BULLETIN NO. SERVICE PARTS LIST 54-42-3302 SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS M12 BRUSHLESS COMPACT 2 SPEED SCREWDRIVER CATALOG NO. 00 2402-20 EXAMPLE: 0 Component Parts (Small #) Are Included When Ordering The Assembly (Large #). STARTING SERIAL NO. E26C REVISED BULLETIN 54-42-3301 DATE July 2014 WIRING INSTRUCTION 42 40 32 See page two for components and installation of the High Voltage protection system 34 33 32 35 38 22 36 37 42 21 23 41 27 28 36 22 (4x) 17 27 39 21 38 14 (4X) 28 37 15.18 15.19 15.25 15.19 15 15.18 15.25 31 35 (6x) FIG. 14 15 15.18 15.19 15.25 17 21 22 23 27 28 31 32 33 34 35 36 37 38 39 40 41 42 50 PART NO. 05-88-0780 14-29-0570 44-10-0710 05-81-0542 --------------45-24-0325 --------------45-30-0270 16-07-0400 40-50-1135 42-42-0610 42-70-0058 --------------42-70-0580 05-88-1010 06-82-1080 --------------12-20-2402 31-44-2025 14-20-1130 42-55-2100 42-42-1120 10-20-2399 23-94-2110 DESCRIPTION OF PART NO. REQ. M3 x 18mm T-10 ST Screw (Gearcase) (4) Gearcase Assembly (1) Speed Selector Lever (1) M2.3 x 4.5mm ST Screw (2) Motor Mounting Plate (1) Speed Selector Button (1) Motor / Switch / PCBA Assembly (1) Rubber Pin (4) Service Rotor (1) Shuttle Spring (1) Forward / Reverse Shuttle (1) Housing Connection Clip (1) Left Housing Halve (1) Belt Clip (1) M2.5 x 6mm Screw (1) M3 x 14mm T-10 ST Scr (Handle Halves) (6) Right Housing Halve (1) Service Nameplate (1) Housing Kit (1) Housing / Electronics Kit (1) Blow Molded Carrying Case (1) Forward / Reverse Shuttle Kit (1) Warning Label (French & Spanish) (1) 146mm Wire Assembly (See page two) (1) (High Voltage Protection) SCREW TORQUE SPECIFICATION CHART SEATING TORQUE FIG. PART NO. DESCRIPTION (IN-LBS) 15.19 05-81-0542 14 05-88-0780 35 06-82-1080 Speed Selector Lever Screw Gearcase Assembly Screw Right Housing Halve Screw 3.5±1 7.0±2.5 7.0±2.5 MILWAUKEE ELECTRIC TOOL CORPORATION 13135 W. Lisbon Road, Brookfield, WI 53005 Drwg.1 Model 2402-20, 2402-059 shown No. 23-94-2110 146mm Service Wire Assembly (High Voltage Protection) Black wire soldered to negative terminal & PCBA Long HV wire assembly to gearcase Closed End Connector Short HV wire soldered to negative terminal PRODUCTION WIRING- For ease in production, the Electronics Assembly (Switch, Stator, PCBA and BatteryTerminal Block) has a short HV wire presoldered to the negative terminal. During production a longer HV wire is joined to the short wire with an open end connector than grounded to the gearcase. Black wire soldered to negative terminal & PCBA 23-94-2110 146mm Wire Assembly. Solder one end to terminal and ground the other end to gearcase Snip short production HV wire at terminal here SERVICE WIRING- When installing a service replacement High Voltage Wire (23-94-2110) it is recommended to snip the old HV wire system at the battery terminal. Remove and discard that short wire, the open end connector and longer wire. Follow the instructions to install new wire assembly. = Wire Traps Solder the kit wire accross the bottom of the negative (left rear) terminal of battery connector block. 1. Remove the six handle screws, the housing connection clip and the four gearcase screws. Remove housing cover (right housing halve). Carefully remove the electronics assembly and gearbox assembly from the housing support (left housing halve). 2. With a small side cutter, snip the short production HV wire close to the terminal (see illustration above). Unscrew the ring terminal from the lower right position of the gearcase. Remove and discard the old HV system (short HV wire, the open end connector and longer HV wire). 3. Place the wire strand end of the 146mm High Voltage Wire (23-94-2110) across the bottom of the negative (rear left) terminal of the battery connector block and carefully solder in place (Note wire is to be positioned so wire extends to the left of the terminal, routing into the left housing halve). See illustration above. 4. As an aid to routing the HV wire, carefully remove the gearcase assembly from the electronics assembly. 5. Loosely place the electronics assembly into the left housing halve. Route the HV wire under the switch/battery connector block wires using the same wire trap at the upper left corner of the switch. Route HV wire behind the PCBA and into the small traps in the left housing halve. Lay HV wire across the PCBA facing outward to the right. 6. Place the ring terminal of HV wire over the screw opening in the lower right position of the gearcase (with wire to the inside of the tool) and reinstall the screw to ground the system. 7. Carefully place the gearcase assembly back onto motor assembly. Secure the gearcase assembly with two of the gearcase screws into the front of the new left housing halve. 8. Take time to make sure that all components are back in place. Press all wires firmly into traps. Be sure the LED, PCBA, switch assembly and battery connector block are squarely and firmly in place. Be sure the fwd./rev. shuttle functions properly and that the shuttle spring is in place. 9. Gently put the right housing halve back in place and check for any interferences prior to securing with the six handle screws and two remaining gearcase screws. Insert housing clip.