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Milwaukee 6238-20 Deep Cut AC/DC Band Saw

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Manual 54-40-6253

This is the main product document for model 6238-20.

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CATALOG NO. 6238-20
REVISED BULLETIN
54-40-6252
SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS
DEEP CUT AC/DC BANDSAW
STARTING
SERIAL NO.
DATE
Dec. 2022
WIRING INSTRUCTION
See Page 4 thru 6
BULLETIN NO.
54-40-6253
SERVICE PARTS LIST
D52D
LUBRICATION NOTES:
Type ‘J’ Grease,
No. 49-08-4220
When replacing Idler
Gear Kit (145), place 4 g,
(.14 oz.) of grease around
gear teeth and ID of Idler
Gear (38).
When replacing Bevel
Pinion Assembly (133),
place 3.8 g, (.13 oz.) grease
around Helical Gear (35).
Coat teeth and end of
Bevel Pinion (30).
Place a heavy coating
of grease in the bevel
pinion bore of
Gearcase (26).
43
13
112
109
108
44
45
143
107
104
70
69
29
75
27
27
26
29
28
30
31
32
25
35
42
41
33 36
38
39
40
37
22
105
103
102
81
117
116
113
115 (2x)
114
118
119
89 88
1
1
24
25
46
1
47
54
64
60
59
58
61
61
68
34
22 40
42 43
129
81 116
117 118
135
44
45
130
29
70
146
57
53
1 47 58 59
60 61 68
141
13 108 109
110 112
144
25 30 31
32 35
133
33 34 36
38 39
145
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
1 06-82-5314 10-24 x 1/2" Pan Hd. Tapt. T-25 (5 of 17) (17)
13 45-88-0406 Washer (1 of 2) (2)
22 --------------- Bushing (1 of 3) (3)
24 05-90-0225 Washer (1)
25 06-82-8828 8-32 x .313" Pan Hd. Taptite T-20 (3)
26 --------------- Gearcase (See Page 3) (1)
27 06-82-5376 12-24 x 1" Pan Hd. Taptite T-27 (7)
28 34-40-0185 Seal Gasket (1)
29 --------------- Pin (2)
30 --------------- Bevel Pinion (1)
31 --------------- Ball Bearing (1)
32 --------------- Bearing Plate (1)
33 45-88-0895 Washer (1)
34 45-88-6230 Spring Washer (1)
35 --------------- Helical Gear (1)
36 --------------- Ball Bearing (2)
37 06-82-5358 12-24 x 3/4" Pan Hd. Taptite T-27 (1)
38 --------------- Idler Gear (1)
39 45-88-6232 Washer (1)
40 --------------- Pin (1)
41 06-82-7326 8-16 x 1" Pan Hd. Plastite T-20 (4)
42 --------------- Diaphragm (1)
43 02-04-0175 Ball Bearing (1 of 2) (2)
44 --------------- Ba󰀪e (1)
45 42-28-0085 Rubber Block (2)
46 22-64-0465 Power Cord (1)
47 06-82-7409 8-16 x 1/2" Pan Hd. Plastite T-20 (2)
53 05-78-0305 M3.5 x 7mm Pan Hd. Screw (4)
54 23-66-2726 On-O󰀨Switch (1)
57 06-82-7251 8-16 x 3/8" Pan Hd. Taptite (1)
58 06-82-7270 8-16 x 5/8" Pan Hd. Plastite T-20 (4)
59 06-82-0125 1/4-20 x 1.65" Pan Hd. Taptite T-30 (1)
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
60 --------------- Handle Cover (1)
61 06-82-5360 1/4-2 x 5/8" Pan Hd. Taptite T-30 (3)
63 23-94-0445 Leadwire Assembly (Not Shown) (1)
64 23-66-0375 Hi-Low Switch (1)
65 23-94-0505 Leadwire Assembly (Not Shown) (1)
66 23-94-0515 Leadwire Assembly (Not Shown) (1)
67 23-94-0525 Leadwire Assembly (Not Shown) (1)
68 --------------- Support Handle (1)
69 23-16-0015 Isolator Support (1)
70 28-50-0045 Outer Motor Housing (1)
75 --------------- Pulley Support (See Page 2) (1)
81 06-65-0115 Coiled Pin (1 of 3) (3)
88 12-20-6232 Service Nameplate (1)
89 --------------- Nameplate Screw (2)
102 23-44-0220 Brush Cap (2)
103 22-18-0025 Carbon Brush (2)
104 05-88-1360 M4 x 13.5mm ST Screw (4)
105 22-20-0080 Brush Holder Assembly (2)
107 31-50-0305 Inner Motor Housing (1)
108 42-96-0016 Bearing Cap (1)
109 02-04-0645 Ball Bearing (1)
112 --------------- Armature (1)
113 06-82-0065 10-32 x 1" Pan Hd. Taptite T-25 (1)
114 30-13-0015 T-Block (1)
115 06-82-5330 10-32 x 5/8" Pan Hd. Taptite T-25 (2)
116 40-50-0845 Lever Release Spring (1)
117 42-42-0060 Release Button (1)
118 --------------- Shoe Bumper (1)
119 43-54-0085 Blade Guard (1)
129 14-13-0010 Diaphragm Kit (1)
130 42-14-0015 FanBa󰀪eKit (1)
133 32-60-0095 Bevel Pinion Assembly (1)
135 42-18-0035 Shoe Bumper Kit (1)
141 31-44-0785 Handle Assembly Kit (1)
143 18-07-0045 Service Field Kit (1)
144 16-10-0035 Service Armature Kit (1)
145 32-60-6230 Idler Gear Kit (1)
146 14-30-6230 Outer Motor Housing Kit (1)
SEE PAGE 3 FOR FASTENER TORQUE CHART
Apply Loctite
®
243
to threads of
screws 113
and 115.
= Part number change from
previous service parts list.
MILWAUKEE TOOL
l
www.milwaukeetool.com
13135 W. LISBON RD., BROOKFIELD, WI 53005
Drwg. 2
background
83
84
85
93
94
91
77
78
81
84
87
8 86 2 58
98
97
96
80
79
82
90
75
71
101
1
76
73
74
147
72
75
92
20
15
14
16
17
18
17
19
95
75 90
91
142
81 82 96
97 98
139
14 15 16
17 18 19
136
14 15 16 17
18 19 20 92
134
14 15 16 17
18 19 20 92
134
7 8 79 80
83 86 150
151
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
1 06-82-5314 10-24 x 1/2" Pan Hd. Tapt. T-25 (4 of 17) (17)
2 31-15-0325 Pulley Cover (1 of 2) (2)
8 45-69-0010 Pulley Tire (1 of 2) (2)
14 --------------- 12-24 UNC x .96" Slotted (2 of 4) (4)
15 --------------- Washer (2 of 4) (4)
16 --------------- Ball Bearing (4 of 8) (8)
17 --------------- Washer (2 of 4) (4)
18 --------------- Ball Bearing (1 of 2) (2)
19 --------------- Pin (1 of 2) (2)
20 06-82-5574 10-24 x 7/8" Pan Hd. Tapt. T-25 (2 of 4) (4)
58 06-82-7270 8-16 x 5/8" Pan Hd. Plastite T-20 Screw (3)
71 06-82-7252 8-32 x .38" Pan Hd. Taptite T-20 (2)
72 31-52-0066 Tension Release Lever (1)
73 06-75-4675 3/8"-16 UNC x 1" Socket Hd. Cap Screw (1)
74 31-44-0740 Front T-Handle (1)
75 --------------- Pulley Support (1)
76 31-15-0335 Front Pulley Shroud (1)
77 45-08-0070 Cam Shaft (1)
78 42-40-0105 Cam Bushing (1)
79 06-75-0035 5/16-18 x 9/16" Screw (1)
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
80 45-88-0395 Washer (1)
81 06-65-0115 Coil Pin (2 of 3) (3)
82 --------------- Driver Plate (1)
83 42-12-0015 Front Pulley Shaft (1)
84 45-88-7165 Washer (2)
85 42-40-0585 Sleeve Bearing (2)
86 28-95-2715 Front Pulley (1)
87 34-60-1400 Snap Ring (1)
90 44-52-0120 Blade Backing Pad (1)
91 02-50-0035 Needle Bearing (1)
92 --------------- Front Roller Block (1)
93 06-81-0075 Shoulder Screw (3)
94 42-40-0115 Tension Bushing (3)
95 44-66-6232 Wear Plate (1)
96 --------------- Support Plate (1)
97 --------------- Blade Tension Spring (2)
98 --------------- Contact Plate (1)
101 31-15-0355 LED Cover (1)
134 42-24-0015 Front Guide Roller Kit (1)
136 14-46-0465 Guide Roller Kit (1)
139 42-18-0015 Tensioning Mechanism Assembly (1)
142 14-30-0060 Pulley Support Kit (1)
147 06-82-0145 8-32 x .48" Pan Hd. M Screw T-20 (1)
151 14-30-2729 Pulley Service Kit (1)
EXAMPLE:
Component Parts
(Small #) Are Included
When Ordering The
Assembly (Large #).
0
00
FIG. NOTE:
75,90 Use Loctite
®
326 or the equivalent
to secure the Blade Backing Pad (90)
to the Pulley Support (75).
= Component change from
previous service parts list.
SEE PAGE 3 FOR FASTENER TORQUE CHART
FIG. NOTE:
73 Use Loctite
®
243 or the equivalent to the threads of Screw (73)
prior to installing T-Handle (74) onto Pulley Support (75).
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FIG. PART NO. DESCRIPTION OF PART NO. REQ.
1 06-82-5314 10-24 x 1/2" Pan Hd. Tapt. T25 (8 of 17) (17)
2 31-15-0325 Pulley Cover (1 of 2) (2)
3 06-75-0010 M Screw, 3/8"-16 UNC 5/8" Hex Hd. (1)
4 40-50-0805 Disc Spring (1)
5 43-06-0010 Clutch Washer (2)
6 43-06-0015 Clutch Plate (2)
7 28-95-2710 Rear Pulley (1)
8 45-69-0010 Pulley Tire (1 of 2) (2)
9 --------------- Spindle (1)
10 --------------- Gearcase Cover (1)
11 --------------- Ball Bearing (1)
12 --------------- Spur Gear (1)
13 45-88-0406 Washer (1 of 2) (2)
14 --------------- 12-24 UNC x .96" Slotted (2 of 4) (4)
15 --------------- Washer (2 of 4) (4)
16 --------------- Ball Bearing (4 of 8) (8)
17 --------------- Washer (2 of 4) (4)
18 --------------- Ball Bearing (1 of 2) (2)
19 --------------- Pin (1 of 2) (2)
20 06-82-5574 10-24 x 7/8" Pan Hd. Tapt. T-25 (2 of 4) (4)
LUBRICATION NOTES:
Type ‘J’ Grease, No. 49-08-4220
When installing Gearcase Cover Kit (140),
place 4.8 g, (.16 oz) grease to the Bevel
Gear (120). Place 6 g (.21 oz.) to the large
Spur Gear (12).
Coat Washers (13 & 150) and ends and
middle of shafts (9 & 122) with J Grease.
Lightly coat both sides of
Washers (5) and Clutch
Plates (6) with J Grease.
18
19
17
21
26
1
23
58
2
3
4
5
6
7
9
1
10
11
12
13
22
123
124
125
120
122
43
29
26
14
15
16
20
7 8 79 80
83 86 150
151
7
150
152
22 26
29
128
14 15 16
17 18 19
136
14 15 16 17
18 19 20 21
127
123 124
125
137
14 15 16 17
18 19 20 21
127
9 10 11 12
13 43 120 122
140
8
150
7
8
3
26
Dowel
To properly tighten
hex head screw (3), use
a wooden dowel or a nylon
rod in the opening between
the rear pulley (7) and gearcase
(26). Be careful not to damage
pulley tire (8). Apply enough pressure
to prevent rear pulley from turning.
Torque hex head screw (3) to 312 in-lbs.
Service Tool 61-30-6232 can be ordered
to secure rear pulley to tighten hex hd. screw.
Service Tool
61-30-6232
Use screws (1) to temp-
orarily attach service
tool to rear pulley. Hold
tool and tighted hex
head screw (3) to 312 in-lbs.
SCREW TORQUE CHART
Torque
Fig. Part No. Location (in-lb)
3 06-75-0010 Rear Pulley 312
20 06-82-5574 Front Roller Block
Rear Roller Block 39
25 06-82-8828 Bearing Plate
Ground Terminal 17
27 06-82-5376 Gearcase
Pulley Support 38
37 06-82-5358 Diaphragm 38
41 06-82-7326 Diaphragm 16
47 06-82-7409 Handle Cover 17
58 06-82-7270 Handle Cover 17
59 06-82-0125 Handle Cover 39
61 06-82-5360 Handle Cover
Support Handle 39
71 06-82-7252 LED Cover 22
73 06-75-4675 Front T-Handle 83
79 06-75-0035 Support Plate 104
93 06-81-0075 Support Plate 36
100 05-81-0010 LED Assembly 6
104 05-88-1360 Brush Holder Assembly 5
113 06-82-0065 T-Block 19
115 06-82-5330 T-Block 19
125 06-82-5346
Tire Cleaning Brush Cover
22
147 06-82-0145 Tension Release Lever 22
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
21 --------------- Rear Roller Block (1)
22 --------------- Bushing (2 of 3) (3)
23 31-15-0330 Rear Pulley Shroud (1)
26 --------------- Gearcase (1)
29 --------------- Pin (1 of 2) (2)
43 02-04-0175 Ball Bearing (1 of 2) (2)
58 06-82-7270 8-16 x 5/8" Pan Hd. Plastite T-20 Screw (3)
120 --------------- Bevel Gear (1)
122 --------------- Shaft (1)
123 --------------- Tire Cleaning Brush (1)
124 --------------- Tire Cleaning Brush Cover (1)
125 06-82-5346 8-32 x 3/4" Pan Hd. Taptite T-20 (2)
127 42-28-0025 Rear Guide Roller Kit (1)
128 14-30-0015 Gearcase Top Assembly (1)
136 14-46-0465 Guide Roller Kit (1)
137 44-60-0295 Tire Clearing Brush Kit (1)
140 14-30-0055 Gearcase Cover Kit (1)
150 45-88-1580 Washer (1)
151 14-30-2729 Pulley Service Kit (1)
152 28-95-0074 Rear Pulley Service Kit (1)
NOTE:
312 in/lbs.
or 26 ft/lbs.
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WIRING SPECIFICATIONS
Terminals, Connectors and 1 or 2 End Wire Preparation
Wire
Color
Origin or
Gauge
Wire
No.
Length
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 Cord ----- Componentofthecordset.Connecttolowerleftpositionoftheon-o󰀨switch.
2 White Cord ----- Componentofthecordset.Connecttoupperleftpositionoftheon-o󰀨switch.
3 Green Cord ----- Component of the cord set. Connect to grounding area on surface of the gearcase.
4 Black 23-94-0525 ----- Leadwireassembly.Connectringterminaltothelowerrightpositionoftheon-o󰀨switch.
Route wire assembly through handle and into the motor housing. Connect to left brush holder.
5 White 23-94-0445 -----
Leadwire assembly. Connect ring terminal (without shrink tubing) to the upper right position of
theon-o󰀨switch.Connectringterminalwithshrinktubingtohi-lowswitchwithwhitewire#10.
RB LB
FRONT VIEW (BRUSH END)
OF OUTSIDE MOTOR HOUSING
BACK VIEW
OF ON-OFF SWITCH
2
1
4
5
Cord jacket is to
extend 1/4” min.
beyond the cord
clamping area
2
4
3
5
1
5
4
5
= WIRE TRAPS
or GUIDES
4
2a
2b
‘2a’
‘2b’
Lo
Side
Hi
Side
NOTE: Hi-Lo Switch is to be placed in the
right handle halve with the side that has
positions ‘2a’ and ‘2b’ facing back towards
the On-Off Switch.
background
9 Black 18-07-0045 ----- Componentoftheeld.Connectringterminaltohi-lowswitchasshownalongwithoneend
of white jumper wire #11.
10 White 18-07-0045 ----- Componentoftheeld.Connectringterminaltohi-lowswitchasshownalongwithring
terminal of white wire #5.
11 White 23-94-0505 ----- Jumper wire. Connect to hi-low switch as shown.
WIRING SPECIFICATIONS
Terminals, Connectors and 1 or 2 End Wire Preparation
Wire
Color
Origin or
Gauge
Wire
No.
Length
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.
RB
LB
FRONT VIEW (BRUSH END)
OF OUTSIDE MOTOR HOUSING
HI-LO SWITCH
WIRING DETAIL
= WIRE TRAPS
or GUIDES
10
11
9
‘2a’
‘2b’
Lo
Side
Hi
Side
10
11
9
10
10
9
9
2a
2b
NOTE: Hi-Lo Switch is to be placed
in the right handle halve with
the side that has positions
‘2a’ and ‘2b’ facing back
towards the On-Off
Switch.
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6 White 23-94-0515 ----- Leadwire assembly. Connect ring terminal end to hi-low switch along with ring terminal of
blueeldwire#7.Connectotherendtotherightbrushholder.
7 Blue 18-07-0045 ----- Componentoftheeld.Connectringterminaltohi-lowswitchalongwithwhitewire#6.
8 Red 18-07-0045 ----- Componentoftheeld.Connectringterminaltohi-lowswitchasshown.
WIRING SPECIFICATIONS
Terminals, Connectors and 1 or 2 End Wire Preparation
Wire
Color
Origin or
Gauge
Wire
No.
Length
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.
RB
LB
FRONT VIEW (BRUSH END)
OF OUTSIDE MOTOR HOUSING
HI-LO SWITCH
WIRING DETAIL
= WIRE TRAPS
or GUIDES
8
6
7
6
7
8
7
8
6 8
2a
2b
‘2a’
‘2b’
Lo
Side
Hi
Side
NOTE: Hi-Lo Switch is to be placed
in the right handle halve with
the side that has positions
‘2a’ and ‘2b’ facing back
towards the On-Off
Switch.

Specifications

Indexed Terms: Band Saw

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