Service Parts List

ManualsBrandsMilwaukee ManualsTools & HardwareM12 Fuel 12-Volt Lithium-Ion Cordless Hackzall Reciprocating Saw Kit

MILWAUKEE ELECTRIC TOOL CORPORATION

13135 W. Lisbon Road, Brookﬁ eld, WI 53005

Drwg. 2

BULLETIN NO.

54-40-2510

SERVICE PARTS LIST

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

1 45-16-0930 Shoe (1)

2 06-82-5320 8-32 x 0.63" Pan Hd. Taptite T-20 (6)

3 45-06-1060 Rubber Seal (1)

4 14-46-1011 Steel Quik-Lok

Blade Clamp Kit (1)

4a 34-60-3680 Retaining Ring (1)

4b 42-50-0076 Front Cam (1)

4c 44-60-0626 Lock Pin (1)

4d 42-50-0077 Rear Cam (1)

4e 45-22-0081 Sleeve (1)

4f 40-50-0161 Torsion Spring (1)

4g 31-15-0511 Spring Cover (1)

5 06-82-2385 M2.6 x 14mm ST Pan Hd. T-8 Screw (9)

6 12-20-2520 Service Nameplate (1)

7 31-44-2425 Handle Assembly (1)

7a --------------- Handle Halve - Right (1)

7b --------------- Handle Halve - Left (1)

8 14-30-1010 Right Gearcase Assembly (1)

9 14-30-0990 Left Gearcase Assembly (1)

10 10-20-4245 Fuel Gauge Label (1)

11 16-07-2500 Rotor Assembly (1)

12 05-78-0105 M4 x 10mm Pan Hd. Tapt. T-20 Screw (2)

14 23-16-1050 Motor Insulator Assembly (1)

14a --------------- Motor Insulator Halve - Right (1)

14b --------------- Motor Insulator Halve - Left (1)

15 05-74-0985 M4 x 12mm Pan Hd. Tapt. T-20 Screw (4)

16 06-82-1050 4-20 x 0.76" ST Pan Hd. T-10 Screw (6)

17 23-66-1725 Switch / Electronics Kit (1)

17a --------------- PCB Assembly (1)

17b --------------- On-Off Switch (1)

CATALOG NO. 2520-20

REVISED BULLETIN

SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS

M12 FUEL™ Hackzall

STARTING

SERIAL NO.

DATE

Apr. 2014

WIRING INSTRUCTION

F51A

EXAMPLE:

Component Parts (Small #)

Are Included When Ordering

The Assembly (Large #).

SEE PAGE 4

FIG. LUBRICATION

(Type 'L' Grease, No. 49-08-4175):

22,23 Saturate Felt (23) with lightweight oil prior to assembly with

Cap (22) onto Bushing (21a) and Spindle (21b).

21a,21b Lightly coat the O.D. of Spindle Shaft (21b) and I.D. of

Bushing (21a) with grease.

21b Place a dab of grease in the rear slot of Spindle Shaft (21b).

8,9 Place .3 ounce (8.5g) grease in gear cavity of Gearcase

Assemblies (8,9).

Coat the spindle shaft pocket in Gearcase Assemblies (8,9).

8,25 Lightly coat the Drive Pin (component pressed into gear in the

right gearcase assembly) and I.D. and O.D. of Drive Pin

Sleeve (25) with grease.

8,9,11 Completely coat all of the teeth of the Spiral Bevel Pinion

on Rotor Assembly (11) and Spiral Bevel Bevel Gears in

gearcase assemblies (8 and 9) with grease.

Lock Pin (4c) to be

coated with graphite

prior to assembly.

NOTE:

Clean Gearcase Kits

(8 and 9) with a clean,

dry cloth. DO NOT wash up.

2(2x)

5(9x)

14a

12(2x)

17d

17a

17c

14b

16(6x)

15(2x)

17b

2(4x)

15(2x)

17e

Alignment Plugs-

For Service Only

Not components

of tool.

Plugs are furnished in

Gearcase Kits #8 & #9.

DO NOT DISCARD

after use. Save for other

possible service

applications. See page

two for specific

instructions.

17a 17b 17c

17d 17e

14a

14b

5 7a

7b 10

4a 4b 4c 4d

4e 4f 4g

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

17c --------------- Terminal Block (1)

17d --------------- Stator Assembly (1)

17e --------------- LED Assembly (1)

18 45-24-2450 Locking Shuttle (1)

19 40-50-1135 Shuttle Spring (1)

20 42-70-0055 Housing Clip (1)

21 42-40-1120 Bushing (1)

22 44-86-0740 Front Cap (1)

23 45-06-0880 Felt Seal (1)

24 23-70-3350 Aluminum Tape (2)

25 44-86-0575 Drive Pin Sleeve (1)

26 42-55-2520 Contractor Bag (1)

27 38-50-1570 Spindle (1)

30 31-53-0280 Alignment Plug - Service Tool

(Not component of tool - one per in kits 8 and 9)

42-70-0058

Improved

Design

Original

Design

42-70-0055

M12™ tools utilize two different Housing

Connection Clip designs depending on the

Handle Set . See page two for details.

Summary of content (4 pages)

PAGE 1
BULLETIN NO. SERVICE PARTS LIST 54-40-2510 M12 FUEL™ Hackzall CATALOG NO. ® STARTING SERIAL NO. 2520-20 WIRING INSTRUCTION F51A SEE PAGE 4 42-70-0058 Improved Original Design Design 42-70-0055 M12™ tools utilize two different Housing Connection Clip designs depending on the Handle Set . See page two for details. * 14a 5(9x) 7a DATE Apr. 2014 REVISED BULLETIN SPECIFY CATALOG NO. AND SERIAL NO.
PAGE 2
Early M12™ Handle Sets utilize Housing Connection Clip No. 42-70-0055. Install this clip design by aligning the side rails of the clip with the two slots in the handle set. Gently push into place with the aid of a small flat blade screwdriver or a similar instrument. Be sure that the clip is properly seated in both slots and that the clip is flush to sub-flush to the end of the handle set.
PAGE 3
Picture ‘A’ Aluminum Tape Picture ‘B’ Screws (3x) Alignment Plug / Key Ball Bearing Right Gearcase Ball Bearing Bearing Retainer Right Spiral Gear Left Spiral Gear Bearing Retainer Left Gearcase Screws (3x) Alignment Plug / Key Aluminum Tape Components of Right Gearcase Kit #14-30-1010 Components of Left Gearcase Kit #14-30-0990 Picture “A and B” show the components that make-up the Right and Left Gearcase kits for M12 FUEL™ Cordless Hackzall® 2520-20.
PAGE 4
REMOVING THE STEEL QUIK-LOK® BLADE CLAMP (49) • Remove external retaining ring (4a) and pull front cam (4b) off. • Pull lock pin (4c) out and remove remainder of parts and discard. 27 4g 4f REASSEMBLY OF THE STEEL QUIK-LOK® BLADE CLAMP (4) • Coat new lock pin with powdered graphite. • Hold tool in a vertical position. • Place spring cover (4g) onto spindle. • Slide torsion spring (4f) onto spindle with spring leg on hole side of spindle.