26
22
35
36
91
42
34
47
73
54
53
44
71
65
39
72
41
30
11
68
9
50
46
7
56
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
14
32
34 44 47 53
54 65 73
80
78
21
3
9
29
77
69
67
70
87
82
22
17
37
23
35
13
79
12
36
25
12
18
79
24
16
83
84
26
88
40 48 49 57
58 61 76
81
43
20
45
19
43
90
19 20
43 45
95
See Page 3
54-40-7572
B36C
1-1/4" STROKE SAWZALL
®
6538-21
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 05-88-0307 Delta 50 x 50mm PT T-25 Screw (4)
6 06-55-3791 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 2.25 Slt. Plastite T-20 Screw (2)
15 06-82-8870 1/2-DG50 Thread Form Screw (4)
16 06-82-7330 4-20 x .875 Plastite T-10 Screw (1)
17 12-20-6550 Service Nameplate (1)
18 14-20-2530 Remote Electronics Assembly (1)
19 --------------- Secondary Wobble Plate Assembly (1)
20 --------------- Primary Wobble Plate Assembly (1)
21 16-30-0705 Service Armature (1)
22 18-31-0221 Service Field (1)
23 22-20-0535 Carbon Brush Assembly (2)
24 22-64-0595 Cord Assembly (1)
25 23-66-2490 Switch (1)
26 23-16-0046 Cardboard Tube (1)
29 14-30-0080 Orbit Pocket Assembly (1)
30 28-14-2600 Gearcase (1)
31 28-28-2600 Diaphragm (1)
32 31-05-0155 Bae (1)
33 31-11-0130 Orbital Cam Plate (1)
34 --------------- Spring Cover (1)
35 --------------- Handle Half - Right (1)
36 --------------- Handle Half - Left (1)
37 31-50-6538 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 --------------- External Retaining Ring (2)
44 34-60-3700 Retaining Ring (1)
45 --------------- 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)
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
DATE
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
56 42-87-0180 Counter Weight (1)
57 43-06-0676 Bronze Plate (1)
58 43-06-0685 Metal Plate (2)
60 43-56-0620 Orbit Plate (1)
61 43-78-0577 Orbit Drive Hub (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 45-12-0700 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)
82 23-38-0200 Magnet (1)
83 31-17-0260 Cord Clamp (1)
84 31-17-0265 Cord Clamp (1)
87 45-06-0501 Felt Seal (1)
88 23-94-7425 Leadwire Assembly (1)
89 23-45-6538 Fiberglass Sleeve (2)
90 42-55-2050 Blow Molded Carrying Case (1)
91 31-50-0972 Handle Service Kit (1)
95 14-67-0131 Wobble Plate Assembly (1)
EXAMPLE:
Component Parts (Small #) Are Included
When Ordering The Assembly (Large #).
00
0
Aug. 2025
54-40-7571
«
MILWAUKEE TOOL
l
www.milwaukeetool.com
13135 W. LISBON RD., BROOKFIELD, WI 53005
Drwg. 4
SERIAL NO.
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.
7,46,50,51,56 Pressdowelpinsushtofrontsideoffrontspindlebushing.Pressdowel
pinsushtobacksideofrearspindlebushing.NOTE: Reciprocating
spindle (46) and counter weight (56) must be installed inside assembly
(7,50) and (7,51) prior to pressing last spindle bushing into place. Be
sure to orientate the counter weight with the hole on bottom towards
rear spindle bushing, as shown.
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
• Removeexternalretainingring(44)andpullfrontcam(53)o.
• 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
rear spindle bushing (51)
counter weight (56)
dowel pin (7)
reciprocating
spindle (46)
front spindle
bushing (50)
Orient counter weight
as shown with hole on
bottom towards rear
spindle bushing.
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"V"grease(Cat.No.49-08-4380),
in mechanism cavity of gear case.
31 Place.8oz.(20grams±2grams)oftype"V"grease(Cat.No.49-08-4380),
in lower needle bearing-gear train cavity of diaphragm.
40,58 Apply a thin coat of type "V" grease
(Cat. No. 49-08-4380) between gear and metal plate.
65 Pin to be coated with graphite prior to assembly.
87 Soak in lightweight bushing oil prior to assembly.
Service Fixture
61-10-0270
(Pressing Pin Tool)
LUBRICATION
Use Type "V" grease, No. 49-08-4380 (1 lb. tub)
NOTE: When servicing, remove 90-95% of the exist-
ing grease prior to installing Type "V". Original grease
may be similar in color but not compatible with "V".
Clean gear assemblies with a clean, dry cloth.
41
29
1
8
3
2
9
5 4
Speed
Dial
Wires
}
15
1
7
3
6
9
5
4
1
7
3
6
9
5
4
8
15
2
14
Prior to installing black module wires #1
and white module wire #3 onto switch, place a
sleeve (23-48-6538) over each wire and slide towards module.
Locate both sleeves between the module and the adjacent wire traps.
Wire traps
23-48-6538
Sleeves
AS AN AID TO REASSEMBLY,
TAKE NOTICE OF WIRE
ROUTING AND POSITION IN
WIRE GUIDES AND TRAPS
WHILE DISMANTLING TOOL.
BE CAREFUL AND AVOID PINCHING WIRES
BETWEEN HANDLE HALVES WHEN ASSEMBLING.
1 Black 14-20-1105 ----- Componentofthespeedcontrolmodule.Connecttoposition'2'onthebackoftheon-oswitch.
2 Yellow 14-20-1105 ----- Componentofthespeedcontrolmodule.Connecttothebottomlefteldterminal.
3 White 14-20-1105 ----- Componentofthespeedcontrolmodule.Connecttoposition'1'onthebackoftheon-oswitch.
4 Black 14-20-1105 ----- Componentofthespeedcontrolmodule.Connecttoposition'3'ontheleftsideoftheon-oswitch.
5 White 14-20-1105 ----- Componentofthespeedcontrolmodule.Connecttoposition'4'ontheleftsideoftheon-oswitch.
6 Black 22-64-4522 ----- Component of the power cord set. Connect the other end to position '2á' on switch.
7 White 22-64-4522 ----- Component of the power cord set. Connect the other end to position '1á' on switch.
8 Black 14-20-1105 ----- Component of the speed control module. Connect to the bottom brush tube terminal.
9 Blue 14-20-1105 ----- Componentofthespeedcontrolmodule.Connecttoposition'5'ontheleftsideoftheon-oswitch.
14 White 23-94-7425 ----- Leadwireassembly.Connecttothetoprightandlefteldterminals.Connecttotopbrushtubeterminal.
15 Yellow 14-20-1105 ----- Componentofthespeedcontrolmodule.Connecttothebottomrighteldterminal.
Terminals, Connectors and 1 or 2 End Wire Preparation
Wire
Color
Origin or
Gauge
Wire
No.
Length
WIRING SPECIFICATIONS
WIRING INSTRUCTIONS
TITLE
DATE
MILWAUKEE ELECTRIC TOOL CORP. 13135 WEST LISBON RD. BROOKFIELD, WIS.
6538-21 SAWZALL
®
with 14-20-1115 Remote Electronics Assembly
BULLETIN
