Milwaukee 54-40-7000 User Manual

SERVICE PARTS LIST

SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS

CORDLESS SAWZALL

CATALOG NO.

NOTES:

Seal side of bearing (2)
to face armature (15).

Stamped arrows (>>) on
fi eld casing (16) to face
armature fan (11).

Concave side of connector
block cover (23) to face
connector block (19).

17

25

9

10

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 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).

FIG. PART NO. DESCRIPTION OF PART NO. REQ.

1 02-04-0719 Ball Bearing (1)
2 02-04-5130 Ball Bearing (1)
3 02-50-2150 Needle Bearing (1)
4 05-88-0302 K50 x 60mm Washer Hd. PT Screw (2)
5 05-88-8309 K50 x 35mm Washer Hd. PT Screw (1)
7 06-82-5363 8-32 x 1 Washer Hd. Taptite T-20 Screw (2)
8 06-82-7253 8-32 x .38 Taptite T-20 Screw (3)
9 06-82-7261 6-19 x .687 Slotted Plastite T-15 Screw (4)
10 06-82-7276 6-19 x 1.00 Slotted Plastite T-15 Screw (2)
13 12-20-0719 Service Nameplate Kit (1)
14 28-14-0997 Gearcase (1)



15 16-01-2121 Service Armature (1)
16 18-01-2120 Service Field (1)
17 22-20-0860 Brush Tube (2)
18 22-32-0400 Brush Spring Clip (2)
19 22-56-0975 Connector Block Assembly (1)
21 28-28-0719 Diaphragm (1)
22 31-05-0719 Baffl e (1)
23 -------------- Connector Block Cover (1)
24 31-15-0511 Spring Cover (1)
25 31-44-0718 Right Handle Half (1)
26 31-44-0719 Left Handle Half (1)
27 31-50-0019 Motor Housing (1)
28 31-52-0090 Shoe Release Lever (1)
29 34-60-0920 External Retaining Ring (1)
30 34-60-3680 Retaining Ring (1)
31 40-50-0161 Torsion Spring (1)
32 40-50-8840 Brush spring (2)
33 42-24-0620 Rear Spindle Bearing (1)
34 42-50-0076 Front Cam (1)
35 42-50-0077 Rear Cam (1)
36 44-60-0626 Lock Pin (1)
37 44-60-1635 Shoe Pin (1)
38 44-66-0880 Shoe Retainer (1)
39 45-12-0999 Gearcase Insulator (1)
40 45-16-0645 Shoe Assembly (1)
41 45-22-0081 Sleeve (1)
42 45-24-0719 Lock Off Lever (1)
43 45-88-1555 Washer (1)
44 40-50-8850 Disc Spring (1)
45 42-12-0155 Wobble Shaft Axel (1)
46 32-40-0719 Intermediate Gear (1)
47 43-06-0685 Metal Plate (1)
48 43-06-0676 Bronz Plate (1)
49 43-78-0525 Drive Hub (1)
50 36-92-0501 Wobble Shaft (1)



18

66
42

68

65

69

68

69

13

27

32

>>

FAN

S

I

DE

2

0719-20

67

19

16

23

BULLETIN NO.

54-40-7000

REVISED BULLETIN DATE

52

41

62

Aug. 2006

64

35

40

58

24 30 31 34
35 36 41

34

30

Drwg. 4

®

STARTING
SERIAL NO.

26

7

8

23

3

43

46

15

44

45

29

21

22





47

8

5

FIG. PART NO. DESCRIPTION OF PART NO. REQ.
51 34-80-2600 Internal Retaining Ring (1)
52 02-04-1510 Ball Bearing (3)
53 30-72-0085 Wobble Plate (1)
54 34-60-1315 Retaining Ring (1)
55 06-82-7253 8-32 x 3/8" Pan Hd. Slt. Taptite T-20 (2)
56 44-86-0055 Bearing Retainer (1)
57 45-36-1445 Spacer (1)
58 06-55-3790 5/16-24 Spinlok Hex Nut (1)
59 38-50-0680 Reciprocating Spindle (1)
60 --------------- Front Spindle Bearing (1)
61 --------------- Felt Seal (2)
62 --------------- Washer (2)
63 42-52-0380 Bearing Cap (1)
64 14-46-1011 Steel Quik-Lok Blade Clamp Kit (1)
65 23-66-1719 Switch Assembly (1)
66 22-18-1719 Carbon Brush Assembly - Black (1)
67 22-18-0719 Carbon Brush Assembly - Red (1)
68 23-94-0016 Leadwire Assembly - Black (1)
69 23-94-0015 Leadwire Assembly - Red (1)

NOTES:

Press rear spindle bearing (33) fl ush to -.030 from front exterior face
in diaphragm boss (21).

A56A

4

60 61

14

62

14

37

59

51

48

49

1

50

33

00

63

39

38

52

53

WIRING INSTRUCTION

SEE REVERSE SIDE

EXAMPLE:

Component Parts (Small #)

0

Are Included When Ordering
The Assembly (Large #).

24

31

28

36

60

55

61

54

56

57

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) fl ush to .015 below interior surface

of gearcase (14).
Needle bearing (3) is to be pressed from the open end fl ush 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

+

-

+

-

+

-

-

-

-

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.

REASSEMBLY OF THE STEEL QUIK-LOK® BLADE CLAMP

• 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.

36

24

Ensure drill point exists
in bottom of pin hole.

Leg

Outer Slot

30

31

41

35

34

WIRING INSTRUCTIONS

Route carbon brush wires #1 and #2 into
wire traps, as shown.

WARNING

!

SWITCH POLARITY SENSITIVE

If wired incorrectly, switch will be
damaged and destroyed!

Carbon brush wires #1 and #2 are to be
positioned with the wire crimps in the traps.

2

2

1

1

1

-

+

3

4

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

POSITION WIRES ON SWITCH
TABS AND SOLDER,
AS SHOWN.

2

1

WIRING SPECIFICATIONS

Wire

No.

Wire

Color

Origin or

Gauge

Length

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. 58-01-0003

2

TERMINAL DESCRIPTION

Part No.Code Qnty.