Panasonic Ey3544 Operating Instructions Manual

							Cordless Reciprocating Saw
Operating Instructions
Model No: EY3544
IMPORTANT
This manual contains safety information. Read manual completely before first using 
this product and save this manual for future use. 
						

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. GENERAL SAFE-
TY RULES - FOR 
ALL BATTERY 
OPERATED TOOLS
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS.
 Failure to follow all instructions listed below,  may  result  in  electric  shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
Work Area
 1) Keep your work area clean and well lit. Cluttered  benches  and  dark  areas invite accidents.
 2) D o   n o t   o p e r a t e   p o w e r   t o o l s   i n  explosive  atmospheres,  such  as in  the  presence  of  flammable  liq-uids, gases, or dust.  Power tools create sparks which may ignite the dust or fumes.
 3) Keep bystanders, children, and vis-itors  away  while  operating  a  power tool. Distractions  can  cause  you  to  lose control.  Make  sure  that  no  one  is beneath,  or  on  the  other  side  of  the area when you are working.
Electrical Safety
 4) A  battery  operated  tool  with  integral batteries  or  a  separate  battery  pack must  be  recharged  only  with  the specified charger for the battery.  A  charger  that  may  be  suitable  for  one type  of  battery  may  create  a  risk  of  fire when used with another battery.
 5) U s e   b a t t e r y   o p e r a t e d   t o o l   o n l y  with  specifically  designated  bat-tery pack.  Use  of  any  other  batteries  may  cre-ate a risk of fire.
Personal Safety
 6) S t a y   a l e r t ,   w a t c h   w h a t   y o u   a r e  d o i n g ,   a n d   u s e   c o m m o n   s e n s e  when  operating  a  power  tool.  Do not  use  tool  while  tired  or  under 
the  influence  of  drugs,  alcohol,  or medication. A  moment  of  inattention  while  operat-ing  power  tools  may  result  in  serious personal injury.
 7) Dress  properly.  Do  not  wear  loose clothing or jewelry. Contain long hair.  K e e p   y o u r   h a i r,   c l o t h i n g ,   a n d  gloves away from moving parts. Loose  clothes,  jewelry,  or  long  hair can be caught in moving parts.
 8) Avoid  accidental  starting.  Be  sure switch  is  in  the  locked  or  off  posi-tion before inserting battery pack.  Carrying  tools  with  your  finger  on  the switch  or  inserting  the  battery  pack into  a  tool  with  the  switch  on  invites accidents.
 9) Remove  adjusting  keys  or  wrenches before turning the tool on. A wrench or a key that is left attached t o   a   r o t a t i n g   p a r t   o f   t h e   t o o l   m a y  result in personal injury.
 10) D o   n o t   o v e r r e a c h .   K e e p   p r o p e r  footing and balance at all times. Proper  footing  and  balance  enable better  control  of  the  tool  in  unexpect-ed situations.
 11) Use safety equipment. Always wear eye protection.  Dust  mask,  non-skid  safety  shoes, hard  hat,  or  hearing  protection  must be used for appropriate conditions.
Tool use and care
 12) Use  clamps  or  other  practical  way to  secure  and  support  the  work-piece to a stable platform.  Holding  the  work  by  hand  or  against your  body  is  unstable  and  may  lead to loss of control.
 13) Do  not  force  tool.  Use  the  correct tool for your application.  The  correct  tool  will  do  the  job  better and  safer  at  the  rate  for  which  it  is designed.
 14) Do  not  use  tool  if  switch  does  not turn it on or off. A  tool  that  cannot  be  controlled  with the  switch  is  dangerous  and  must  be repaired.
 15) Disconnect  battery  pack  from  tool  or place  the  switch  in  the  locked  or  off position  before  making  any  adjust-ments,  changing  accessories,  or  stor- 
						

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ing the tool. S u c h   p r e v e n t i v e   s a f e t y   m e a s u r e s  reduce  the  risk  of  starting  the  tool accidentally.
 16) Store  idle  tools  out  of  reach  of  chil-dren and other untrained persons.  Tools  are  dangerous  in  the  hands  of untrained users.
 17) When  battery  pack  is  not  in  use, k e e p   i t   a w a y   f r o m   o t h e r   m e t a l  objects like: paper clips, coins, keys, nails,  screws,  or  other  small  metal objects  that  can  make  a  connection from one terminal to another. Shorting  the  battery  terminals  togeth-er may cause sparks, burns or a fire.
 18) Maintain  tools  with  care.  Keep  cut-ting tools sharp and clean. Properly  maintained  tools  with  sharp cutting  edge  are  less  likely  to  bind and are easier to control.
 19) Check  for  misalignment  or  binding  of moving  parts,  breakage  of  parts,  and any  other  condition  that  may  affect the  tool’s  operations.  If  damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.
 20) Use only accessories that are recom-mended  by  the  manufacturer  for your model. Accessories  that  may  be  suitable  for one  tool  may  create  a  risk  of  injury when used on another tool.
Service
 21) Tool  service  must  be  performed only by qualified repair personnel. Service or maintenance performed by unqualified  personnel  may  result  in  a risk of injury. 
 22) When  servicing  a  tool,  use  only identical  replacement  parts.  Follow instructions  in  the  Maintenance section of this manual.  Use  of  unauthorized  parts  or  failure to  follow  Maintenance  Instructions may create a risk of shock or injury. 
. SPECIFIC SAFETY 
RULES
   DO  NOT  let  comfort  or  familiarity with  product  (gained  from  repeated use)  replace  strict  adherence  to cordless  reciprocating  saw  safety rules.   If you use this tool unsafely or incor-rectly,  you  can  suffer  serious  per-sonal injury.
 1) Before each use, it is a good practice to  always  inspect  this  tool  for  physi-cal damage. If the tool has been dam-aged  or  does  not  operate  properly, do not use. Have it serviced immedi-ately by a qualified seviceman.
 2) When  installing  the  battery  pack, make  sure  that  it  snaps  in  place  and is mounted to the tool firmly. Replace the  battery  pack  if  it  cannot  be  held in place securely.
 3) Hold tool by insulated gripping sur-faces  when  performing  an  opera-tion  where  the  cutting  tool  may contact hidden wiring. Contact  with  a  "live"  wire  will  make exposed  metal  parts  of  the  tool  “live” and shock the operator.
 4) Be  aware  that  this  tool  is  always  in an  operating  condition, it  does  not have  to  be  plugged  into  an  electrical outlet.
 5) A l w a y s   u s e   s a f e t y   g o g g l e s   o r  glasses with side shields.  Ordinary eye or sun glasses are NOT safety glasses.
 6) Avoid  cutting  nails.  Inspect  work-piece for any nails and remove them before operation.
 7) Do not cut oversized workpiece.
 8) C h e c k   f o r   t h e   p r o p e r   c l e a r a n c e  beyond the workpiece before cutting so  that  the  blade  will  not  strike  the floor, workbench, etc.
 9) Hold the tool firmly.
 10) Make  sure  the  blade  is  not  contact-ing the workpiece before the switch is turned on.
 11) K e e p   h a n d s   a w a y   f r o m   m o v i n g  parts.
 12) Always  switch  off  and  wait  for  the blade  to  come  to  a  complete  stop  
						

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before removing the blade from the workpiece.
 13) Do  not  touch  the  blade  or  work-piece  immediately  after  operation; t h e y   m a y   b e   e x t r e m e l y   h o t   a n d  could burn your skin.
 14) Some  material  contains  chemicals which  may  be  toxic.  Take  caution to  prevent  working  dust  inhalation and  skin  contact.  Follow  material supplier safety data.
 15) When  working  on  a  ladder  or  on scaffolding  be  sure  to  lay  the  tool down on its side when not in use.   Some  tools  with  large  battery  packs will  stand  upright  but  may  be  easily knocked over.
Symbol meaning
VVolts
Direct Current
n0no load speed
…/minrevolutions orreciprocations per minute
WARNING:
Some  dust  created  by  power  sand-ing,  sawing,  grinding,  drilling,  and o t h e r   c o n s t r u c t i o n   a c t i v i t i e s   c o n-tains  chemicals  known  to  the  State of  California  to  cause  cancer,  birth defects  or  other  reproductive  harm. Some  examples  of  these  chemicals are: Lead from lead-based paints Crystalline  silica  from  bricks  and cement  and  other  masonry  prod-ucts Arsenic and chromium from chemi-cally-treated lumber.To  reduce  your  exposure  to  these chemicals:  work  in  a  well  ventilated area, and work with approved safety equipment,  such  as  dust  masks  that are  specially  designed  to  filter  out microscopic particles.
. FOR
 BATTERY  CHARGER 
& BATTERY PACK
IMPORTANT  SAFETY 
INSTRUCTIONS
 1) SAVE THESE INSTRUC-
TIONS    -This manual contains impor-
tant safety  and  operating  instructions for battery charger EY0110.
 2) Before  using  battery  charger,  read  all instructions  and  cautionary  markings on (1) battery charger, (2) battery pack.
 3) CAUTION -To reduce the risk
of injury, charge only Battery Pack as shown below.  EY9065, EY9066, EY9168, EY9080, EY9086, EY9180, EY9182, EY9001,
EY9006, EY9101, EY9106, EY9200, EY9201, EY9136, EY9230, EY9231EY9251, EY9117, EY9210 Other  types  of  batteries  may  burst causing personal injury and damage. 
 4) Do  not  expose  charger  to  rain  or snow.
 5) To reduce risk of damaging the electric plug and cord, pull by plug rather than cord when disconnecting charger.
 6) Make  sure  cord  is  located  so  that  it will  not  be  stepped  on,  tripped  over, or  otherwise  subjected  to  damage  or stress.
 7) An extension cord should not be used unless absolutely necessary. Use of improper extension cord could result  in  a  risk  of  fire  and  electric shock.  If  extension  cord  must  be used, make sure that: a. pins  on  plug  of  extension  cord are  the  same  number,  size  and shape  as  those  of  plug  on  char-ger.b. e x t e n s i o n   c o r d   i s   p r o p e r l y  w i r e d   a n d   i n   g o o d   e l e c t r i c a l  condition.c. extension  cord  has  a  minimum wire size of 16 AWG. 
						

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 8) Do  not  operate  charger  with  dam-aged  cord  or  plug   have  qualified serviceman replace them immediately.
 9) Do  not  operate  charger  if  it  has  re-ceived a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman. 
 10) Do not disassemble charger; take it to a  qualified  serviceman  when  service or  repair  is  required.  Incorrect  reas-sembly  may  result  in  a  risk  of  electric shock or fire.
 11) To  reduce  the  risk  of  electric  shock, unplug  charger  from  outlet  before  at-tempting  any  maintenance  or  clean-ing.
 12) The  charger  and  battery  pack  are specifically  designed  to  work  together. Do  not  attempt  to  charge  any  other cordless  tool  or  battery  pack  with  this charger.
 13) Do  not  attempt  to  charge  the  battery pack with any other charger.
 14) Do  not  attempt  to  disassemble  the battery pack housing.
 15) Do  not  store  the  tool  and  battery  pack in  locations  where  the  temperature may  reach  or  exceed  50°C  (122°F)( s u c h   a   m e t a l   t o o l   s h e d ,   o r   a   c a r  in  the  summer),  which  can  lead  to deterioration of the storage battery.
 16) Do  not  charge  battery  pack  when  the temperature  is  BELOW  0°C  (32°F) or  ABOVE  40°C  (104°F). This  is  very important  in  order  to  maintain  optimal condition of the battery pack.
 17) Do  not  incinerate  the  battery  pack.  It can explode in a fire.
 18) Avoid  dangerous  environment.  Do  not use charger in damp or wet locations.
 19) The charger is designed to operate on standard  household  electrical  power only.  Do  not  attempt  to  use  it  on  any other voltage!
 20) Do  not  abuse  cord.  Never  carry  charger by  cord  or  yank  it  to  disconnect  from outlet.  Keep  cord  away  from  heat,  oil 
and sharp edges.
 21) Charge the battery pack in a well ven-tilated place, do not cover the charger and  battery  pack  with  a  cloth,  etc., 
while charging.
 22) U s e   o f   a n   a t t a c h m e n t   n o t   r e c o m-mended  may  result  in  a  risk  of  fire, electric shock, or injury to persons.
 23) Do not short the battery pack. A battery 
short  can  cause  a  large  current  flow, over heating and  create  the  risk  of  fire or personal injury.
 24) NOTE:  If  the  supply  cord  of  this  ap-pliance  is  damaged,  it  must  only  be replaced  by  a  repair  shop  authorized  by  the  manufacturer,  because  special purpose tools are required.
 25) TO  REDUCE  THE  RISK  OF  ELEC-T R I C   S H O C K ,   T H I S   A P P L I A N C E  H A S   A  P O L A R I Z E D   P L U G   ( O N E  B L A D E   I S   W I D E R   T H A N   T H E  OTHER). This  plug  will  fit  in  a  polarized  outlet only  one  way.  If  the  plug  does  not  fit fully  in  the  outlet,  reverse  the  plug.  If it  still  does  not  fit,  contact  a  qualified electrician  to  install  the  proper  outlet. Do not change the plug in any way. 
						

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. FUNCTIONAL DESCRIPTION
(F)
(C)
(B)
(D)(E)
(A)
(I)
(G)
(J)
(H)(K)
(A)Battery pack (EY9251)(G)Blade clamp
(B)Trigger switch(H)Slider
(C)Switch lock lever(I)Battery charger (EY0110)
(D)Shoe(J)Saw blade
(E)Shoe lock lever(K)Blade clamp sleeve
(F)Insulated rubber boot 
						

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.  ASSEMBLY
WARNING:To  reduce  the  risk  of  injury,  always remove  battery  pack  before  chang-ing the blade.
Selecting a blade
The  blade  clamp  sleeve  can  be  used with  all  1/2"  shank  universal  reciprocat-ing saw blade. When selecting a blade, choose the right type and length.
C h o o s e   a   l e n g t h   l o n g   e n o u g h   t o  extend  beyond  the  shoe  and  your work throughout the stroke. Do not use blades  less  than 3-9/16"  (90  mm) long since  they  will  not  extend  beyond  the shoe throughout the stroke.
Installing or removing the 
saw blade
CAUTION:Always  clean  out  all  chips  or  foreign material adhering to the blade, blade clamp  and/or  slider  before  use. Failure  to  do  so  may  cause  insuf-ficient  tightening  of  the  blade,  result-ing in a serious injury.
Depending  on  the  job,  the  blade  may be  inserted  with  the  teeth  facing  up  or down.  To  install  the  saw  blade,  always make  sure  that  the  blade  clamp  sleeve is  in  open  position  before  inserting  the saw  blade.  If  the  blade  clamp  sleeve  is in  the  close  position,  rotate  the  sleeve to the open position until it clicks.
Blade clamp sleeve
Open positionClose position
Insert  the  saw  blade  into  the  blade clamp  until  the  saw  blade  snaps  in place and clamp sleeve rotates.
When  the  blade  clamp  sleeve  rotates,  
the  saw  blade  is  fixed.  Make  sure  that the saw blade is firmly fixed and locked. If the blade clamp does not lock proper-ly,  have  the  tool  serviced  by  a  qualified repair personnel.
Blade
WARNING:If you do not insert the saw blade deep enough,  the  saw  blade  may  be  eject-ed  unexpectedly  during  operation. This can be extremely dangerous.
To  remove  the  saw  blade,  rotate  the blade  clamp  sleeve  in  the  direction of  the  arrow  (clockwise  from  the  front view)  fully.  The  saw  blade  is  removed and  the  blade  clamp  sleeve  is  fixed  at the open position. Be careful when han-dling hot blades after use.
Blade clamp sleeve
NOTE:If you remove the saw blade without rotating the blade clamp sleeve fully, the  sleeve  may  not  be  fixed.  In  this case,  rotate  the  blade  clamp  sleeve fully,  then  make  the  sleeve  fixed  at the open position.
Blade Clamp Maintenance
Always  keep  blade  clamp  sleeve  clean and dry after use.Periodically lubricate blade clamp sleeve with  a  dry  lubricant.  Using  wet  lubricant may  keep  the  dust  and  debris,  and causes malfunction of the blade clamp. 
						

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. OPERATION
Hold  tool  by  the  insulated  gripping surfaces  when  performing  an  oper-ation  where  the  cutting  tool  may contact hidden wiring.
A l w a y s   w e a r   s a f e t y   g o g g l e s   o r  glasses with side shields.
Adjusting shoe
When  the  blade  loses  its  cutting  effi-ciency  in  one  place  along  its  cutting edge,  reposition  the  shoe  to  utilize  a sharp,  unused  portion  of  its  cutting edge. This will help to lengthen the life of  the  blade.  To  reposition  the  shoe, loosen  the  shoe  lock  lever  counter-clockwise  and  slide  the  shoe  forward or  back  to  the  desired  position.  Then tighten  the  lever  clockwise  to  firmly secure the shoe.
Shoe lock lever
Shoe
Switch action
CAUTION:Before inserting the battery pack into the tool, always check to see that the trigger  switch  actuates  properly  and returns  to  the  “OFF”  position  when released.
Switch lock lever
Trigger switch
To  prevent  the  trigger  switch  from being  accidentally  pulled,  a  lock-off button  switch  lock  lever  is  provided. 
Always make sure the switch is locked when  carrying  or  storing  the  tool  to eliminate unintentional starting.
To start the motor, press the switch lock lever, then squeeze the trigger switch.
WARNING:
To  reduce  the  risk  of  injury,  keep h a n d s   a w a y   f r o m   t h e   b l a d e   a n d  other moving parts.
Starting and Stopping
To  start  the  tool,  grasp  the  handle firmly.  Press  the  switch  lock  lever, which  can  be  pressed  in  from  either left or right side of the tool.Then pull the trigger switch.
To  stop  the  tool,  release  the  trigger. Allow  the  tool  to  come  to  a  complete stop  before  removing  the  blade  from  a partial cut or before laying the tool down.
Controlling speed by Trig-
ger Switch
The  reciprocating  saw  is  equipped with  a  trigger  speed  control  switch. I t   m a y   b e   o p e r a t e d   a t   a n y   s p e e d  from  zero  stroke  per  minute  to  full speed.  Always  start  tool  before  blade contacts  the  workpiece.  To  vary  the speed,  simply  increase  or  decrease the pressure on the trigger. The further the  trigger  is  pulled,  the  greater  the speed.
Cutting materials
Before  the  blade  contacts  the  work-piece,  grasp  the  handle  firmly  and pull  the  trigger.  Begin  cutting  at  slow speed,  gradually  increasing  speed  as you  cut.  When  cutting  into  materials or  hard  materials  that  can  not  be  cut from an edge, drill a starting hole larg-er than the widest part of the blade.
CAUTION:•  A l w a y s   p r e s s   t h e   s h o e   f i r m l y  against the workpiece during oper-ation. If the shoe is held away from the  workpiece  during  operation, strong  vibration  and/or  twisting  will be  produced,  causing  the  blade  to 
snap dangerously.
•  Always wear gloves to protect your hands  from  flying  hot  chips  when  
						

							- 8 - - 9 -  
cutting metal.
•  Always use a suitable coolant (cut-ting  oil)  when  cutting  metal.  Fail-ure  to  do  so  will  cause  premature blade wear.
•  If  the  tool  is  operated  continuously u n t i l   t h e   b a t t e r y   p a c k   h a s   d i s-charged,  allow  the  tool  to  rest  for 15  minutes  before  proceeding  with a fresh battery pack.
P r e s s   t h e   s h o e   f i r m l y   a g a i n s t   t h e  workpiece.  Do  not  allow  the  tool  to bounce. Bring the blade into light con-tact  with  the  workpiece.  First,  make a  pilot  groove,  using  a  slower  speed. Then  use  a  faster  speed  to  continue cutting.
F o r   A p p ro p r i a t e   u s e   o f  
Battery pack
Ni-MH Battery pack (EY9251)
  Charge  the  Ni-MH  battery  fully  before storage in order to ensure a longer ser-vice life.
  The  ambient  temperature  range  is  be-tween 0°C (32°F) and 40°C (104°F).   If  the  battery  pack  is  used  when  the b a t t e r y   t e m p e r a t u r e   i s   b e l o w   0 ° C  (32°F),  the  tool  may  fail  to  function properly.  In that case, charge the bat-tery until charging is completed for ap-propriate functioning of the battery.
  When  battery  pack  is  not  in  use,  keep it  away  from  other  metal  objects  like: paper  clips,  coins,  keys,  nails,  screws, or  other  small  metal  objects  that  can make a connection from one terminal to another.   Shorting  the  battery  terminals  together may cause sparks, burns or a fire.
  When  operating  with  a  Ni-MH  battery pack,  make  sure  the  place  is  well-ventilated.
Battery Pack Life
The  rechargeable  batteries  have  a limited  life.    If  operation  time  becomes e x t r e m e l y   s h o r t   a f t e r   r e c h a r g i n g ,  replace the battery pack with a new one.
NOTE:Use  under  extremely  hot  or  cold conditions  will  reduce  operating capacity per charge.
Charging
NOTE: When you charge the battery pack for the  first  time,  or  after  prolonged  stor-age,  charge  it  for  about  24  hours  to bring the batteries up to full capacity.
Battery charger (EY0110)
 1. Plug the charger into the AC outlet.
NOTE:
Sparks may be produced when the 
plug  is  inserted  into  the  AC  power 
supply,  but  this  is  not  a  problem  in 
terms of safety.
 2. Insert  the  battery  pack  firmly  into  the 
charger.
Battery pack
To AC 
outlet
Battery charger
 3. During  charging,  the  charging  lamp 
will be lit.
    When charging is completed, an inter
-
nal  electronic  switch  will  automatically 
be triggered to prevent overcharging.
  Charging  will  not  start  if  the  battery 
pack  is  warm  (for  example,  immedi-
ately after heavy-duty operation).
  The  orange  standby  lamp  will  be  lit 
until the battery cools down.  Charging 
will then begin automatically.
 4.  W h e n   c h a r g i n g   i s   c o m p l e t e d ,   t h e  
c h a r g i n g   l a m p   w i l l   s t a r t   f l a s h i n g   
						

							- 10 - - 11 -  
. LAMP INDICATIONS
Red Flashing
Red Lit
Green Flashing quickly
Orange Lit
Orange Flashing
Charger is plugged into the AC outlet. Ready to charge.
Now charging
Charging is completed.
Battery pack is warm. Charging will beginwhen temperature of battery pack drops.
Charging is not possible. Clogged with dust or malfunction of the battery pack.
. MAINTENANCE
CAUTION: Always  be  sure  that  the  tool  is  switched  off  and  the  battery  pack  is removed before attempting to perform inspection or maintenance.
Keep  your  Reciprocating  saw  clean  for  good  cutting  performance  and  to  help  keep  it safe to use.Wipe the reciprocating saw with a dry, soft cloth. Do not use a wet cloth or cleaning liq-uids. They could damage the reciprocating saw’s finish.Be sure to rub off any oil or grease which could make the tool slippery or hard to handle.
BATTERY RECYCLING
ATTENTION:
FOR Ni-MH Battery Pack, EY9251A  nickel  metal  hydride  battery  that  is  recyclable  powers  the  product  you  have  pur-
chased.
quickly in green color.
 5. When in any of the conditions that bat-tery  pack  is  too  cool,  or  the  battery pack  has  not  been  used  for  a  long time, the charging lamp is lit.   In  this  case,  charging  takes  longer  to fully  charge  the  battery  pack,  than  the standard charging time. If  a  fully  charged  battery  pack  is inserted  into  the  charger  again,  the charging  lamp  light  up.  After  several minutes, the charging lamp may flash quickly  to  indicate  the  charging  is completed.
 6. If  the  charging  lamp  does  not  light i m m e d i a t e l y   a f t e r   t h e   c h a r g e r   i s  plugged  in,  or  if  after  the  standard charging  time  the  lamp  does  not  go off, consult an authorized dealer.
NOTE: When  charging  a  cool  battery  pack (below 5°C (41°F)) in a warm place, 
leave  the  battery  pack  at  the  place and  wait  for  more  than  one  hour  to warm  up  the  battery  to  the  level  of the  ambient  temperature.  Other-wise  battery  pack  may  not  be  fully charged.
 C o o l   d o w n   t h e   c h a r g e r   w h e n  charging  more  than  two  battery packs consecutively.
 Do not insert your fingers into con-tact  hole,  when  holding  charger  or any other occasions.
CAUTION:•  Do  not  use  power  source  from  an engine generator.  This  can  damage  the  charger  and present  the  risk  of  fire  or  personal injury.
•  Do  not  cover  vent  holes  on  the charger and the battery pack..