Panasonic Ey4542 Operating Instructions Manual

							
- 11 -  

Installing Blade
Follow these steps:
1. Remove the battery pack from the tool.
.  Remove any cutting debris from blade area.
3.  Use  the  retracting  handle  to  retract  (open) 
the lower guard.
4.  Install the blade as illustrated. (See Fig. )
  Make  sure  that  both  the  direction  arrow  on 
the  blade  and  the  direction  arrow  on  the transparent  guard  point  in  the  same  direc-tion.
.  Set the outer washer in place.
.  Insert the hex bolt.
7.  Hold  the  spindle  lock  button  down.  This  pre-
vents the blade from rotating.
8.  Tighten the hex bolt securely with the provid
-ed hex wrench. Store the hex wrench.
NOTE:Keep  the  hex  wrench  in  the  storage  slot  on the tool’s body when not using it.
WARNINGFailure  to  follow  these  instructions  can  result  in serious personal injury.
Removing Blade
CAUTION:The  blade  will  be  hot  right  after  cutting.  Be  sure to let the blade cool down before removing it.
Follow these steps:
1. Remove the battery pack from the tool.
.  Hold  the  spindle  lock  button  down.  This  pre-
vents the blade from rotating.
3.  Use  the  provided  hex  wrench  to  loosen  the 
hex bolt.
NOTE:Keep  the  hex  wrench  in  the  storage  slot  on the tool’s body when not using it.
4.  Remove the hex bolt and outer washer.
.  Use  the  retracting  handle  to  retract  (open) 
the lower guard.
.  Carefully remove the blade.
7.  Clean the tool if necessary.
CAUTION:Be  careful  to  avoid  cutting  your  hands  on  the blade.
•  When disposing of a blade, secure it inside heavy 
or corrugated paper. This will help prevent anyone from being cut by the discarded blade.
Retracting handle
Hex boltLoosen
Tighten
Outer washer Place the protrusion of the outer washer into the position of the washer.
Lower guard
Inner washer Place the inner washer with cut-out facing you.
Spindle lock button
Fig.   
						

							
- 1 - 

Using the Tool
CAUTION:To  reduce  the  risk  of  injury  read  the  Safety 
In structions  at  the  front  of  this  manual  before 
using the tool.
WARNINGTo  reduce  the  risk  of  injury,  wear  safety  gog-gles  or  glasses  with  side  shields  while  using  the tool. Additionally, wear a dust mask when cutting materials  that  generate  excessive  particulate matter. Do not use tool in the rain. Doing so may result  in  electric  shock  or  cause  the  tool  to  emit smoke.
Do  not  cut  materials  on  which  there  is  any paint  thinner,  gasoline,  oil,  or  similar  build-up. Doing  so  may  cause  the  dust  case  to  crack, resulting in injury.
Follow these steps:Hold  the  tool  with  both  hands.  (See  Fig.  8)  Do not  attempt  to  remove  cut  material  when  blade is moving. 
1.  Line  up  the  sight  line  on  shoe  with  your  cut
-ting line. (See Fig. 7)
Alignment with cutting line
•  Position the notch on the shoe over the cutting line, aligning the top and bottom corners of the diamond-shaped opening with the line.
  As the cutting position may differ depending on 
the blade, do a trial cut beforehand.
Cutting line
Notch
Fig. 7 . 
P r e s s   t h e   s w i t c h   l o c k   l e v e r   d o w n ,   t h e n 
squeeze  the  power  switch  to  start  the  motor, and then release the switch lock lever.
Switch lock lever
Front grip
Handle
Power switch
Fig. 8
CAUTION:
• Check that the switch lock lever works.
  I f   p o w e r   s w i t c h   c a n   b e   a c t i v a t e d   w i t h o u t 
depressing  the  switch  lock  lever,  discontinue use immediately. Take the tool to an authorized service center.
•  Always  hold  the  handle  with  one  hand  and  the 
front grip with the other. (See Fig. 8) Maintain a firm grip and depress the switch fully.
•  The blade should not touch the cutting material 
before  you  start  the  motor.  Wait  until  the  blade reaches full speed before starting a cut.
•  This  tool  has  no  provision  to  lock  the  power 
switch  in  the  “ON”  position,  and  you  must  not attempt to secure it in the “ON” position.
3.  Start  cutting  when  the  blade  reaches  full 
speed.
4.  During cutting, keep your cutting line straight. 
Move  the  tool  forward  at  a  steady  speed, while  looking  at  the  tip  of  the  blade  through the transparent guard.
WARNING• To  prevent  dangerous  kickback,  keep  the shoe  of  the  tool  flat  on  the  surface  of  the material being cut.
•  Never force the tool. Use light and continuous 
pressure.
.  If  the  motor  become  too  warm,  stop  cutting. 
Let the tool cool down before continuing work.
.    It is always a safe practice to remove the bat
-tery pack after use and before storing the tool. 
						

							
- 13 -  

Cutting depth adjustment
• Remove battery pack.
•  Loosen  the  depth  adjustment  nut  and  adjust 
the cutting depth, using the graduations on the lower  guard  to  gauge  the  depth.  Once  finished adjusting  the  depth,  tighten  the  depth  adjust-ment nut securely.
*  When  wood  material  is  10  mm  (3/8")  or  less 
thick,  adjust  the  cutting  depth  so  that  the  blade 
protrudes approx.   mm (3/1 ") from the bottom 
of the material.
Depth adjustment nut
Pull down
Loosen
Tighten
Fig. 9
Rip fence (EY3500B7727)
(Available as an accessory, not included)
  Rip fence is convenient for rip cuts and repeated 
cuts of uniform width.
•  Remove battery pack.
•  Insert  rip  fence  and  adjust  cutting  width.  (See 
Fig. 10)
•  Fasten screw securely to fix rip fence.
Insert andadjust
Fasten screw
Rip fence
Fig. 10
Collecting Dust
WARNING* Before cutting metal materials, always empty  the  dust  case,  open  the  front  cover  and remove the dust.
• 
Use  the  tool  with  the  flammable  materials in the dust case to cut metal materials may result in fire
* When  cutting  metal  materials,  always  use  the tool with the dust case attached.• Flying  sparks  and  metal  chips  may  cause injury.
* Do  not  carry  or  store  the  battery  pack  in the  same  container  as  nails  or  similar  metal objects.
(1)  Collect dust in the dust case.
* Empty the dust case when it is filled up with 
dust.
*  Empty the dust case before storing the tool.
*  Dust case capacity 
• When  cutting  electrical  conduit  with  a 
diameter  of    mm  (1"),  approximately 
130 cuts
•  When  cutting  4  mm  (1-/3")  x  4  mm 
(1-/3") lumber, approximately 10 cuts
NOTE:Some  materials  may  cause  dust  to  become clogged  inside  the  front  cover  when  cutting those materials.
Front cover
Fig. 11
()  Use with vacuum cleaner to collect dust.
* Connect  the  tool  to  the  hose  using  the 
EY9X01 E  vacuum  cleaner  hose  adapter 
(sold separately).
  Compatible  hose  inner  diameter:    mm 
(1") to 38 mm (1-/1")
*  Operate  the  vacuum  cleaner  obeying  its 
instructions. 
						

							
- 14 - 

Fig. 1NOTE:
  When  the  tool  has  difficulty  in  ejecting  or  col-lecting  dust,  the  dust  outlet  may  be  clogged with  dust.  Open  the  front  cover  and  remove any dust.
Control Panel
(1) ()(3)
(1) LED light
LED light
Fig. 13
Before  the  use  of  LED  light,  always  pull  the power switch once. Press  the LED light on button.The light illuminates with very low current, and it does not adversely affect the performance of the tool during use or its battery capacity.
CAUTION:
•  The built-in LED light is designed to illuminate the 
small work area temporarily.
•   Do not use it as a substitute for a regular flashlight, 
since it does not have enough brightness.
•   LED  light  turns  off  when  the  tool  has  not  been 
used for   minutes.
Caution : DO NOT STARE INTO BEAM.
Use  of  controls  or  adjustments  or  performance of  procedures  other  than  those  specified  herein may result in hazardous radiation exposure.
(2)  Overheat warning lamp
The  overheating  protection  feature  halts  tool operation to protect the battery pack in the event of  overheating.  The  overheat  warning  lamp  on the  control  panel  flashes  when  this  feature  is active.
• If  the  overheating  protection  feature  activates, 
allow  the  tool  to  cool  thoroughly  (at  least  30 minutes).  The  tool  is  ready  for  use  when  the overheat warning lamp goes out.
•  Avoid  using  the  tool  in  a  way  that  causes  the 
o v e r h e a t i n g   p r o t e c t i o n   f e a t u r e   t o   a c t i v a t e repeatedly.
(3)  Battery low warning lamp
Excessive  (complete)  discharging  of  lithium  ion batteries  shortens  their  service  life  dra-matically. The  tool  includes  a  battery  protec-tion  feature designed  to  prevent  excessive  discharging  of the battery pack.
• The  battery  protection  feature  activates  imme-diately  before  the  battery  loses  its  charge, causing the battery low warning lamp to flash.
•  If  you  notice  the  battery  low  warning  lamp 
flashing, charge the battery pack immediately.
Off (normal operation)
Flashing: Overheat
Indicates operation has been halted due to battery overheating.
Off(normal operation)
Flashing(No charge)Battery protection feature active 
						

							
- 1 -  

For Proper Use (Further Detail)
WARNINGTo prevent the risk of serious personal injury:l It  is  important  to  use  an  appropriate  device to  hold  the  material  being  cut  properly,  and to  hold  the  tool  firmly  with  both  hands  to prevent  loss  of  control  which  could  cause personal injury.
• 
Figure 14 shows proper cutting position.
• Note that hands are kept away from cutting area.
• Make  sure  bystanders  are  away  from  work area and from underneath of workpiece.
• When  cutting,  do  not  try  to  hold  the  mate-rial with your hand.
Cutting large sheets;Support large sheets. Be sure to set the depth of  the  cut  so  that  you  only  cut  through  the workpiece,  not  through  the  supports.  (See 
Fig. 1)
Large  sheets  sag  or  bend  if  they  are  not  cor-rectly  supported.  If  you  attempt  to  cut  without levelling  and  properly  supporting  the  work-piece,  the  blade  will  tend  to  bind,  causing 
kickback. (See Fig. 1)
• 
Don’t support the material away from the cut.
Cutting thin or corrugated materials;
Cut  thin  and  corrugated  materials  at  least   
mm  (1")  from  the  edge  of  the  workpiece  to avoid  injury  or  damage  to  the  tool  caused  by thin  strips  of  metal  being  pulled  into  the  upper guard.
• 
Use sharp blades only. Clean and sharp blades minimize stalling and kickback.
Fig. 14
Fig. 1
Fig. 1 
						

							
- 1 - 

WARNINGTo prevent the risk of serious personal injury:•  When  making  an  incomplete  cut  or  cutting  is  interrupted,  or  blade  is  binding  or  tool  is  stalling; release  the  power  switch  immediately  and  hold  the  tool  motionless  in  the  material  until  the  blade comes to a complete stop.•  To  avoid  kickback,  never  attempt  to  remove  the  tool  from  the  work  or  pull  the  tool  backward  while the  blade  is  in  motion.  Make  sure  the  blade  has  come  to  a  complete  stop,  then  remove  tool  from cut.•  To resume cutting, start tool, allow the blade to reach full speed, reenter the cut slowly and resume cutting.
1.  Place  the  wider  part  of  the  shoe  on  the  part  of  the  work  piece  which  is  solidly  supported  (See  Fig. 
17), never on the section that will fall off when the cut is made. (See Fig. 18)
  Hold the tool firmly to prevent loss of control. Working carelessly can cause severe personal injury.
. Make sure the blade stops.
  Even though your tool has a brake, before setting the tool down, make sure the blade has come to 
a complete stop and the lower guard has closed.
3.  Do not use if anything seem unusual. Remove battery pack immediately.
  If  the  tool  body  becomes  very  hot,  or  does  not  work  properly,  remove  the  battery  pack  and  do  not 
use. Have it checked by an authorized service center.
WARNINGTo  prevent  the  risk  of  serious  personal  injury  or  fire,  do  not  try  to  repair  the  tool  by  yourself.  Never disassemble or modify the tool body. There are no user-repairable parts inside.
4.  NEVER ALLOW THE TOOL TO COME IN CONTACT WITH YOUR BODY.
  After completing a cut, do not allow the tool to brush against your leg \
or side. 
  Since  the  lower  guard  is  retractable,  it  could  catch  on  your  clothing  and  expose  the  blade.  Keep 
clothing  away  from  tool.  Be  aware  of  the  exposed  blade  sections  that  exist  in  both  the  upper  and lower guard areas.
WARNINGBecause cutting metal creates sparks;•  Always use safety goggles.•  Do  not  use  tool  near  any  flammable  substance  or  in  an  area  where  flammable  substances  are used. Fire and burn injury could result.
.  Never engage the spindle lock while blade is running, or engage in an effort to stop the tool. Never 
turn the switch on when the spindle lock is engaged. Serious damage to y\
our tool will result. 
						

							
- 17 -  

[Battery Pack]
For Appropriate Use of Bat-
tery Pack
Li-ion Battery Pack (EY9L40)
• For optimum battery life, store the Li-ion bat-tery pack following use without charging it.
• When  charging  the  battery  pack,  confirm that  the  terminals  on  the  battery  charger are  free  of  foreign  substances  such  as  dust and  water  etc.  Clean  the  terminals  before charging  the  battery  pack  if  any  foreign  sub-stances are found on the terminals.  The  life  of  the  battery  pack  terminals  may  be affected  by  foreign  substances  such  as  dust and water etc. during operation.
• 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  the  battery  pack,  make  sure the work place is well ventilated.
• When  the  battery  pack  is  removed  from  the main  body  of  the  tool,  replace  the  battery pack  cover  immediately  in  order  to  prevent dust or dirt from contaminating the battery ter-minals and causing a short circuit.
Battery Pack Life
The  rechargeable  batteries  have  a  limited  life.  If the operation time becomes extremely short after recharging,  replace  the  battery  pack  with  a  new one.
Battery Recycling
ATTENTION:
FOR Li-ion Battery Pack, EY9L40A  Li-ion  battery  that  is  recyclable  powers  the product  you  have  purchased.  Please  call 1-800-8-BATTERY  for  information  on  how  to  recycle this battery.
[Battery Charger]
Charging
Cautions for the Li-ion Battery 
Pack
• If  the  temperature  of  the  battery  pack  falls approximately  below  −10°C  (14°F),  charging will  automatically  stop  to  prevent  degradation of the battery.
Common  Cautions  for  the  Li-
ion/Ni-MH/Ni-Cd Battery Pack
• The  ambient  temperature  range  is  between 0°C (3°F) and 40°C (104°F).  If  the  battery  pack  is  used  when  the  battery temperature  is  below  0°C  (3°F),  the  tool may fail to function properly. 
•  When  charging  a  cool  battery  pack  (below 0°C  (3°F))  in  a  warm  place,  leave  the  bat-tery pack at the place and wait for more than one  hour  to  warm  up  the  battery  to  the  level of the ambient temperature.
• Cool down the charger when charging more than two battery packs consecutively.
• Do  not  insert  your  fingers  into  contact  hole, when holding charger or any other occasions.
CAUTION:To  prevent  the  risk  of  fire  or  damage  to  the  bat-tery charger.
•  Do  not  use  power  source  from  an  engine  gen-erator.
•  Do not cover vent holes on the charger and the battery pack.
•  Unplug the charger when not in use. 
						

							
- 18 - 

Li-ion Battery Pack
NOTE:Your  battery  pack  is  not  fully  charged  at  the time  of  purchase.  Be  sure  to  charge  the  battery before use.
Battery charger (EY0L80)
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.
. 
Insert the battery pack firmly into the charger.
1   Line  up  the  alignment  marks  and  place  the 
battery onto the dock on the charger.
  Slide forward in the direction of the arrow.
 
Alignment marks
3. During charging, the charging lamp will be lit.When  charging  is  completed,  an  internal electronic  switch  will  automatically  be  trig-gered to prevent overcharging.
•  Charging  will  not  start  if  the  battery  pack 
is  warm  (for  example,  immediately  after heavy-duty operation).
  The  orange  standby  lamp  will  be  flashing 
until the battery cools down.
  Charging will then begin automatically.
4. 
The  charge  lamp  (green)  will  flash  slowly o n c e   t h e   b a t t e r y   i s   a p p r o x i m a t e l y   8 0 % charged.
.  When  charging  is  completed,  the  charging 
lamp will start flashing quickly in green color.
.  If the temperature of the battery pack is 0°C or 
less, charging takes longer to fully charge the battery pack than the standard charging time.
  Even  when  the  battery  is  fully  charged,  it  will 
have  approximately  0%  of  the  power  of  a 
fully charged battery at normal operating tem-perature.
7.  If  the  power  lamp  does  not  light  immediate
-ly  after  the  charger  is  plugged  in,  or  if  after the  standard  charging  time  the  charging  lamp does  not  flash  quickly  in  green,  consult  an authorized dealer.
8.  If a fully charged battery pack is inserted into 
the  charger  again,  the  charging  lamp  lights up. After  several  minutes,  the  charging  lamp 
may  flash  quickly  to  indicate  the  charging  is completed.
Ni-MH/Ni-Cd Battery Pack
NOTE:When  you  charge  the  battery  pack  for  the  first time,  or  after  prolonged  storage,  charge  it  for 
about  4  hours  to  bring  the  battery  up  to  full 
capacity.
Battery charger (EY0L80)
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.
. 
Insert the battery pack firmly into the charger.
3. During charging, the charging lamp will be lit.When  charging  is  completed,  an  internal electronic  switch  will  automatically  be  trig-gered to prevent overcharging. •  Charging  will  not  start  if  the  battery  pack 
is  warm  (for  example,  immediately  after heavy-duty operation).
  The  orange  standby  lamp  will  be  flashing 
until  the  battery  cools  down.  Charging  will then begin automatically.
4. 
When  charging  is  completed,  the  charging lamp will start flashing quickly in green color.
. If  the  charging  lamp  does  not  light  immediate-ly  after  the  charger  is  plugged  in,  or  if  after  the standard charging time the charging lamp does not flash quickly in green, consult an authorized dealer.
.  If a fully charged battery pack is inserted into the  charger  again,  the  charging  lamp  lights up. After  several  minutes,  the  charging  lamp may  flash  quickly  to  indicate  the  charging  is completed. 
						

							
- 19 -  

Lamp Indications
Green LitCharger is plugged into the AC outlet.Ready to charge.
Green Flashing QuicklyCharging is completed. (Full charge.)
Green FlashingBattery  is  approximately  80%  charged  (Usable  charge.  Li-ion only).
Green LitNow charging
Orange LitBattery pack is cool.The battery pack is being charged slowly to reduce the load on the battery. (Li-ion only)
Orange FlashingBattery pack is warm. Charging will begin when temperature of battery pack drops.
If  the  temperature  of  the  battery  pack  is  -10°C  or  less,  the charging  status  lamp  (orange)  will  also  start  flashing.  Charg-ing  will  begin  when  the  temperature  of  the  battery  pack  goes up (Li-ion only).
Charging Status LampLeft: green Right: orange will be displayed.
Both Orange and Green Flashing QuicklyCharging is not possible. Clogged with dust or malfunction of the battery pack.
X. MAINTENANCE
WARNINGTo  avoid  severe  personal  injury,  always  remove the battery pack from the tool before starting any maintenance procedure.
CAUTION:To  assure  product  SAFETY  and  RELIABILITY, servicing  should  be  performed  by  an  autho-rized  service  center.  Always  insist  on  genuine Panasonic replacement parts.
Cleaning Tool
Keep  your  tool  clean  for  good  cutting  perform-ance, and to help keep it safe to use.
Follow these steps:
1.  Remove the battery pack from the tool.
.  Wipe  the  tool  with  a  dry,  soft  cloth.  Do  not 
use a wet cloth or cleaning liquids.
  They could damage the tool’s finish.
3.  Be  sure  to  rub  off  any  oil  or  grease  which 
could make the tool slippery or hard to handle. 4. 
Remove the blade and brush off any dust.
CAUTION:To  avoid  injury  or  damage  to  the  unit,  never immerse any part of the tool in a liquid.
Transparent Guard
WARNINGIf the guard is cracked, or is broken, take the tool to  an  authorized  service  center  for  replacement. Do  not  attempt  to  operate  tool.  It  could  result  in serious personal injury.Never use your tool with a damaged transparent guard  or  without  the  transparent  guard  installed. Flying chips could result in serious injury. 
						

							
- 0 - 

XI. ACCESSORIES
WARNING•   The  use  of  any  accessories  not  specified in  this  manual  may  result  in  fire,  electric shock, or personal injury. Use recommended 
accessories only.•  Use  of  a  blade  on  material  that  is  thicker or  thinner  than  that  recommended  for  that blade  will  result  in  a  rough  cut,  and  could increase the risk of “kickback” or other injury.
Carbide-tipped Blade for Metal
• EY9PM13CFor cutting unhardened ferrous materialThickness of material
0. mm – .0 mm (1/3"-1/4")
Carbide-tipped  Blade  for  Thin  Metal  (Optional accessory)
• EY9PM13DFor cutting unhardened thin ferrous thin material that clean cutting edge required Thickness of material
0. mm – .0 mm (1/3"-1/4")
C a r b i d e - t i p p e d   B l a d e   f o r   W o o d   ( O p t i o n a l accessory)
• EY9PW13A For cutting wood in general
Carbide-tipped  Blade  for  Thin  Wood  (Optional accessory)
• EY9PW13BFor  cutting  thin  wood  that  clean  cutting  edge required
Recommended  thickness  of  material  up  to  1 
mm
C a r b i d e - t i p p e d   B l a d e   f o r   P l a s t i c   ( O p t i o n a l accessory)
• EY9PP13BFor cutting plasticRecomneded  thickness  of  material  acrylic  and vinyl chloride plates:
.0 mm – .0 mm (/4" – 3/1")corrugated pates, pipes
0.8 mm – .0 mm (1/3" – 3/1")
Vacuum hose adaptor (Optional accessory)
•  EY9X01E
Rip Fence (Optional accessory)
• EY300B777
 For convenience of rip cuts and repeated cut of uniform width
XII. SPECIFICATIONS
Motor voltage14.4 V DC
Blade speed 300 min-1 (rpm)
Blade size
Outside diameter13 mm (-3/8")
Arbor size 0 mm (/3")
Maximum cutting depth0 – 4 mm (0" – 1-13/1") (φ13 mm blade)
Overall length 39 mm (1-1/4")
Weight (with battery pack: EY9L40) . kg (.7 lbs)
BATTERY PACK
ModelEY9L40
Storage batteryLi-ion Battery
Battery voltage 14.4 V DC (3. V x 4 cells)
Capacity3 Ah