Milwaukee 54-40-7000 User's Manual
Contents
1. 2 into wire traps as shown AWARNING SWITCH POLARITY SENSITIVE If wired incorrectly switch will be damaged and destroyed 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 BAWY DUTY TERMINAL DESCRIPTION No Color Gauge Terminals Connectors and 1 or 2 End Wire Preparation 1 Red 22 18 0719 Carbon brush assembly 2 Black 22 18 1719 Carbon brush assembly 3 Red 23 94 0015 Leadwire assembly 4 Black 23 94 0016 Leadwire assembly BULK LEAD WIRE BULLETIN NO 58 01 00032. Insulator 40 45 16 0645 Shoe Assembly 41 45 22 0081 Sleeve 42 45 24 0719 Lock Off Lever 43 45 88 1555 Washer 44 40 50 8850 Disc Spring 45 42 12 0155 Wobble Shaft Axel 46 32 40 0719 Intermediate Gear 47 48 06 0685 Metal Plate 48 48 06 0676 Bronz Plate 49 48 78 0525 Drive Hub 50 36 92 0501 Wobble Shaft Press rear spindle bearing 33 flush to 030 from front exterior face in diaphragm boss 21 Torque spinlok hex nut 58 to 180 in Ibs to 210 in Ibs 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 eek kk ak sk hk sk st es st st st et N SS Ss eS St Ss Ss Ss St Ss St St PO ZN SH H NH NM HD BR WYD AH YD HH SH REMOVING THE STEEL QUIK LOK BLADE CLAMP REASSEMBLY OF THE STEEL QUIK LOK BLADE CLAMP WIRING INSTRUCTIONS Carbon brush wires 1 and 2 are to be Remove external retaining ring 30 and pull fr
3. 06 82 5363 8 32 x 1 Washer Hd Taptite T 20 Screw 56 44 86 0055 Bearing Retainer 1 8 06 82 7253 8 32 x 38 Taptite T 20 Screw 57 45 36 1445 a 1 9 06 82 7261 6 19 x 687 Slotted Plastite T 15 Screw 58 06 55 3790 5 16 24 Spinlok Hex Nut 1 10 06 82 7276 6 19 x 1 00 Slotted Plastite T 15 Screw 59 38 50 0680 Reciprocating Spindle 1 13 12 20 0719 Service Nameplate Kit 60 Front Spindle Bearing 1 14 28 14 0997 Gearcase 610 Felt Seal 2 15 16 01 2121 Service Armature k62 Washer 2 16 18 01 2120 Service Field 63 42 52 0380 Bearing aly 1 17 22 20 0860 Brush Tube 64 14 46 1011 Steel Quik Lok Blade Clamp Kit 1 18 22 32 0400 Brush Spring Clip 65 23 66 1719 Switch Assembly 1 19 22 56 0975 Connector Block Assembly 66 22 18 1719 Carbon Brush Assembly Black 1 21 28 28 0719 Se ragm 67 22 18 0719 Carbon Brush Assembly Red 1 22 31 05 0719 Baffle 68 23 94 0016 Leadwire Assembly Black 1 e E oe Connector Block Cover 69 23 94 0015 Leadwire Assembly Red 1 24 31 15 0511 Spring Cover NOTES 25 31 44 0718 Right Handle Half 26 31 44 0719 Left Handle Half 27 31 50 0019 Motor Housing 28 31 52 0090 Shoe Release Lever 29 34 60 0920 External Retaining Ring 30 34 60 3680 Retaining Ring 31 40 50 0161 Torsion Spring 32 40 50 8840 Brush spring 33 42 24 0620 Rear Spindle Bearing 34 42 50 0076 Front Cam 35 42 50 0077 Rear Cam 36 44 60 0626 Lock Pin 37 44 60 1635 Shoe Pin 38 44 66 0880 Shoe Retainer 39 45 12 0999 Gearcase
4. ilw SERVICE PARTS LIST 54 40 7000 SPECIFY CATALOG NO AND SERIAL NO WHEN ORDERING PARTS CORDLESS SAWZALL Sa eel STARTING WIRING INSTRUCTION CATALOG 0719 20 SPRING A56A SEE REVERSE SIDE 26 EXAMPLE 00 gt Component Parts Small Are Included When Ordering The Assembly Large NOTES Seal side of oe to face armature 1 2 Stamped arrows gt gt on field casing 16 to face armature fan 11 Concave side of connector block cover 23 to face connector block 19 24 30 31 34 35 36 41 LUBRICATION Place 1 2 oz of type Y grease No 49 08 5270 in diaphragm cavity near the needle bearing Place 2 1 2 oz of Hee L grease No 49 08 4175 in cavity in front of bearing plate in the gearcase Place a heavy coat of De 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 FIG PART NO DESCRIPTION OF PART NO REQ FIG PARTNO DESCRIPTION OF PART NO REQ 1 02 04 0719 Ball Bearing 1 51 34 80 2600 Internal Retaining Ring 1 2 02 04 5130 Ball Bearing 52 02 04 1510 Ball Bearing 3 3 02 50 2150 Needle Bearin 53 30 72 0085 Wobble Plate 1 4 05 88 0302 K50 x 60mm Washer Hd PT Screw 54 34 60 1315 Retaining Ring 1 5 05 88 8309 K50 x 35mm Washer Hd PT Screw 55 06 82 7253 8 32 x 3 8 Pan Hd Sit Taptite T 20 2 7
5. ont cam 34 off Ensure drill point exists in bottom of pin hole Pull lock pin 36 out and remove remainder of parts and discard Outer Slot 367 if Coat new lock pin with powdered graphite a M 4 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 POSITION WIRES ON SWITCH TABS AND SOLDER AS SHOWN positioned with the wire crimps in the traps Route carbon brush wires 1 and
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