Milwaukee M18 FUEL HACKZALL Guide

MILWAUKEE TOOL lwww.milwaukeetool.com
13135 W. Lisbon Road, Brookeld, WI 53005
Drwg. 1
BULLETIN NO.
54-40-2740
SERVICE PARTS LIST
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
1 45-16-0927 Shoe/Water Barrier Assembly (1)
2 06-82-5320 8-32 x 5/8" Pan Hd. Tapt. T-20 Screw (2)
3 14-46-1011 Steel Quik-Lok® Blade Clamp Kit (1)
3a 34-60-3680 Retaining Ring (1)
3b 42-50-0076 Front Cam (1)
3c 44-60-0626 Lock Pin (1)
3d 42-50-0077 Rear Cam (1)
3e 45-22-0081 Sleeve (1)
3f 40-50-0161 Torsion Spring (1)
3g 31-15-0511 Spring Cover (1)
3h 44-86-0740 Front Cap (1)
3j 45-06-0880 Felt Seal (1)
3k --------------- Spindle Bushing (1)
3m --------------- Spindle Shaft (1)
4 06-82-2025 M3.5 x 16mm Pan Hd. Plast. T-10 Scr. (10)
5 31-44-2719 Housing Kit (1)
5a --------------- Housing Cover - Right Housing (1)
5b --------------- Housing Support - Left Housing (1)
6 14-30-1033 Right Gear Case Kit (1)
6a 23-70-3350 Aluminum Tape (2)
6b --------------- Gear Case - Right (1)
6c --------------- Ball Bearing (2)
6d --------------- Bearing Plate (2)
6e --------------- Bearing Plate Screw (6)
6f --------------- Spiral Beval Gear (1)
6g 44-86-0803 Drive Pin Sleeve (1)
7 14-30-1043 Left Gear Case Kit (1)
7a --------------- Spiral Bevel Gear (1)
7b --------------- Gear Case - Left (1)
8 06-82-5320 8-32 x 5/8 Pan Hd Slt. T-20 Screw (7)
CATALOG NO. 2719-20
REVISED BULLETIN
SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS
M18™ FUEL™ HACKZALL® Reciprocating Saw
STARTING
SERIAL NO.
DATE
July 2017
WIRING INSTRUCTION
H98A
EXAMPLE:
Component Parts (Small #) Are Included
When Ordering The Assembly (Large #).
0
00
SEE PAGE 3
FIG. LUBRICATION
(Type 'L' Grease, No. 49-08-4175):
3h,3j Saturate Felt (3j) with lightweight oil prior to assembly with
Cap (3h) onto Bushing (3k) and Spindle (3m).
3k,3m Lightly coat the O.D. of Spindle Shaft (3m) and I.D. of Bush
ing (3k) with grease.
3m Place a dab of grease in the rear slot of Spindle Shaft (3m).
6b,7b Place .25 ounce grease in gear cavity of Gear Cases (6b,7b).
Coat the spindle shaft pocket in Gear Cases (6b,7b).
6f,6g Lightly coat the Drive Pin of Spiral Bevel Gear (6f) and I.D.
and O.D. of Bearing Sleeve (6g) with grease.
6f,7a,9 Completely coat all of the teeth of the Spiral Bevel Pinion
on Rotor (9) and Spiral Bevel Gears (6f,7a) with grease.
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
9 16-01-0900 Rotor Assembly (1)
10 05-78-0105 M4 x 10mm Pan Hd. Taptite T-20 Scr (2)
12 31-50-1155 Motor Insulator Kit (1)
12a --------------- Motor Insulator Halve - Right (1)
12b --------------- Motor Insulator Halve - Left (1)
13 06-82-1050 4-20 x 0.76 Pan Hd. ST T-10 Screw (6)
14 40-50-1090 Terminal Block Spring (1)
15 14-20-2719 Electronic Assembly (1)
16 45-24-0682 Locking Shuttle (1)
17 05-74-0985 M4 x 12mmPan Hd. Tapt. T-20 Screw (4)
20 12-20-1119 Service Nameplate (1)
31 38-50-0415 Spindle/Bushing Kit (1)
40 50-55-3560 M18 FUEL Contractor Bag (1)
50 31-53-0280 Alignment Plug - Service Tool
(Not component of tool - one per in kits 6 & 7)
3g
3e
3b
3a
3f
3d
8
(2x)
6g
6e
(3x) 3m
3c
3k
3j
3h
4
(10x)
5a
20
6a
6c
6d
6e
(3x)
6f
7a
10
(2x)
6d
6c
7b
6b
16
6a
8
(5x)
5b
12a
15
12b
13
(6x)
14
9
17
(4x)
6 6a 6b 6c 6d
6e 6f 6g 50
3 3a 3b 3c 3d
3e 3f 3g
31 3h 3j
3k 3m
7 6a 6c 6d 6e
7a 7b 50
12 17 12a
12b 13
5 4 5a
5b 20
NOTE:
Clean Gear Case
Kits (6 and 7) with
a clean, dry cloth.
DO NOT wash up.
NOTE:
Lock Pin (3c) to
be coated with
graphite prior to
assembly.
50
Alignment Plugs- For Service Only
Plugs are furnished in Gear Case Kits
#6 and #7. Plugs are not components
of the tool. DO NOT DISCARD after
use. Save for other possible
service applications.
1 8
40

Components of Right Gearcase Kit #14-30-1033 Components of Left Gearcase Kit #14-30-1043
Aluminum Tape
Alignment Plug / Key
Right
Gearcase
Ball Bearing
Bearing Retainer
Right Helical Gear
Screws (3x)
Picture ‘A’ Picture ‘B’ Aluminum Tape
Alignment Plug / Key
Left Gearcase
Ball Bearing
Bearing Retainer
Left Helical Gear
Screws (3x)
Drive Pin Sleeve
Spiral Gear
Keyway
not in-line with
Gearcase Keyway
FIG. 1
Gearcase
Keyway
Opening
FIG. 2
FIG. 3
Alignment Plug / Key
installed in
Gearcase
Right
Gearcase
14-30-1033
‘Shown’
Plug / Key from kit
Spiral Gear
Keyway
in-line with
Gearcase Keyway
Gearcase
Keyway
Opening
Picture “A and B” show the components that make-up the Right and Left Gearcase kits for
M18™ FUEL™ Hackzall® 2719-20. Each kit contains one [1] Alignment Plug / Key and [1]
round Aluminum adhesive backed disc (not sold separately) which will be needed when ser-
vicing / replacing the gearcase assemblies of the M18™ FUEL™ Hackzall®.
The Right and Left helical gear assemblies are supported independently in their respective
gearcase assembly and turn independently. Each of the helical gears have a counter weight
and when the two gearcase halves are assembled together gearing must be synchronized
to eliminate excessive vibration.
Synchronization of the two gear case halves can be accomplished by using the Alignment
Plug / Key supplied with each gearcase kit. Anytime rotor assembly 16-01-0900 has to be
removed from the gearcase halves, helical gears will need to be resynchronized using the
alignment plug / keys.
Synchronizing / Assembling Gearcase Kit Assemblies 14-30-1033 – 14-30-1043
Once the rotor assembly has been removed from the gearcase assembly the keyway cut
into each helical gear will no longer be aligned with the gearcase keyway ( g. 1) due to the
counter balance of the helical gear.
1. Rotate (by hand) helical gear in right gearcase (picture “A”) until helical gear keyway is
in-line with the gearcase keyway (g. 2).
2. Install plug / key from kit into gearcase / helical gear keyway (g. 3).
3. Install drive pin sleeve onto pin located on right helical gear (coat with type “L” grease).
FIG. 4
With pinion of Rotor Assembly secured in
Gear Case Kits, remove and save Alignment
Plug/Keys. Apply Aluminum Tape from kits as
shown. Stator of the Electronic Assembly is than
carefully placed over Rotor Assembly. Stator/Rotor
Assemblies are captured
in Motor Insulator halves
and secured with
fasteners.
4. Install spindle / gearcase
bushing assembly into right
gearcase (coat components with
type “L” grease and make sure
spindle lock pin hole faces right
gearcase).
Note: If new felt seal is being
installed saturate seal with a
lightweight oil.
5. Place approximately 1/8oz. Type
“L” grease onto teeth of right
helical gear. (Set assembly aside).
6. Rotate (by hand) helical gear in left gearcase (picture “B”) until helical gear keyway is
in-line with the gearcase keyway (g. 2).
7. Install plug / key from kit into gearcase / helical gear keyway (g. 3).
8. Place approximately 1/8oz. Type “L” grease onto teeth of left helical gear.
9. Assemble lubricated left gearcase assembly onto lubricated right gearcase assembly and
install ve [5] gearcase screws.
10. Install rotor assembly 16-01-0900 and secure to gearcase assembly.
11. Remove left and right alignment plug (s) and apply aluminum tape disc from kits to each
side of gearcase (g.4). SAVE PLUGS in case rotor needs servicing or replacing.

Ground Wire Terminal
is secured to the other
side of gear case = Wire Traps
LED Assembly
On-Off Switch
Potted PCBA
Battery Connector Block
Rotor, Stator and Hall Board
are captured inside Motor
Insulator Kit.
LED
Assembly
4. Install spindle / gearcase
bushing assembly into right
gearcase (coat components with
type “L” grease and make sure
spindle lock pin hole faces right
gearcase).
Note: If new felt seal is being
installed saturate seal with a
lightweight oil.
5. Place approximately 1/8oz. Type
“L” grease onto teeth of right
helical gear. (Set assembly aside).
6. Rotate (by hand) helical gear in left gearcase (picture “B”) until helical gear keyway is
in-line with the gearcase keyway (g. 2).
7. Install plug / key from kit into gearcase / helical gear keyway (g. 3).
8. Place approximately 1/8oz. Type “L” grease onto teeth of left helical gear.
9. Assemble lubricated left gearcase assembly onto lubricated right gearcase assembly and
install ve [5] gearcase screws.
10. Install rotor assembly 16-01-0900 and secure to gearcase assembly.
11. Remove left and right alignment plug (s) and apply aluminum tape disc from kits to each
side of gearcase (g.4). SAVE PLUGS in case rotor needs servicing or replacing.
3m
3c
3g
3f
3e
3d
3b
3a
Leg
Inner Slot
3 3a 3b 3c 3d
3e 3f 3g
REMOVING THE STEEL QUIK-LOK®BLADE CLAMP (3)
• Remove external retaining ring (3a) and pull front cam (3b) off.
• Pull lock pin (3c) out and remove remainder of parts and discard.
REASSEMBLY OF THE STEEL QUIK-LOK®BLADE CLAMP (3)
• Coat new lock pin with powdered graphite.
• Hold tool in a vertical position.
• Place spring cover (3g) onto spindle.
• Slide torsion spring (3f) onto spindle with spring leg on hole side of spindle.
• Slide sleeve (3e) onto spindle aligning hole on sleeve with hole in spindle.
• Slide rear cam (3d) over sleeve (3e) until it bottoms on sleeve shoulder,
ensure leg of spring (3f) inserts into inner slot in rear cam (3d).
• Rotate rear cam in the direction of the arrows located on spring cover until there is
clearance for lock pin (3c) to be inserted into sleeve/spindle holes. Insert lock pin.
• Align front cam (3b) inner ribs with rear cam outer slots and slide front cam
onto sleeve until it bottoms. Retaining ring groove on the spindle
shaft (3m) should be completely visible.
• Attach retaining ring (3a) 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.
SCREW TORQUE SPECIFICATIONS
SEAT TORQUE
FIG. PART NO. WHERE USED (KG/CM) (IN/LBS)
2 05-74-0985 Shoe Assembly 18-24 15.6-20.8
2 05-74-0985 Motor Insulator 18-24 15.6-20.8
4 06-82-2025 Housing Cover 5-8 4.3-6.9
6e --------------- Bearing Plate 14-18 12.1-15.6
8 06-82-5320 Gear Case-Left 36-42 31.2-36.4
10 05-78-0105 Rotor Assembly 24-30 20.8-26.0
13 06-82-1080 Motor Insulator 12-18 10.4-15.6
WIRING
§As an aid to reassembly, take note of wire routings and position in wire
guides and traps while dismantling tool.
§ Be sure all components are rmly and squarely seated in handle cavities.
§ Be careful and avoid pinching wires between housing halves by tucking
wires completely down in traps and channels when assembling.
§ Prior to installing battery, check for proper functionality of switches, slides
and buttons after housing halves are secure.
§ Install battery and verify the proper operation of tool.