Panasonic EY3544-U1 Service Manual

Text of Panasonic EY3544-U1 User Guide:

• Panasonic EY3544-U1, 1 SCHEMATIC DIAGRAM 2 2 DISASSEMBLY INSTRUCTIONS 3 3 ASSEMBLY INSTRUCTIONS 6 © 2003 Matsushita Electric Works Ltd. All rights reserved. Unauthorized copying and distribution is a violation of law. EY3544-U1 4 TROUBLESHOOTING GUIDE 7 5 EXPLODED VIEW 8 6 REPLACEMENT PARTS LIST 9 Reciprocating Saw SPECIFICATIONS CONTENTS Page Page ORDER NO.PT D0310 U42C1 F16

• Panasonic EY3544-U1, ■HOW TO DISASSEMBLE BLADE CLAMP ASSEMBLY. 2 DISASSEMBLY INSTRUCTIONS Ref. No. 1A Procedure 1A Removal of the shoe. 1. Loosen a screw (M4X10) with washer tightened on the rear side of shoe lock lever. 2. Remove the shoe lock lever and loosen the hexagonal head bolt. NOTE : Make sure not to lose a hexagonal nut (M4) where located inside of the shoe lock lever. Ref. No. 1B Procedure 1A → →→ → 1B Removal of the insulated rubber boot. 1. Wind the insulated rubber boot down started from the motor side. NOTE : The insulated rubber boot may not pull off due to scratched badly inside of the hook. 3 EY3544-U1

• ■HOW TO DISASSEMBLE GEAR CASE or MOTOR ASSEMBLY. Ref. No. 1C Procedure 1A → →→ → 1B → →→ → 1C Removal of the blade clamp block. 1. Loosen four screws (M5X18) where tightening on the gear housing. Ref. No. 1D Procedure 1A → →→ → 1B → →→ → 1D Removal of the housing. 1. Loose seven housing screws (4X18). 2. Open the housing B. 3. Take out the motor with gear c

• Panasonic EY3544-U1, Ref. No. 1E Procedure 1A → →→ → 1B → →→ → 1D → →→ → 1E Removal of the motor housing. 1. Remove the holder cap and take out the carbon brush on right and left side. 2. Loosen four tapping screws (5X35) tighten the gear case. 3. Pull out the gear case assembly from the motor housing. Ref. No. 1F Procedure 1A → →→ → 1B → →→ → 1D → →→ → 1E → →→ → 1F → →→ → 1C Removal of the gear case block. 1. Loosen two screws (M4X12) an d pull out the rotor assembly. 2. Follow the procedure 1C. NOTE: Greasing No. 1 grease about 10g into the gear for reassembly. 5 EY3544-U1

• Panasonic EY3544-U1, ■ HOW TO ASSEMBLE SWITCH. 3 ASSEMBLY INSTRUCTIONS Ref. No. 1A Procedure 1A Attachment of the brush holder. 1. Insert the brush holders on both right and left side. 2. Press fit the lead wires into the lead guide A. 3. Press fit the lead wires into the lead guide B. 4. Insert the carbon brushes. 5. Tighten the holder caps. Ref. No. 1B Procedure 1A → →→ → 1B Attachment of the switch. 1. Check the lead wires whether they are mounted in the proper position. NOTE: Make sure they are not set on the screw bosses or over the housing ribs. 6 EY3544-U1

• Panasonic EY3544-U1, 4 TROUBLESHOOTING GUIDE < TROUBLE > < CHECK > < REMEDY > Does not operate. <CHECK BATTER Y PACK.> NO Replace battery pack. → If no less than 18V DC is available across the (+) and (-) terminals → after charging for the rated charging time (approx. 65 minutes for EY9250), the battery pack is OK. NOTE: The battery pack is sold separately as an optional accessory. See the nearest sales dealer for details. The battery pack has a limited life. The pack should be replaced if; - after being charged for the rated charging time the battery voltage is less than 18V DC or the usable time is extremely short. - the battery leaks.

• Panasonic EY3544-U1, 6 REPLACEMENT PARTS LIST NOTE: *B=only available as set *C=available individually Ref.No. Part No. Part Name & Description Remarks Per Unit 1 WEY3544K6708 SCREW *C M5*18 4 2 WEY3544S1168 BLADE CLAMP BLOCK 1 3 WEY3544K0228 SHOE 1 4 WEY3544H3648 INSULATED RUBBER BOOT 1 5 WEY3544K6278 SCREW M4*10 1 6 WEY3544K0478 SLEEVE 1 7 WEY3544K1168 INNER PLATE 1 8 WEY3544K1178 LOCK PLATE 1 9 WEY3544K1558 SHOE LOCK LEVER 1 10 WEY3544K6398 HEXAGONAL HEAD BOLT M8*25 1 11 WEY3544K6428 HEXAGONAL NUT M4 1 12 WEY3544S1768 GEAR CASE BLOCK 1 13 WEY3544L9388 TAPPING SCREW *C 5*35 4 14 WEY3544L4628 MOTOR ROTOR ASSEMBLY 1 15 WEY3

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