagram

7 Exploded View and Replacement Parts List

Model No. : EY7542 Exploded View

Model No. : EY7542 Parts List

Ref.

No.

Safety

Part No.

Part Name & Description

Q'ty

Remarks

WEY7542K3078

WEY6507K1167

WEY6507L0857

WEY6507L0197

WEY6507K3717

WEY6504S9067

WEY6507S0647

WEY7542K3747

WEY7542L0968

WEY6505L0867

WEY6507L6977

WEY7542L1128

WEY7542K1128

WEY6631L0887

WEY6507L1417

WEY6507L0637

WEY6507L0167

WEY6505L0577

WEY6631L6977

WEY6481L0356

WEY6631L1067

WEY6505L0927

WEY6631L1397

WEY6505L1346

WEY6631L1357

WEY6631L0907

WEY6505L0917

WEY6507L1367

WEY6507L1457

WEY7542L0027

WEY7440L1187

WEY7542L1467

WEY7542L2307

WEY7542K2007

WEY7540L2157

WEY6230L6026

WEY7542L2117

WEY7440K3958

WEY7540L0167

WEY7540H0407

WEY7542K3187

WEY7205K0257

WEY6230K9216

HOUSING AB SET

C-TYPE RING

THRUST PLATE

BIT HOLDER SPRING

BIT HOLDER

TIGHT SCREW

4 (4*25)

FIXING COVER

CLUTCH HANDLE

O-RING

SLIDER

STEEL BALL

2 (φ3.5)

ANVIL

FIXATION COVER ASSEMBLY

CONNECT PIECE

DRIVING SHAFT ASSEMBLY

ADJUSTING SCREW

CLUTCH SCREW

CLUTCH PLATE

STEEL BALL

6 (φ5), (6PCS/PK)

THRUST PIN SET

GEAR CASE

2 (φ2.5*33.6), (2PCS/PK)

THRUST PLATE

CARRIER

PLANET GEAR

3 (3PCS/PK)

CLUTCH GEAR

THRUST PLATE

SP PIN

CARRIER

RING GEAR

MOTOR MOUNTING PLATE

STATOR

MOTOR ROTOR ASSEMBLY

MOTOR BRUSH ASSEMBLY

SWITCH ASSEMBLY

BATTERY TERMINAL BLOCK

SCREW

2 (K3-6)

CONTROL PCB

OPERATION PANEL

SPRING FOR RELEASE LEVER

HOOK RELEASE LEVER

BELT HOOK SET

BELT HOOK BOLT

TORX TAPPING SCREW

9 (K3-20)

Model No. : EY7542 Parts List

Ref.

No.

Safety

Part No.

Part Name & Description

Q'ty

Remarks

WEY7542H3247

WEY6631L0977

WEY6505L0187

WEY7542S3238

WEY7542K3257

WEY7542L1458

WEY7440K7018

WEY7542K8108

F/R SELECTOR HANDLE

CLICK SPRING

SELECT SWITCH COVER

I/D CHANGE HANDLE

GEAR BOX BLOCK

TOOL CASE

1 [SH]

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