Panasonic MC-E540 User manual

SPECIFICATIONS MC-E540
Power source AC230-240V
50Hz
Input power (Max) 1700W
Vacuum 18 kPa
Power cord length 6.5 m
Radius of operation 6.5 m
Net weight 7.2 kg
Dimensions (WxLxH) 335x330x1095
Attachments:Dusting brush •
Upholstery nozzle •
Crevice nozzle •
Extension wand •
Specifications are subject to change without notice for further improvement.
MODEL MC-E540
Ref.: Z32J9000
Matsushita Electric España, S.A.
DIVISION DE ASPIRADORAS
Zona Industrial del Polígono de CELRÀ
17460 CELRÀ(Girona) Spain
Vacuum Cleaner

2
TABLE OF CONTENTS PAGE
SPECIFICATIONS ............................................................................... 1
SCHEMATIC DIAGRAM ....................................................................... 2
PICTORIALWIRING DIAGRAM ................................................................. 3
EXPLODED VIEW .............................................................................. 4
SPARE PARTS LIST ........................................................................... 6
REPLACEMENT OF MAIN PARTS ........................................................... 8
TROUBLE SHOOTING GUIDE ............................................................... 14
PACKING INSTRUCTIONS .................................................................... 15
SCHEMATIC DIAGRAM
MC-E540
THERMAL
CUT-OUT
CAPACITOR
REAR COVER SWITCH COMPARTMENT MOTOR COMPARTMENT
MAINS SWITCH
POWER
SUPPLY
M
Yellow
Black
BlackBlack
MAIN FUSE
Blue
Blue
Blue
Brown
Brown

3
PICTORIALWIRING DIAGRAM
MC-E540
POWER
SUPPLY
SWITCH COMPARTMENT
CAPACITOR
ON/OFF
SWITCH
Blue
Black Black
Brown
Brown
Yellow
REAR COVER MOTOR COMPARTMENT
Black
MOTOR
Yellow
Blue
Blue
Brown
PARALLEL WIRE
Blue
Black
THERMAL
CUT-OUT
MAIN FUSE

4
EXPLODED VIEW
29
30
39
41
68
22
43
65
63
64
48
23
31
23
70
42
37
72 51 52
54
71
59
58
60
34
33
27
32
53
46
58
62
55
61
35
40
28
67
30 27 29
49
50
66
24
44
38 42
57
73
58
36
47
56
69
25
26
74

5
EXPLODED VIEW
8
19
1
19
11
3
18
42
5
6
7
17
14
13 10
20 21 16
21
18
76
75
80
81
15
12
79
9
77
78

6
SPARE PARTS LIST
REF. No. DESCRIPTION PART No. Pcs/Set MC-E540 REMARKS
1 FLOOR NOZZLE COVER ASS'Y AMC8A80J90A4 1 •
2 PLASTIC SHAFT AMC8C27M1000 1 •
3 FLOOR NOZZLE BUMPER AMC8A33M1034 1 •
4 FLOOR NOZZLE PEDALASS'Y AMC8A78J9034 1 •
5 TAPPING SCREW XTN4+18B 1 •
6 FRAME ASS'Y AMC8AZ7M1000 1 •
7 TAPPING SCREW XTN4+18B 2 •
8 SUCTION PIPE AMC8H02M1034 1 •
9 BELT (PACK 2/PCS.) AMC8S03G2000 1 •
10 ROTARY FELT A AMC8R42B1000 1 •
11 ROTARY FELT B AMC8R43B1100 1 •
12 BEATER BAR ASS’Y AMC8R98M1064 1 •
13 BEATER BAR AMC8R88M1064 1 •
14 BEARING SUPPORT B AMC8R13G1061 1 •
15 BEARING SUPPORT A AMC8R12G1061 1 •
16 SIDE BRUSH A AMC8R96B7061 1 •
17 SIDE BRUSH AMC8R91G1061 1 •
18 TAPPING SCREW XSN3+16E 2 •
19 SIDE BRUSH PROTECTOR AMC8R45B1134 2 •
20 BASE PLATE ASS'Y AMC8AZ3M1034 1 •
21 TAPPING SCREW XTN4+18B 5 •
22 LOWER BODY AMC8C02M12A4 1 •
23 DUST SEAL AMC8T04M1034 2 •
24 UPHOLSTERY NOZZLE CLIP AMC8AZ1M1034 1 •
25 DUSTING BRUSH CLIP AMC8AZ2M1034 1 •
26 TAPPING SCREW XTN4+18B 1 •
27 WHEEL AMC8R0191034 2 •
28 WHEEL SHAFT AMC8A55M1000 1 •
29 FIXING WASHER XUB7000I 2 •
30 PLAIN WASHER XWG7000J 2 •
31 CENTRAL FILTER AMC8F03M1000 1 •
32 FUSE UNIT AMC8B82J9000 1 •
33 ON/OFF SWITCH AMC8E01B7000 1 •
34 DUST BAG CHECK INDICATOR AMC8I99M1000 1 •
35 CAPACITOR AMC8E15B7000 1 •
36 SWITCH COVER AMC8T37J90A4 1 •
37 SWITCH COVER SEAL AMC8C24B1034 1 •
38 TAPPING SCREW XTN4+18B 2 •
39 POTENTIOMETER BUTTON AMC8E17M1034 1 •
40 BUTTON SUPPLEMENT AMC8E21J9061 1 •
41 MOTOR UNIT SDS-1704MD AMC81SH04MD0 1 •
42 CARBON BRUSH AMC8191C9801 2 •
43 REAR MOTOR SUPPORT AMC8E09B1000 1 •
44 FRONT MOTOR SUPPORT AMC8E0891000 1 •
46 THERMAL CUT-OUT AMC8E14J9000 1 •

7
SPARE PARTS LIST
REF. No. DESCRIPTION PART No. Pcs/Set MC-E540 REMARKS
47 UPPER BODY ASS'Y AMC8C97M10A4 1 •
48 TAPPING SCREW XTN4+18B 4 •
49 REAR FILTER AMC8T09M1000 1 •
50 UPPER BODY SEAL AMC8C09M1034 1 •
51 POWER SUPPLY CORD AMC8EZ1L1061 1 •Applied to UK, IRL
52 POWER SUPPLY CORD AMC8EZ3L1061 1 •Applied to Australia, N. Zealand
53 POWER SUPPLY CORD AMC8E98L1061 1 •Applied to Switzerland
54 POWER SUPPLY CORD AMC8E97L1061 1 •Applied to East European & West
countries, except above
55 CORD COVER AMC8C07W0034 1 •
56 WIRE CONNECTOR AMC8E0671000 5 •
57 REAR COVER AMC8T06M00A4 1 •
58 TAPPING SCREW XTN4+18B 5 •
59 DETACHABLE HOSE AMC8AZ0M1034 1 •
60 SUCTION INLET AMC8T11J9034 1 •
61 TAPPING SCREW XTN4+18B 3 •
62 DUST COVER AMC8T01J90A4 1 •
63 LOCKING AMC8T03M10A4 1 •
64 SPRING AMC8T19A1000 1 •
65 EXHAUST COVER AMC8T07M60A4 1 •
66 EXHAUST COVER SEAL AMC8T34M6000 1 •
67 EXHAUST FILTER AMC8S04J9000 1 •HEPA Type F-5H
68 UPHOLSTERY NOZZLE AMC8A2791134 1 •
69 DUSTING BRUSH AMC8A97G1034 1 •
70 EXTENSION TUBE AMC8A1291034 1 •
71 CREVICE NOZZLE AMC8A1391034 1 •
72 HANDLE UNIT AMC8H99M40A4 1 •
73 UPPER CORD HOOK AMC8H07910A4 1 •
74 HANDLE SCREW AMC8H10B1000 1 •
75 SET COVER AMC8Z05G1100 1 •
76 PAPER BAG /TYPE U-20E AMC8F96W2000 1 •Detachable type (pack of 5/pcs.)
77 CLOTH DUST BAG (RU-USABLE) AMC8F99G0000 - •Optional
78 OPERATING INSTRUCTIONS AMC8Z07J9090 1 •English language
OPERATING INSTRUCTIONS AMC8Z07J9070 1 •German language
79 CARTON BOX AMC8Z01J9000 1 •
80 CUSHION A AMC8Z02M1000 1 •
81 CUSHION B AMC8Z03M1000 1 •
NOTE: Mechanical contruction of this model is similar to current one MC-E568. Differences between them are, MC-E540
without BEATER BAR SELECTOR and POWER CONTROL.

8
REPLACEMENT OF MAIN PARTS
IMPORTANT: Before replacing any part always
DISCONNECT THE CLEANER FROM THE
ELECTRICITY SUPPLY.
NOTE: Before any replacing operation, remove the
hose to avoid damaging. (Fig. 1)
Fig. 2
Screws
Belt
Base plate
12
Top
suction inlet
Fig. 1
•BELT
1. Remove the 5 screws from the base plate and lift it off. (Fig. 2)

9
REPLACEMENT OF MAIN PARTS
Fig. 3
Fig. 4
Motor
Belt
Fig. 5
Frame Screws Pedal
Screw
Cover rib
Screw
2. Release the belt from the motor shaft and lift the beater bar
ass’y to remove the belt. (Fig. 3)
3. Replace the belt with a new one and place it around the motor
shaft and beater bar pulley. Then reinstall the beater bar ass’y
in its holding points. (Fig. 4)
IMPORTANT: Make sure the belt is placed between the screw
and inside cover rib.
4. Replace the base plate and refasten the screws.
•BEATER BAR ASS’Y
1. Remove the beater bar ass’y as explained previously in
paragraph " Replacement of Belt ", points 1-2.
2. Replace the beater bar ass’y with a new one. Before
reinstall the beater bar ass’y into its holding point, place the
belt around the beater bar pulley and motor shaft (see fig.4).
IMPORTANT: Make sure the belt is placed between the
screw and inside cover rib.
3. Replace the base plate and refasten the screws.
•FLOOR NOZZLE PEDAL
1. Remove the base plate as explained previously.
2. Release the belt from the motor shaft.
3. Loosen two screws from the frame and one from the pedal
shaft and take out both parts. (Fig.5 )
Motor
shaft
Beater bar
pulley
Bater bar
ass’y

10
REPLACEMENT OF MAIN PARTS
4. Replace the pedal ass’y with a new one and reinstall it in its
place refastening the screw. (Fig. 6)
5. Reinstall the frame and refasten de two screws, then place
the belt around the motor shaft.
IMPORTANT: Before reinstall the base plate, make sure the
belt is placed correctly between the screw and inside cover
rib, as indicated in Fig. 4.
6. Place the base plate and refasten de screws.
Fig. 6
•MOTOR
1. Remove the base plate as explained previously.
2. Release the belt from the motor shaft. Then remove two
screws from the frame, and release it from the pedal shaft.
3. Insert a flat-head screwdriver between nozzle cover and
plastic shaft and pry out the plastic shaft. (Fig. 7). Then
remove the nozzle cover.
Fig. 7
4. Turn the vacuum cleaner over and loosen 4 screws from the
upper body. (Fig. 8)
Fig. 8
Plastic
shaft
Upper
body
Screws
Motor
Lower
body
Fig. 9
Terminal
5. Take out the motor unit and remove the lead wire (provided
with quick-terminals) from the carbon brush holder
terminals. (Fig. 9)
Pedal
ass’y

11
REPLACEMENT OF MAIN PARTS
6. Remove front and rear motor supports from the motor and
replace it with a new one . (Fig. 10)
7. Reassemble front and rear motor supports in the new motor
and connect the lead wires according to the schematic
diagram.
8. Place the motor in the lower body and reinstall the remaining
parts in the reverse order.
Fig. 10
•THERMAL CUT-OUT
1. Remove upper body as explained previously in paragraph
" Motor replacement ”, points 1- 4.
2. Take out the motor and remove the wire connector from the
thermal cut-out. (Fig. 11)
3. Disconnect the thermal cut-out lead wire from the carbon
brush holder terminal and replace the thermal cut-out with a
new one.
4. Connect the new thermal cut-out according to the schematic
diagram and reinstall the remaining parts in the reverse
order.
•CARBON BRUSHES
Note: Replace both carbon brushes at the sametime.
1. Remove upper body as explained previously in paragraph
" Motor replacement ”, points 1-4.
2. Take out the motor and disconnect the lead wires from the
carbon brush holder terminals.
3. Bend the metal end of the carbon brush holder and take out
the carbon brush. (Fig. 12)
4. Cut off the metal end of the carbon brush holder and replace
the carbon brush with a new one. (Fig. 13)
Fig. 11
Fig. 13
Fig. 12
Front motor support
Motor Rear
motor
support
Metal end Cut-off
metal end
5. Insert the new carbon brush into the brush holder and push
it until the protruded pins of the brush holder fix into the
holes of the metal end. (Fig. 14)
6. Connect the lead wires according to the schematic diagram
and reinstall the remaining parts in the reverse order.
Fig. 14
Fix into
the holes
Carbon brush
Thermal cut-out
Wire connector

12
REPLACEMENT OF MAIN PARTS
Fig. 16
2. Remove the cord cover and power supply cord connections.
(Fig. 16)
3. Replace power supply cord with a new one. Place the power
supply cord around the cord cover and connect according to
the schematic diagram.
4. Replace the rear cover and refasten the screws.
Cord cover
Power supply cord
connections
Fig. 15
•POWER SUPPLY CORD
1. Loosen the 5 screws from the rear cover and take it out.
(Fig. 15) Rear cover
Power supply
cord

13
REPLACEMENT OF MAIN PARTS
Fig. 17
Fig. 18
Fig. 19
2. Remove the two lead wires (provided with quick-terminal)
from the switch terminals and replace the ON/OFF switch
with a new one. (Fig. 18)
3. Place the new ON/OFF switch into place and connect the
lead wires according to the schematic diagram. Then
reinstall the remaining parts in the reverse order.
Switch cover
ON/OFF
Switch
4. Connect the main fuse according to the schematic diagram and
reinstall it.
Note: Observe the correct position of the main fuse before
reinstalling. (Fig.20)
5. Reassemble the switch cover and refasten the screws.
Fig. 20
Switch
terminal
Main
fuse
•ON/OFF SWITCH
1. Loosen the 2 screws of the switch cover and remove it. (Fig. 17)
•MAIN FUSE
1. Remove the switch cover as explained previously in paragraph
"ON/OFF Switch Replacement", point 1.
2. Take out ON/OFF switch from its housing and remove the black
lead wire from the switch tab.
3. Remove the main fuse connection and replace the fuse with a
new one. (Fig.19)

14
CONDITION CHECKPOINT METHOD OF INSPECTION CAUSE / REMEDY
TROUBLE SHOOTING GUIDE
Motor fails to
rotate.
(no noise is
heard at all)
Motor runs but
there is no
suction.
Noise or
vibration.
Beater bar does
not rotate.
Power supply cord
Fuse (Plug for
UK only)
Motor continuity
Carbon brushes
ON/OFF Switch
Thermal cut-out
Main fuse
Hose or suction pipe
Dust bag / Central
filter
Dust in motor fan
Carbon brushes
Beater bar ass’y
(bearing support A-B)
Beater bar ass’y
(bearings)
Belt
Check power supply cord continuity.
Check fuse continuity.
Check motor continuity.
Check if there is gap between the
carbon brush and conmutator.
Check the contact between carbon
brush and conmutator.
Check continuity across switch
terminals.
Check thermal cut-out continuity.
Note: Continuity should be checked 1
hour after removing the plug from the
mains socket.
Check main fuse continuity.
Check if there is any blockage in the
hose or suction pipe.
Check if dust bag is full or dust
accumulated in the central filter.
Check dust accumulated in motor fan.
(It could happen if the vacuum cleaner
has been used with a broken dust bag
or without central filter).
Check uneven wear of carbon brushes.
Remove beater bar ass’y and check
if bearing support A or B is broken or
deformed.
Place the beater bar ass’y on a flat
surface and turn the beater bar to check
bearing noise or clearance.
Remove the base plate and check if the
belt is broken or loose.
If there is no continuity, replace it.
If there is no continuity, replace it.
If there is no continuity, replace it.
If there is gap between carbon brush
and conmutator, replace both carbon
brushes.
If the contact is not correct, replace
the motor.
If there is no contact, replace it.
If there is no continuity, replace it.
If there is no continuity, replace it.
If there is any blockage, remove it.
If paper bag is choked up, replace it.
If central filter is completely dirt, clean
or replace it.
If there is dust accumulated in the
motor fan, replace the motor and
check the filter condition. (Never tray
to dismantle the motor fan).
If there is uneven wear, replace both
carbon brushes.
If bearing support is defective, replace it.
If there is noise or clearance, replace
the beater bar ass’y.
If the belt is broken, replace it.
If it is loose, reinstall it.
NOTE: Place the belt between the
screw and inside cover rib.

15
PACKING INSTRUCTIONS
12
34