Panasonic Impact Driver EY7542 User Manual
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  
© 2007 Matsushita Electric Works, Ltd. All rights  
reserved. Unauthorized copying and distribution is a  
violation of law.  
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3 Troubleshooting Guide  
(Refer to WIRING CONNECTION DIAGRAM)  
3
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4
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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.  
5
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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.  
6
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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.  
7
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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.  
8
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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.  
9
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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.  
10  
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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.  
11  
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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.  
12  
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5 Wiring Connection Diagram  
6 Schematic Diagram  
13  
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7 Exploded View and Replacement Parts List  
Model No. : EY7542 Exploded View  
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Model No. : EY7542 Parts List  
Ref.  
No.  
Safety  
Part No.  
Part Name & Description  
Q'ty  
Remarks  
1
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  
1
2
C-TYPE RING  
1
3
THRUST PLATE  
BIT HOLDER SPRING  
BIT HOLDER  
1
4
1
5
1
6
TIGHT SCREW  
4 (4*25)  
7
FIXING COVER  
CLUTCH HANDLE  
O-RING  
1
8
1
9
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
SLIDER  
1
STEEL BALL  
2 (φ3.5)  
ANVIL  
1
FIXATION COVER ASSEMBLY  
CONNECT PIECE  
DRIVING SHAFT ASSEMBLY  
ADJUSTING SCREW  
CLUTCH SCREW  
CLUTCH PLATE  
STEEL BALL  
1
1
1
1
1
1
6 (φ5), (6PCS/PK)  
THRUST PIN SET  
GEAR CASE  
2 (φ2.5*33.6), (2PCS/PK)  
1
THRUST PLATE  
CARRIER  
1
1
PLANET GEAR  
3 (3PCS/PK)  
CLUTCH GEAR  
1
THRUST PLATE  
SP PIN  
1
1
CARRIER  
1
RING GEAR  
1
MOTOR MOUNTING PLATE  
STATOR  
1
1
MOTOR ROTOR ASSEMBLY  
MOTOR BRUSH ASSEMBLY  
SWITCH ASSEMBLY  
BATTERY TERMINAL BLOCK  
SCREW  
1
1
1
1
2 (K3-6)  
CONTROL PCB  
1
OPERATION PANEL  
SPRING FOR RELEASE LEVER  
HOOK RELEASE LEVER  
BELT HOOK SET  
BELT HOOK BOLT  
TORX TAPPING SCREW  
1
1
1
1
1
9 (K3-20)  
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Model No. : EY7542 Parts List  
Ref.  
No.  
Safety  
Part No.  
Part Name & Description  
Q'ty  
Remarks  
44  
WEY7542H3247  
WEY6631L0977  
WEY6505L0187  
WEY7542S3238  
WEY7542K3257  
WEY7542L1458  
WEY7440K7018  
WEY7542K8108  
F/R SELECTOR HANDLE  
1
45  
46  
47  
48  
49  
-
CLICK SPRING  
1
CLICK SPRING  
1
SELECT SWITCH COVER  
I/D CHANGE HANDLE  
GEAR BOX BLOCK  
TOOL CASE  
1
1
1
1 [SH]  
1 [SH]  
-
OPERATING INSTRUCTIONS  
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