ORDER NO.PTD0310U42C1
F16
Reciprocating Saw
EY3544-U1
SPECIFICATIONS
CONTENTS
Page
Page
1 SCHEMATIC DIAGRAM
2
3
6
4 TROUBLESHOOTING GUIDE
5 EXPLODED VIEW
7
8
9
2 DISASSEMBLY INSTRUCTIONS
3 ASSEMBLY INSTRUCTIONS
6 REPLACEMENT PARTS LIST
© 2003 Matsushita Electric Works Ltd. All rights
reserved. Unauthorized copying and distribution is a
violation of law.
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EY3544-U1
2 DISASSEMBLY INSTRUCTIONS
IHOW TO DISASSEMBLE BLADE CLAMP ASSEMBLY.
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
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EY3544-U1
Ref. No. 1C
Procedure 1A → 1B → 1C
Removal of the blade clamp block.
1. Loosen four screws (M5X18) where tightening on the gear
housing.
IHOW TO DISASSEMBLE GEAR CASE or MOTOR
Ref. No. 1D Procedure 1A → 1B → 1D
ASSEMBLY.
Removal of the housing.
1. Loose seven housing screws (4X18).
2. Open the housing B.
3. Take out the motor with gear case assembly from the housing A.
4
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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) and pull out the rotor assembly.
2. Follow the procedure 1C.
NOTE:
Greasing No. 1 grease about 10g into the gear for reassembly.
5
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EY3544-U1
3 ASSEMBLY INSTRUCTIONS
I HOW TO ASSEMBLE SWITCH.
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
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EY3544-U1
4 TROUBLESHOOTING GUIDE
< TROUBLE >
< CHECK >
< REMEDY >
NO Replace battery pack.
→
Does not operate.
<CHECK 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.
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 18V 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 Repair contacts.
→
Check for proper terminal contacts.
↓OK
<CHECK SWITCH BLOCK.>
NO Contacts in switch block
(See WIRING CONNECTION DIAGRAM.)
→
are defective.
Replace switch &
FET block.
Check continuity between following terminals.
1) Inspection of the switch operated contact.
When switch handle is depressed all the way:
-
There should be 0Ω between (A) - (D) , and between (B) - (C) ;
when switch lever is set to forward side.
2) Inspection of the brake.
When switch handle is not depressed:
-
There should be 0Ω between (A) - (B)
↓OK
<CHECK CARBON BRUSH.>
1) The condition of carbon brush.
NO Replace carbon
brushes.
→
-
There should be more than 1mm from the line of the carbon brush.
2) The continuity of carbon brush.
-
There should be 0Ωbetween the motor lead wire and the
metal fitting of carbon brush.
↓OK
<CHECK MOTOR ROTOR.>
NO Replace motor
rotor assembly.
Check the condition of rotor if there is any wear, crack and deformation.
→
↓OK
<CHECK MOTOR STATOR.>
Check the condition of motor case if there is any crack and deformation.
NO Replace motor
stator.
→
Does not speed-
control.
<CHECK SWITCH.>
Follow the procedure above “CHECK SWITCH”.
Attach the battery pack and confirm the switch operation
when depressing the switch handle little by little.
NO Repair the contact
→
→
or replace switch
& FET block.
7
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EY3544-U1
5 EXPLODED VIEW
8
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EY3544-U1
6 REPLACEMENT PARTS LIST
NOTE:
*B=only available as set
*C=available individually
Ref.No.
1
Part No.
WEY3544K6708
Part Name
&
Description
Remarks
Per Unit
SCREW
*C
M5*18
M4*10
4
1
1
1
1
1
1
1
1
1
1
1
4
1
2
1
2
1
1
2
2
1ST
1
1
1
1
1
7
1
1
1
1
2
WEY3544S1168
WEY3544K0228
WEY3544H3648
WEY3544K6278
WEY3544K0478
WEY3544K1168
WEY3544K1178
WEY3544K1558
WEY3544K6398
WEY3544K6428
WEY3544S1768
WEY3544L9388
WEY3544L4628
WEY3544L6218
WEY3544L0478
WEY3544L9668
WEY3544L1188
WEY3544K0538
WEY3544K0558
WEY3544L4638
WEY3544L4368
WEY3544K3078
WEY3544L0178
WEY3544Y3568
WEY3544L6208
WEY3544L0088
WEY3544K9218
WEY3544L2568
WEY3544L0208
WEY3544Y2008
WEY3544K8108
BLADE CLAMP BLOCK
SHOE
3
4
INSULATED RUBBER BOOT
SCREW
5
6
SLEEVE
7
INNER PLATE
LOCK PLATE
8
9
SHOE LOCK LEVER
HEXAGONAL HEAD BOLT
HEXAGONAL NUT
GEAR CASE BLOCK
TAPPING SCREW
MOTOR ROTOR ASSEMBLY
SCREW
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
-
M8*25
M4
*C
*C
*C
5*35
M4*12
4*60
BAFFLE PLATE
TAPPING SCREW
STATOR
MOTOR HOUSING
HOLDER CAP
*B
*B
(2PCS/PK)
(2PCS/PK)
CARBON BRUSH
BRUSH HOLDER
HOUSING AB SET
SPRING
RELEASE LEVER
SCREW
M3*8
4*18
SWITCH FRAME
TAPPING SCREW
HEAT SINK
*C
HOLDER PLATE
SWITCH
OPERATING INSTRUCTIONS
**Battery Pack, 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.
Charger complete set is available as an optional accessory. See the nearest sales dealer for details.
9
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