42
34
47
73
54
53
44
71
65
39
72
41
30
11
68
9
50
46
7
51
8
52
38
33
15
60
5
10
64
66
6
75
61
58
57
55
40
48
76
49
74
4
31
2
10
78
1
32
14
22
17
37233513
36
12
79
12
18
62
34 44 47 53
54 65 73
80
78
21
79
24
3
9
29
77
69
67
70
87
18
25
40 48 49 57
58 61 76
81
45
20
43
See Page 3
54-40-7595
B02F
1-1/8" STROKE DOUBLE INSULATED SAWZALL
®
6520-21
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
1 02-04-0845 Ball Bearing (1)
2 02-04-0915 Ball Bearing (1)
3 02-04-1511 Ball Bearing (1)
4 02-50-2150 Needle Bearing (1)
5 05-88-0302 K50 x 60mm Washer Hd. PT Screw (4)
6 06-55-3790 5/16-24 Spinlock Hex Nut (1)
7 06-65-0045 Dowel Pin (2)
8 43-36-0125 Cam Follower (1)
9 --------------- Orbit Pivot Pin (2)
10 06-82-7253 8-32 x .38 Taptite T-20 Screw (3)
11 06-82-7255 DG50 x 10mm Screw (3)
12 06-82-7270 8-16 x .625 Slt. Plastite T-20 Screw (6)
13 06-82-7326 8-16 x 1" Slt. Plastite T-20 Screw (2)
14 06-82-7453 8-16 x 2025 Slt. Plastite T-20 Screw (2)
15 06-82-8870 1/2-DG50 Thread Form Screw (4)
17 12-99-2576 Service Nameplate (1)
18 --------------- Remote Electronics Assembly (1)
20 14-67-0136 Primary Wobble Plate Assembly (1)
21 16-30-0700 Service Armature (1)
22 18-30-1700 Service Field (1)
23 22-20-0590 Carbon Brush Assembly (2)
24 22-64-1622 Cord Assembly (1)
25 23-66-4245 Switch Assembly (1)
29 14-30-0080 Orbit Pocket Assembly (2)
30 28-14-2600 Gearcase (1)
31 28-28-2600 Diaphragm (1)
32 31-05-0155 Bafe (1)
33 31-11-0130 Orbital Cam Plate (1)
34 --------------- Spring Cover (1)
35 31-44-2505 Handle Half - Right (1)
36 31-44-2506 Handle Half - Left (1)
37 31-50-0085 Motor Housing (1)
38 31-52-0045 Orbit Shift Lever (1)
39 31-52-0090 Shoe Release Lever (1)
40 32-40-2050 Intermediate Gear (1)
41 34-40-0040 O-Ring (2)
42 34-60-0125 Retaining Ring (1)
43 34-60-1315 External Retaining Ring (1)
44 34-60-3700 Retaining Ring (1)
45 36-92-0506 Wobble Shaft (1)
46 38-50-6400 Reciprocating Spindle (1)
47 --------------- Torsion Spring (1)
48 40-50-8850 Disc Spring (1)
49 42-12-0190 Wobble Shaft Axle (1)
50 42-24-0066 Front Spindle Bushing (1)
51 42-24-0525 Rear Spindle Bushing (1)
52 42-38-0055 Orbit Bumper (1)
53 --------------- Front Cam (1)
54 --------------- Rear Cam (1)
55 42-52-0380 Bearing Cap (1)
57 43-06-0676 Bronze Plate (1)
SEE REVERSE SIDE FOR IMPORTANT SERVICE NOTES
REVISED BULLETIN
SERVICE PARTS LIST
BULLETIN NO.
CATALOG NO.
SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS
WIRING INSTRUCTION
STARTING
SERIAL NO.
DATE
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
58 43-06-0685 Metal Plate (2)
60 43-56-0620 Orbit Plate (1)
61 43-78-0577 Orbit Drive Hub (1)
62 44-52-0105 Cushion Grip (1)
64 44-60-1635 Shoe Pin (1)
65 --------------- Lock Pin (1)
66 44-66-0880 Shoe Retainer (1)
67 44-86-0035 Front Orbit Cap (1)
68 44-86-0655 Bearing Retainer (1)
69 45-06-0110 Orbit Seal (1)
70 45-06-0475 Polypak Seal (1)
71 45-12-0710 Gearcase Insulator (1)
72 45-16-0645 Shoe Assembly (1)
73 --------------- Sleeve (1)
74 45-28-0555 Slinger (1)
75 45-36-1445 Spacer (1)
76 45-88-1555 Washer (1)
77 45-88-8577 Washer (1)
78 22-84-0531 Fan (1)
79 44-76-0210 Cord Protector (1)
80 14-46-1062 Large Quik-Lok Blade Clamp (1)
81 14-08-0075 Gear Protecting Clutch Assembly (1)
87 45-06-0501 Felt Seal (1)
23-94-6750 Leadwire Assembly (Not Shown) (1)
23-94-6755 Leadwire Assembly (Not Shown) (1)
42-55-2051 Carrying Case (Not Shown) (1)
EXAMPLE:
Component Parts (Small #) Are Included
When Ordering The Assembly (Large #).
00
0
Jan. 2017
Drwg. 1
54-40-7594
MILWAUKEE TOOL
l
www.milwaukeetool.com
13135 W. LISBON RD., BROOKFIELD, WI 53005
FIG. NOTES:
1 Bearing to be installed with seal towards commutator.
4,31 Pressneedlebearingush±.005withinnersurfaceofdiaphragm.
6,49 Apply Blue Loctite
®
242 to treads of wobble shaft axle prior to installing spinlock hex nut. Torque spinlock hex nut to 160-190 in. lbs.
6,40 Hold the intermediate gear still with a
large pair of pliers and a piece of rubber
hose (or other tough, but pliable material
to protect the gear from the jaws of the
pliers) and remove the 5/16" spinlock
hex nut with a wrench, as shown.
7,46,50,51 Pressdowelpinsushtofrontsideoffrontspindlebushing.Pressdowel
pinsushtobacksideofrearspindlebushing.NOTE: Reciprocating
spindle (46) must be installed inside assembly (7,50) and (7,51) prior
to pressing last spindle bushing into place.
17,37 Install nameplate in motor housing recess prior
to assembling diaphragm onto motor housing.
29,42 Service xture #61-10-0205 must be used
when installing retaining ring (42) onto orbit
pocket assembly (29).
40,57 Tabs of bronze plate engage intermediate gear.
40,48 Concave side of disc spring towards intermediate gear.
58,61 Tabs of metal plates engage orbit drive hub.
70 O-ring of polypak seal faces mechanism - toward rear of tool.
74 Shoulder extension of grease slinger should face bearing.
REMOVING THE STEEL QUIK-LOK
®
BLADE CLAMP
• Remove external retaining ring (44) and pull front cam (53) off.
• Pull lock pin (65) 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 (34) onto spindle.
• Slide torsion spring (47) onto spindle shaft
with leg positioned at the 6:00 position.
• Slide sleeve (73) onto spindle aligning hole on sleeve with hole in spindle.
• Slide rear cam (54) over sleeve, aligning hole in rear cam with spring leg.
Ensure spring leg inserts into hole in rear cam.
• Rotate rear cam (54) counter clockwise until there is clearance for
lock pin (65) to be inserted into sleeve/spindle holes. Insert lock pin.
• Align front cam (53) inner ribs with rear cam outer slots (see insert) and slide front
cam onto sleeve until it bottoms. Retaining ring (44) 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.
34
47
73
54
44
65
53
46
leg
hole
12:00
6:00
top of spindle
41
29
rear spindle bushing (51)
dowel pin (7)
reciprocating
spindle (46)
front spindle
bushing (50)
Place a thin film of lubrication
on dowel pins prior to assembly
.
LARGE
INNER
RIB
LARGE
OUTER
SLOT
SMALL
OUTER
SLOT
(53)
(54)
SMALL
INNER
RIB
FIG. LUBRICATION:
29,41 Lightly coat o-rings with lubrication for ease of installation onto assembled orbit pockets.
30 Place3.2oz.(80grams±8grams)oftype"T"grease(Cat.No.49-08-4290),
in mechanism cavity of gear case.
31 Place.8oz.(20grams±2grams)oftype"T"grease(Cat.No.49-08-4290),
in lower needle bearing-gear train cavity of diaphragm.
40,58 Apply a thin coat of type "T" grease
(Cat. No. 49-08-4290) between gear and metal plate.
65 Pin to be coated with graphite prior to assembly.
87 Soak in lightweight bushing oil prior to assembly.
WIRING SPECIFICATIONS
Wire Wire Origin or
No. Color Part No. Ga. Length Terminals, Connectors and End Wire Preparation
1A Black TRIAC --- --- Component of Switch Assembly 23-66-4245.
1B Yellow TRIAC --- --- Component of Switch Assembly 23-66-4245.
1C Blue TRIAC --- --- Component of Switch Assembly 23-66-4245.
1D Red TRIAC --- --- Component of Switch Assembly 23-66-4245.
2A Black Cord Assembly 16 4.00 Strip .340 and tin.
2B White Cord Assembly 16 3.25 Strip .340 and tin.
2C Green Cord Assembly 16 11.25 Strip .19 for T6.
3 Green 23-94-0025 18 7.00 Strip each end .190 for T4 and T5.
4A White 23-94-6750 18 2.90 Strip one end .19 for T2.
4B White 23-94-6750 18 5.00 Strip one end .15 for T1.
5A White 23-94-6755 18 9.25 Strip one .320 and tin.
5B White 23-94-6755 18 5.00 Strip one end .15 for T1.
BULK LEAD WIRE - BULLETIN 58-01-0003
The wires inserted into
the back of switch are not
to be routed underneath
switch. Route wires as
shown.
Cord jacket to extend .25”
minimum beyond the cord
clamp area.
2C
2A
2B
3
4A
4B
3
4B
5B
5A
5B
1D
1B
1C
1A
Insert 2 wires
into trap
(3 places)
Barrels of terminals
‘T1’ to face either
inward or outward
(4 places)
T4
T6
T5
T2
T2
1A
2B
1C
2A
1D
5B
Terminal (T3) of
black lead (1A)
from triac is to
have barrels
facing
outward.
Bottom View
of Switch
NOTE: For (DI) Double Insulated tools disregard the following:
Green cord lead '2C', green leadwire assembly 23-94-0025 '3',
terminals 'T4', 'T5', 'T6' and the grounding pin.
NOTE:
Allleadsmustbeheldto±1/8".
All lead lengths are before stripping.
TERMINAL DESCRIPTION
T1 23-74-1060 4
T2 23-74-0017 2
T3 23-74-0010 1
T4 23-74-0605 1
T5 23-74-0105 1
T6 23-74-1095 1
Qnty.
Part No.
Code
Strip both .15 and join for T1.
Strip both .15 and join for T1.
