Panasonic EY4541 User manual

© Panasonic Electric Works Co., Ltd. 2008.
All rights reserved. Unauthorized copying and distri-
bution is a violation of law.
Order Number PTD0810X47CE
Cordless Jigsaw
Model No. EY4541
Europe
Oceania
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 ---------------------------------- 9
6 Schematic Diagram ---------------------------------------------- 9
7 Exploded View and Replacement Parts List -----------10

2
1Warning
Caution:
• Pb free solder has a higher melting point that standard solder; Typicall the melting point is 50 - 70°F (30 - 40°C) higher. Please
use a soldering iron with temperature control and adjust it to 750 ± 20°F (400 ± 10°C). In case of using high temperature solder-
ing iron, please be careful not to heat too long.
• Pb free solder will tend to splash when heated too high (about 1100°F / 600°C).
2 Specifications

3
3 Troubleshooting Guide
(Refer to Wiring Connection Diagram)

4
3.1. Trial Operation (after checking Troubleshooting Guide.)

5
4 Disassembly and Assembly Instructions
4.1. How to Disassemble the Blade.
Ref. No. 1A Procedure 1A Removal of blade.
WARNING:
To reduce the risk of injury, always remove battery pack before
removing/installing the blade.
1. Lift up the blade attach/remove lever.
2. Pull out the blade.
CAUTION:
Be careful to avoid cutting your hands on the blade.
Ref. No. 1B Procedure 1A →1B Removal of base.
1. Use the provided hex wrench to loosen the base fixing screw.
NOTE:
Keep the hex wrench in the storage slot on the tool’s body when not
using it.
2. Remove the hex bolt and base.

6
Ref. No. 1C Procedure 1A →1B →1C Removal of the housing.
1. Loosen 11 housing screws.
2. Hold the housing A and take the housing B up vertically.
Ref. No. 1D Procedure 1A →1B →1C →1D Removal of driving block.
1. Take out the arbor assembly together with the plate spring.
2. Remove the arbor roller.
3. Remove the gear assembly including the gear, weight plate and gear
stand.

7
Ref. No. 1E Procedure 1A →1B →1C →1D →1E Removal of the switch.
1. Pull out the lead wires from the side closed terminal.
(for reassembly)
1. Connect the same color of lead wires (black or red) from switch and
brush assembly with the side closed terminals.
Ref. No. 1F Procedure 1A →1B →1C →1D →1E →1F Removal of the brush assembly.
1. Remove the motor assembly from the housing.
2. Take out the rotor assembly from the stator.

8
Ref. No. 1G Procedure 1A →1B →1C →1D →1E →1F
→1G
Assembly of main unit.
1. Press fit the lead wire firmly.
2. Close the housing A and B.

9
5 Wiring Connection Diagram
6 Schematic Diagram

Model No. : EY4541 Exploded View
7 Exploded View and Replacement Parts List

Model No. : EY4541 Parts List
Safety
Ref.
No. Part No. Part Name & Description Q'ty Remarks
1 WEY4541K3079 HOUSING AB SET 1 (for EUROPE)
1 WEY4541K3070 HOUSING AB SET 1 (for OCEANIA)
2 WEYT510L1037 BRUSH HOLDER 1
3 WEYT510L2317 BRUSH ASSEMBLY 2 (2PCS/PK)
4 WEYT510L2397 HEAT SINK 1
5 WEYT510L6037 TIGHT SCREW 2 (M3*6)
6 WEYT510L1587 STATOR ASSEMBLY 1
7 WEY4541L1007 ROTOR ASSEMBLY 1
8 WEYT510L4347 GEAR STAND 1
9 WEYT510L6507 WASHER 2 (5.5×12×0.2), (2PCS/PK)
10 WEYT510L6527 WASHER 1
11 WEYT510L0067 FORK 1
12 WEYT510L1457 MID GEAR 1
13 WEYT510L1417 GEAR ASSEMBLY 1
14 WEYT510L0437 C-TYPE RING 2 (2PCS/PK)
15 WEYT510L0377 ARBOR ROLLER 1
16 WEYT510L0697 WEIGHT PLATE 2 (2PCS/PK)
17 WEYT510L0497 GEAR RETAINING PLATE 1
18 WEYT510L0087 ARBOR ASSEMBLY 1
19 WEYT510L0177 ARBOR STOPPER 1
20 WEYT510L3147 PROTECTION PLATE 2 (2PCS/PK)
21 WEYT510L3137 DUST PREVENT RUBBER 1
22 WEY4541L1897 BASE 1
23 WEY4541L3327 BEVEL INDEX 1
24 WEY4541L1907 BASE PLATE 1
25 WEY4541L6117 TIGHT SCREW 4 (M4x8)
26 WEYT510L6307 HEX BOLT 1 (M4X6)
27 WEYT510L3107 BLADE GUARD B 1
28 WEYT510L3117 BLADE GUARD A 1
29 WEYT510L0097 ANTI-SPLINTERING PLATE 1
30 WEYT510L1627 MOUNTING PLATE 1
31 WEY4541K2007 SWITCH ASSEMBLY 1
32 WEY4541L2127 CONTROL PCB 1
33 WEY4541L2337 LED ASSEMBLY 1
34 WEYT510L2167 LOCK COVER 1
35 WEYT510L2177 LOCK SPRING 1
36 WEY4541H3247 SWITCH LOCK LEVER 1
37 WEYT510L0167 SPRING 1
38 WEY4541H1557 ORBITAL SELECTOR LEVER 1
39 WEYT510L0337 ORBITAL SHAFT 1
40 WEYT510L0187 SPRING 1
41 WEYT510L6967 STEEL BALL 1
42 WEYT510L0927 PLATE SPRING 1

Model No. : EY4541 Parts List
Safety
Ref.
No. Part No. Part Name & Description Q'ty Remarks
43 WEYT510L0387 ROLLER ASSEMBLY 1
44 WEYT510L0907 NEEDLE PIN 1 (F2*23.8)
45 WEY4541L0917 NEEDLE PIN 2 (F2*6.8)
46 WEYT510L3157 DUST PREVENT PLATE 1
47 WEYT510L1637 FIXING BRACKET 1
48 WEYT510L6337 BASE FIXING SCREW 1 M4*12
49 WEYT510L0607 PIN 2 (2PCS/PK)
50 WEYT510L9447 TIGHT SCREW 11 (M4*18), (5PCS/PK)
51 WEYT510L2157 SIDE CLOSED TERMINAL 2 (2PCS/PK)
52 WEY3571L0967 O-RING 1
53 WEY4541X3107 DUST COVER 1
54 WEYT510L7867 HEX WRENCH 1
55 WEY9L40R2788 BATTERY PACK COVER 1
- WEYT510L8917 GREASE 1
- WEY9638K7018 TOOL CASE 1 <SH>
- WEY4541K8109 OPERATING INSTRUCTIONS 1 <SH>