Milwaukee 54-40-7000 User manual

Milwaukee 54-40-7000 User manual
BULLETIN NO.
SERVICE PARTS LIST
54-40-7000
REVISED BULLETIN
SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS
DATE
Aug. 2006
®
CORDLESS SAWZALL
0719-20
CATALOG NO.
67
WIRING INSTRUCTION
STARTING
SERIAL NO.
A56A
26
4
66
NOTES:
Seal side of bearing (2)
to face armature (15).
14 1460
62
SEE REVERSE SIDE
61
00
63
42
0
39
65 68
69
Stamped arrows (>>) on
field casing (16) to face
armature fan (11).
EXAMPLE:
Component Parts (Small #)
Are Included When Ordering
The Assembly (Large #).
24
68
Concave side of connector
block cover (23) to face
connector block (19).
30 31 34
64 24
35 36 41
31
7
41
69
8
35
13
34
19 23
17
30
23
25
38
37
3
43
27
46
28
2
32
9
10
18
FA
SID N
E
36
16
>>
59
45
47
29
LUBRICATION
Place 1/2 oz. of type "Y" grease, No. 49-08-5270,
in diaphragm cavity near the needle bearing.
48
8
60
PART NO.
02-04-0719
02-04-5130
02-50-2150
05-88-0302
05-88-8309
06-82-5363
06-82-7253
06-82-7261
06-82-7276
12-20-0719
28-14-0997
16-01-2121
18-01-2120
22-20-0860
22-32-0400
22-56-0975
28-28-0719
31-05-0719
-------------31-15-0511
31-44-0718
31-44-0719
31-50-0019
31-52-0090
34-60-0920
34-60-3680
40-50-0161
40-50-8840
42-24-0620
42-50-0076
42-50-0077
44-60-0626
44-60-1635
44-66-0880
45-12-0999
45-16-0645
45-22-0081
45-24-0719
45-88-1555
40-50-8850
42-12-0155
32-40-0719
43-06-0685
43-06-0676
43-78-0525
36-92-0501
61
50
33
62
52
53
22
54
21
56
57
5
FIG.
1
2
3
4
5
7
8
9
10
13
 14
15
16
17
18
19
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
 50
55
49
1
Place 2-1/2 oz. of type "L" grease, No. 49-08-4175,
in cavity in front of bearing plate in the gearcase.
Place a heavy coat of Type "X" contact grease, No. 49-08-5000,
in/on terminals of wires #68 and #69 after installing into
connector block (19) but prior to snapping on the cover (23).
40
51
44
15
DESCRIPTION OF PART
NO. REQ.
Ball Bearing
(1)
Ball Bearing
(1)
Needle Bearing
(1)
K50 x 60mm Washer Hd. PT Screw
(2)
K50 x 35mm Washer Hd. PT Screw
(1)
8-32 x 1 Washer Hd. Taptite T-20 Screw
(2)
8-32 x .38 Taptite T-20 Screw
(3)
6-19 x .687 Slotted Plastite T-15 Screw
(4)
6-19 x 1.00 Slotted Plastite T-15 Screw
(2)
Service Nameplate Kit
(1)
Gearcase
(1)
Service Armature
(1)
Service Field
(1)
Brush Tube
(2)
Brush Spring Clip
(2)
Connector Block Assembly
(1)
Diaphragm
(1)
Baffle
(1)
Connector Block Cover
(1)
Spring Cover
(1)
Right Handle Half
(1)
Left Handle Half
(1)
Motor Housing
(1)
Shoe Release Lever
(1)
External Retaining Ring
(1)
Retaining Ring
(1)
Torsion Spring
(1)
Brush spring
(2)
Rear Spindle Bearing
(1)
Front Cam
(1)
Rear Cam
(1)
Lock Pin
(1)
Shoe Pin
(1)
Shoe Retainer
(1)
Gearcase Insulator
(1)
Shoe Assembly
(1)
Sleeve
(1)
Lock Off Lever
(1)
Washer
(1)
Disc Spring
(1)
Wobble Shaft Axel
(1)
Intermediate Gear
(1)
Metal Plate
(1)
Bronz Plate
(1)
Drive Hub
(1)
Wobble Shaft
(1)
FIG.
51
52
53
54
55
56
57
58
59
 60
 61
 62
63
64
65
66
67
68
69
52
PART NO.
34-80-2600
02-04-1510
30-72-0085
34-60-1315
06-82-7253
44-86-0055
45-36-1445
06-55-3790
38-50-0680
------------------------------------------42-52-0380
14-46-1011
23-66-1719
22-18-1719
22-18-0719
23-94-0016
23-94-0015
58
DESCRIPTION OF PART
Internal Retaining Ring
Ball Bearing
Wobble Plate
Retaining Ring
8-32 x 3/8" Pan Hd. Slt. Taptite T-20
Bearing Retainer
Spacer
5/16-24 Spinlok Hex Nut
Reciprocating Spindle
Front Spindle Bearing
Felt Seal
Washer
Bearing Cap
Steel Quik-Lok Blade Clamp Kit
Switch Assembly
Carbon Brush Assembly - Black
Carbon Brush Assembly - Red
Leadwire Assembly - Black
Leadwire Assembly - Red
NO. REQ.
(1)
(3)
(1)
(1)
(2)
(1)
(1)
(1)
(1)
(1)
(2)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
NOTES:
Press rear spindle bearing (33) flush to -.030 from front exterior face
in diaphragm boss (21).
Torque spinlok hex nut (58) to 180 in./lbs. to 210 in./ lbs.
Retaining ring (51) is to be installed with the beveled side away from
the bearing (52).
Press front spindle bearing (60) flush to .015 below interior surface
of gearcase (14).
Needle bearing (3) is to be pressed from the open end flush to ±.005
to face of bearing boss of diaphragm (21).
Wobble plate retaining ring (51), to face wobble shaft (50) in assembly.
Remove brush tubes (17) prior to removing armature assembly (15) from
motor housing (27).
Install brush tubes (17) into motor housing (27) only after armature
assembly (15) has been secured into motor housing (27).
MILWAUKEE ELECTRIC TOOL CORPORATION
13135 W. LISBON RD., BROOKFIELD, WI 53005
Drwg. 4
REMOVING THE STEEL QUIK-LOK® BLADE CLAMP
•
Remove external retaining ring (30) and pull front cam (34) off.
•
Pull lock pin (36) out and remove remainder of parts and discard.
Ensure drill point exists
in bottom of pin hole.
Leg
REASSEMBLY OF THE STEEL QUIK-LOK® BLADE CLAMP
Outer Slot
36
•
Coat new lock pin with powdered graphite.
•
Hold tool in a vertical position.
•
Place spring cover (24) onto spindle.
•
Slide torsion spring (31) onto spindle with spring leg on hole side of spindle.
•
Slide sleeve (41) onto spindle aligning hole on sleeve with hole in spindle.
•
Slide rear cam (35) over sleeve until it bottoms on sleeve shoulder, ensure spring leg inserts into hole in rear cam.
•
Rotate rear cam in the direction of the arrows located on spring cover until there is clearance for lock pin (36) to be inserted into sleeve/spindle
holes. Insert lock pin.
•
Align front cam (34) inner ribs with rear cam outer slots and slide front cam onto sleeve until it bottoms.
Retaining ring (30) groove should be completely visible.
•
Attach retaining ring by separating coils and inserting end of ring into groove, then wind remainder of ring into groove.
Ensure ring is seated in groove.
•
Blade clamp should rotate freely. During normal usage, debris may not allow blade clamp to rotate freely. The use of spray lubricant can help free
blade clamp. In extreme conditions, follow these instructions to remove, clean and reassemble blade clamp.
24
30
31
41
35
34
Carbon brush wires #1 and #2 are to be
positioned with the wire crimps in the traps.
WIRING INSTRUCTIONS
Route carbon brush wires #1 and #2 into
wire traps, as shown.
POSITION WIRES ON SWITCH
TABS AND SOLDER,
AS SHOWN.
2
1
--
2
+
1
1
1
2
--
! WARNING
+
SWITCH POLARITY SENSITIVE
If wired incorrectly, switch will be
damaged and destroyed!
4
3
Place a heavy coat of Type "X"
contact grease, No. 49-08-5000,
in/on terminals of wires #3 and
#4 after installing into connector
block but prior to snapping on
the connector block cover.
4
3
-- +
2
WIRING SPECIFICATIONS
Wire
No.
1
2
3
4
Wire
Color
Origin or
Gauge
Length
Red
22-18-0719
-----
Carbon brush assembly.
Black 22-18-1719
-----
Carbon brush assembly.
23-94-0015
-----
Leadwire assembly.
Black 23-94-0016
-----
Leadwire assembly.
Red
TERMINAL DESCRIPTION
Code
Terminals, Connectors and 1 or 2 End Wire Preparation
BULK LEAD WIRE - BULLETIN NO. 58-01-0003
Part No.
Qnty.
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