Milwaukee 5339-20 Setup guide

58-92-5305 d1 022005
Cat. No. 5339-20
SDS Max Demolition Hammer
Cat. No. 5342-20
SDS Max Rotary Hammer
MILWAUKEE ELECTRIC TOOL CORPORATION
13135 W. LISBON ROAD • BROOKFIELD, WISCONSIN 53005-2550
REPAIR
INSTRUCTIONS

2
PAGE
INSTRUCTIONS
REPAIR
58-92-5305 d1
Special Tools
Require –Forcing discs 61-10-0011 –Hex key 4 mm
–Hex key 5 mm
–Sleeve 61-10-0013
–Pin-type face spanner 61-10-0012
–Spindle Fixture (optional) 61-30-0290
Important!–Before beginning the maintenance work, perform an initial check with a high voltage test.
–Before performing repair work, disconnect the power cord from the electrical outlet!
Disassembly
Removing the
auxiliary handle 1Remove handle (1) by turning it counter- clockwise.
Disassembling
the handle 1Unscrew knob (3) and remove screw (1).
2Press spring ring (2) in direction of the ar-
rows and remove handle (4).
1
1
34
2
61
-
10
-
0011
61
-
10
-
0012
61
-
10
-
0013
61
-
30
-
0290

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Removing the
spring ring 1Remove both retainers (1).
2Slightlyspreadspringring(2)andpullitoff
the machine towards the front.
Removing the
end cover cap ☞Position machine in a vertical position.
1Depress sleeve (2) and remove end cover
cap (1) with aid of a screwdriver.
2Remove sleeve (2).
3Remove retaining ring (3).
4Remove the following parts:
–damping element (4)
–damping ring (5)
–interlock sleeve (6).
☞Removing/leveringoff damping ring(5)
prior to removing retaining rings (3) will
be an alternative method of spindle
disassembly
Removing the
interlock
elements
1Depress interlock plate (2) against pres-
sure springs (3) until interlock elements
(1) are released. Remove them, if neces-
sary with aid of a screwdriver.
2Remove the following parts:
–interlock plate (2)
–pressure spring (3),
–washers (4).
☞Usingservicefixture#61-30-0290,with
two legs removed, will allow equal
pressure to be applied to both sides of
the interlocking elements for easy re-
moval.
1
1
2
1
2
3
4
5
6
1
2
3
4

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Removing the
seal retainer 1Remove four screws (1) with a 5 mm hex key.
2Turn seal retainer (2) 45° and remove it
with a plastic face hammer from below
(see illustration).
☞Removal of seal retainer (2) only re-
quires light hammer blows at each of
the four screw holes. Striking seal re-
tainer with heavy blows can damage
retainer.
Disassembling
the seal retainer 1Remove outer o-ring (2) from seal retainer (1).
2Remove inner seal ring (3) from seal re-
tainer (1).
3Remove retaining ring (4) from the gear-
box.
Removing the up-
per gear box cov-
er
1Remove six screws (1) with washers from
the gear box cover.
2Remove gasket (2) from groove of gear
box (3).
1
2
2
1
2
3
44
2
1
3

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Removing the
lever 1Removeadjustingplateassembly(4)from pin (2) located on lever (1).
2Squeeze spring (5) together at the bottom
side of lever (1) and remove lever from
gear box cover.
3Remove O-ring (3).
☞When removing adjusting plate (4)
from pin (2) take care to not bend
spring assembly.
Combined
drill/chisel
hammer:
Removing
spindle assembly
1Loosen spindle assembly (1) by turning it
slightly and pulling it from the front of the
gear box (in direction of arrow).
☞In case of stiffness, lightly tap gear box
(2) with a plastic face hammer. Spindle
assembly (1) will be released in direc-
tion of arrow.
Chisel
hammer:
Removing
spindle assembly
1Remove retaining ring (3) using retaining
ring pliers from spindle groove.
2Loosen spindle assembly (5) by turning it
slightly and pulling it from front of gear box
(in direction of arrow).
☞In case of stiffness, lightly tap gear box
(4) with a plastic face hammer. Spindle
(5) will be released in direction of ar-
row.
3Remove retaining ring (3), washer (2) and
O-ring (1) from gear box (4).
1
2
3
5
4
12
321
4
5

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Disassembling
the spindle as-
sembly
1Remove thrust collar (1) from spindle (4).
Remove O-ring (2) from thrust collar (1).
2Remove ram assembly (5) from spindle
(4) by tapping it lightly with a plastic face
hammer.
Remove O-ring (6) from ram (5).
3Remove retaining ring (3) from spindle.
Disassembling
the spindle as-
sembly
1Remove following parts from spindle (D):
–roller race (1)
–washer (2)
–o-ring (3)
–attachment washer (4).
2Remove four rollers (C) with a magnetic
screwdriver from spindle (D).
☞In case of stiffness, remove rollers (C)
with light taps with a plastic face ham-
mer. Twist the spindle and driver back
and forth while tapping to aid in easy
roller removal.
3Remove striker guide (5) from spindle (D).
4Remove striker (7) and o-ring (6) from
striker guide (5).
5Remove three o-rings (8) from striker (7).
6Remove thrust collar (9), pressure o-ring
(A), and washer (B) from spindle (D).
12
3
4
56
A
1
9
2
5
678
BC
D
34

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Removing the
piston assembly 1Position piston assembly (5) into the back dead center position.
2Combined drill/chisel hammer:
Remove spindle bevel gear (3) from gear
box.
3Remove set collar (1) and locking plate (2)
from gear box.
4Removethe piston assembly (5) upwards.
Remove o-ring (4) from piston (5).
Disassembling
the motor hous-
ing
1Remove the two screws (1) from service
cover (2) and remove service cover (2) in
direction of arrow.
2Lift springs (3) on both sides of carbon
brush cover and pull carbon brushes out
(4). Pull the carbon brush leads off.
3Remove four hex head screws (4) from
the motor housing.
4Pull gear box (5) with the armature from
the motor housing.
☞Carbon brush set consists of two
brushes, one brush has a secondary
lead incorporated into it. This lead
must be disconnected from the elec-
tronic module at this time.
1
2
3
45
5
3
4
124

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Disassembling
the armature 1Remove three hex head screws (8) from bearing end plate (7) and pull complete ar-
mature assembly (B) with bearing end
plate (7) from gear box (1).
2Remove o-ring (2) from gear box (1).
3Insert the pin-type face spanner (61-10-
0012)(3)intosealnut(4)andremoveseal
nut (4) counter-clockwise. Remove bear-
ing end plate (7).
4Remove retaining ring (5) from bearing
end plate (7) and press out bearing (6).
5Separate fan (9) from armature (B) with
forcing discs (A).
6Remove bearing cup (D) and press off
bearing (C).
☞If armature fan (9) requires removal,
use service fixture (A) #61-10-0011 as
illustrated. (Follow fan reassembly pro-
cedure).
Removing the
crank wheel 1Remove following parts from gear box (8):
–crank wheel (1)
–thrust washer (2)
–thrust bearing (3)
–thrust washer (4).
2Combined drill/chisel hammer:
Additionally remove clutch (5) from gear
box (8).
3Remove caged needle bearings (6 and 7)
by simply lifting them out of the gear box.
☞The chisel hammer does not have a
clutch (5) and needle bearings (6 & 7)!
☞No cleaning solvent should penetrate
into clutch; wipe any old lubrication off
clutch assembly using a dry, clean rag.
9
23456
8
7
A
B
CD
1
5
6
7
8
1
3
4
2

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Removing the
lower gear box
cover
1Remove two screws (1) and remove lower
gear box cover (2).
☞The exposed plane surface serves
only for manufacturing the gear box
and has no other function!
Disassembling
the electronic
component
1Remove the four screws (1) from the
handle and remove handle half (2).
2To remove cord leads, remove/loosen two
screws (4) from switch (3).
3Remove screws (5) from cord clamp (6)
and remove the cord (7).
4Remove the following parts:
–four o-rings (C)
–two wires (D)
–two screws (A)
–two carbon brush holders (B)
–electronic part (E)
–four screws (8)
–side handle plate (9).
12
3
4
5
6
D
8
9
A
BC
E
7
1
2

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Removing the
anti-vibration
mechanism
and the field
1Remove air deflector ring (5).
2Remove screw (4). Remove the following
partsof the anti-vibration mechanismfrom
motor housing (8):
–thrust piece (1)
–spring (2)
–vibration lever(3).
☞Caution: Screw (4) and vibration spring
cover (1) are under spring pressure.
3Remove two screws (7) and remove field
(6) from motor housing (8).
☞Should the field be stuck, tap motor
housing (8) lightly with a plastic face
hammer.
12
3
4
56
78

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Maintenance
General It is recommended that maintenance be performed on the machine at regular intervals or when the car-
bon brushes reach end of life.
Cleaning Clean all parts – with the exception of the electrical parts and clutch– with cold cleaning solvent. Cau-
tion! No cleaning solvent should penetrate into the bearing. Clean the electrical parts with a dry brush.
Check for wear Check the disassembled parts for wear (visual inspection) and replace worn parts.
Electrical tests Before reassembling, perform an electrical test on all relevant parts (refer to repair instructions).
Lubrication Each time carbon brushes wear out and loose contact with commutator it is recommended that the ma-
chine be fully disassembled and all old grease removed and replaced with new grease. Service main-
tenance kit No. 14-46-0041 contains all necessary lubrication, gaskets and o-rings to properly service
the macine.
Refer to service maintenance kit information below to determine which lubrication instructions need to
be followed.
Maintenance Kit No. 14-46-0041 contains three (3) different greases:
Type ‘P’ grease (2 - 100g tubes)
Type ‘L’ bit grease (1 - 20g tube)
Type ‘Q’ grease (1 - 45g tube)
OR
Type ‘P’ grease (2 - 100g tubes)
Type ‘L’ bit grease (1 - 20g tube)
Type ‘Q2’
grease (1 - 45g tube)
Check your maintenance kit and determine if there is Type ‘Q’ or Type Q2” grease and follow the
instructions for the tool that you have located on pages 12 and 13.

12
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INSTRUCTIONS
REPAIR
58-92-5305 d1
Lubrication: Combined drill/chisel hammer (5342-20)

13
PAGE
INSTRUCTIONS
REPAIR
58-92-5305 d1
Lubrication: Chisel hammer (5339-20)

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Sequence and torques of the screws:
BA
C
D
E
F
G
H
I
J
K
L
M
N

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Assembly
Installing the
anti-vibration
mechanism
and field
1Install field (6) into motor housing (8) and
secure it with two screws (7) (torque = 2
Nm / 18 in. lbs.).
2Install following parts of the anti-vibration
mechanism into motor housing (8):
–vibration lever (3)
–spring (2)
–vibration spring cover (1).
3Tighten anti-vibration mechanism with
screw (4) (torque = 3 Nm / 27 in. lbs.).
4Insert air deflector ring (5) into motor
housing (8). Mind the right position!
Assembling
the electronic
component
1Install the following parts:
–side handle plate (9)
–motor housing screws (8) (torque = 4
Nm / 35 in. lbs.)
–dial switch (E)
–two carbon brush holders (B)
☞Insert end of flat spiral spring (G) into
slot(H) in pin ofcarbon brush holder as
indicated in enlargement of figure
(meaning: hook flat spiral spring (G)
into pin in “11 o’clock” position!).
Tension flat spiral spring by 1 turn in a
clockwise direction. Afterwards posi-
tion other spring end (I) onto carbon
brush holder (“ready position”).
☞twoswitch screws (A) (torque=1.3 Nm
/ 12 in. lbs.)
–two wires (D)
–four O-rings (C).
☞Take care that no wires are jammed or
pinched.
☞All wires must be correctly installed
between the cable entry lugs
(refer to wiring instructions).
2Install switch (3) into handle half (F).
3Install cord (7) and secure cord clamp (6)
with screws (5) (torque = 1.3 Nm / 12 in.
lbs).
4Connect cord leads (7) to switch (3) and
secure screws (4)
(torque = 0.5 Nm / 4 in. lbs.).
5Install handle half (2) and secure handle
half with four screws (1) (torque = 3 Nm /
27 in. lbs.).
12
3
4
5 6 7
8
34
56
D
8
9
A
BC
E
7
1
2
F
G
H
I

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Installing the
gear box cover 1Securegear box cover (2)withtwo screws (1) onto the gear box (torque = 3 Nm / 27
in. lbs.).
Combined
drill/chisel
hammer:
Installing the
clutch and crank
assembly
1Place caged needle bearings (1) into lu-
bricated steel sleeve in gear box (2).
2Install clutch assembly (3) into gear box
(2) in direction of arrow.
3Install the following pre-lubricated parts
over the stationary axle inside gear box
(2).
–thrust washer (4)
–thrust bearing (5)
–thrust washer (6)
4Install crank wheel assembly (7) over gear
box axle assembly in direction of arrow.
☞The clutch is pre-set and should re-
lease between (96 ft. lbs. / 130 Nm) to
(140 ft lbs. / 190 Nm). See instructions
for checking the static slip of the clutch.
Chisel ham-
mer:
Installing the
crank assembly
1Install the following pre-lubricated parts
over stationary axle inside gear box (1).
–thrust washer (2)
–thrust bearing (3)
–thrust washer (4)
2Install crank wheel assembly (5) over gear
box axle assembly.
12
3
1
1
2
7
6
5
4
1
5
4
3
2

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Assembling the
armature 1Press bearing (B) onto armature shaft and install bearing cup (C) into rear bearing
bore of motor housing (not shown).
2See illustration below:
☞Refertochart”A”belowwhenremoving or
installing the armature fan. It is very im-
portant to press armature fan to dimen-
sion shown, then apply Loctite®401
Porous Material Bonding Adhesive
around the entire base of fan (360°).
Allow the bonding agent to cure com-
pletely per manufacturers instructions.
3Press bearing (6) into bearing end plate
(7) and install locking ring (5).
4Install bearing end plate assembly (5,6,7)
onto the armature shaft.
5Screw in seal nut (4) with pin-type face
spanner (3) [61-10-0012] (torque = 16 Nm
/ 141 in. lbs.).
6Install o-ring (2) into gear box (1).
7Apply Blue Loctite®to three screws (8).
Install bearing end plate with armature
assembly (A) into rear bearing bore in
gear box (1) and tighten the three screws
(8) (torque = 4 Nm / 35 in. lbs.).
9
2345
68
7
A
BC
1

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Installing the
motor housing 1Apply Blue loctite®onto four screws (4). Install gear box and armature (5) into mo-
tor housing (6) and tighten four screws (4)
cross-wise (torque = 13Nm / 115 in. lbs.).
2Install and connect carbon brushes (3) on
both sides (refer to wiring instruction bulle-
tin).
3Install service cover (1) and secure it with
two screws (2) (torque = 1.3Nm / 12 in.
lbs.).
☞Slant service lid (1) slightly when install-
ing and tighten screws (torque =
1.3Nm / 12 in. lbs.).
☞Note: Carbon brush set consists of two
brushes, one brush has a secondary
lead incorporated into it. This lead
must be connected to the electronic
module at this time.
Installing
the piston 1Combined drill/chisel hammer: Install spindle bevel gear (3) into gear box
(7).
2Install O-ring (4) onto piston (5).
3Insert piston (5) into the set collar (1) and
locking plate (2). Install assembly into
gear box: put connecting rod of piston (5)
on pin (6) of crank wheel.
5
3
4
2
1
6
12
345
6
7

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INSTRUCTIONS
REPAIR
58-92-5305 d1
Assembling
the spindle 1Install thrust washer (C), back-pressure o- ring (B), and thrust collar (A) into spindle
(E). Lubricate prior to assembly.
☞Mind the right position when installing
thrust collar (A): the bevel-edge of
thrust collar (A) must face striker (8)!
2Check: should striker guide (6) or
rollers(D) be damaged or burred, all
parts must to be replaced (striker and
striker guide).
3Install O-ring (7) onto striker guide (6). In-
stall three O-rings (9) onto striker (8) and
insert the assembly into striker guide (6).
☞The short end of striker (8) must face
the nosepiece!
☞Thestriker(8) must protrude thestriker
guide (6) approx. 0.5 mm!
4Installstriker guide assembly(6,7,8,9)into
spindle (E) facing thrust collar (A).
5Install four rollers (D) into spindle (E).
6Install the following parts onto spindle(E):
–attachment washer (5)
–o-ring (4)
–washer (3)
–roller race (2)
–retaining ring (1).
Assembling the
ram into the spin-
dle
1Install o-ring (3) onto ram (2). Lubricate
ram prior to assembly.
2Install ram assembly (2 and 3) into spindle
(1).
☞Lubricate front of gear box per lubrication
chart specifications prior to installing
spindle assembly.
B
2
A
3
6
789
C
E
6
8
1
6
8
4
5
D
1
23

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INSTRUCTIONS
REPAIR
58-92-5305 d1
SDS Max
combined
drill/chisel
hammer:
To check static
slip of clutch
1Secure hammer gear box in a machinists
vise.
2Install service fixture #61-10-2060 into
front spindle.
3Engage / lock external splines of set collar
into internal splines of spindle bevel gear
(figs. 2 and 3).
4Install a piece of nylon bar stock or equiv-
alent material, approximately 3/4” x 1-1/8”
in between locking plate and gear box.
Turn service fixture slowly clockwise until
nylon bar stock is wedged tight between
wall of gear box and crank wheel, as
shown (fig. 3). Once crank wheel has been
secured, continue to turn torque wrench in
a clockwise direction until clutch slips.
5Clutch must slip at 96-140 ft. lbs. (130-190
Nm.) at spindle, checked clockwise as
viewed from the front of the tool. (Refer to
note below).
Note: If the static slip of the clutch doesn’t
fall between the listings, do the following:
Run the tool at the highest speed (“G” on the
dial switch) for 10 minutes. Immediately re-
move gear box cover and insert recommend-
ed nylon / plastic block into gear box to
prevent gears from rotating. Turn the torque
wrench clockwise and slip the clutch 8 times
before actual slip torque readings are taken.
Take an additional 8 slip torque readings and
determine the average of the 8 readings. The
average should be within the torque range
specified.
Spline ham-
mer:
To check static
slip of clutch
1Install service fixture #61-10-2065 into
front spindle.
2Install a piece of nylon bar stock or equiv-
alentmaterial,approximately3/4” x 1-1/8”
into gear box on the opposite side of pis-
ton connecting rod. Turn service fixture
slowly clockwise until nylon bar stock is
wedged tight between wall of gear box
and crank wheel, as shown (fig. 1). Once
crank wheel has been secured, continue
to turn torque wrench in a clockwise direc-
tion until clutch slips.
3Clutch must slip at 96-140 ft. lbs. (130-
190 Nm.) at spindle, checked clockwise
asviewed from the frontof the tool. (Refer
to note above).