BULLETIN NO.

SERVICE PARTS LIST 54-40-7060

SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS REVISED BULLETIN DATE
Sept. 2013
CORDLESS 5-3/8" METAL CUTTING SAW
WIRING INSTRUCTION
STARTING
EXAMPLE:
CATALOG NO. 2682-20 SERIAL NO. C74A SEE REVERSE SIDE
00 0 Component Parts (Small #) 29 28 27 26 21
Are Included When Ordering
31
61 22 23
31 33
57 59 58
The Assembly (Large #).
32 62 20
56
55
LUBRICATION:
Type 'Y' Grease, No. 49-08-5270
Liberally coat the teeth of the
Armature Pinion (45). 33 30
Lightly coat the bearing bores
of the Gearcase (41) prior to
installing bearings (39 & 44). 21 23 55
25 56
Fill back end of Gear Housing
Cover (35) with grease, making 24
sure that the teeth of Gear (38)
are completely covered. 67 44 45 46
48 49 51
14 46
50
13 22 45
49
12 44
20 48
43
47
66 11
15 18 42 68

17 21
8 41
16 19
6
15 40 34
Functionally check switch lock-out #27 by
39 54 attempting to turn on tool by applying a
38 53 reasonable amount of force, up to 8 lbs., to
the switch trigger #28. The tool must not turn
11 37 on. Release trigger. Actuate the lock-out lever
3 36 and apply a reasonable amount of force to the
10
switch trigger. The tool must turn on. While the
9 35 trigger is still in the "ON" position, release the
60 52 lock-out. Release the trigger. The tool must
64 41
43 65 53
54
stop and the lock-out lever must again prevent
the actuation of the switch. Repeat the switch
check two more times.
1 2 4 5 6 7 34 63 35 36 37
38 39
Functionally check the lower guard #11, with the saw set
FIG. PART NO. DESCRIPTION OF PART NO REQ. at full depth. Place the saw upside down with the shoe
1 45-04-1020 Hex Flange Blade Screw (1) horizontal. Fully retract the guard and then release it.
2 43-34-0685 Outer Blade Flange (1) The guard must return briskly.
3 43-34-0680 Inner Blade Flange (1)
4 45-04-1060 Bumper Screw (1) FIG. PART NO. DESCRIPTION OF PART NO REQ.
5 42-38-0222 Rubber Bumper (1) 40 43-44-1350 Gasket (1)
6 05-81-1420 M3 x 10 Pan Hd. T-10 Screw (3) 41 --------------- Gearcase (1)
7 44-06-0200 Transparent Window (1) 42 42-14-0500 Baffle (1)
8 42-92-1290 Guard Cover (1) 43 45-06-1050 Rubber Seal (1)
9 43-54-0950 Upper Guard (1) 44 02-04-1920 Ball Bearing (1)
10 34-60-0630 Retaining Ring (1) 45 --------------- Armature Pinion (1)
11 --------------- Lower Guard (1) 46 --------------- Armature (1)
12 40-50-1710 Spring (1) 47 18-10-0300 Service Field (1)
13 06-75-5860 1/4" x 20 UNC Screw (1) 48 45-88-3225 Washer (2)
14 42-18-0400 Hexagon Bar (1) 49 02-04-1930 Ball Bearing (1)
15 --------------- Lower Guard Plate (1) 50 22-22-0760 Brush Card Assembly (1)
16 45-88-3095 Dust Seal (1) 51 06-82-6350 M3 x 16 Screw (4)
17 45-22-0515 Sleeve (1) 52 40-50-1740 Spring (1)
18 45-88-3220 Washer (1) 53 --------------- Spindle Lock (1)
19 42-32-0425 Shoulder Bolt (1) 54 --------------- Lock Button (1)
20 --------------- Housing Support (1) 55 34-40-4480 O-Ring (1)
21 06-82-2025 M3.5 x 15 Pan Hd. Plastite Screw (12) 56 --------------- Housing Cover (1)
22 --------------- LED Assembly (1) 57 49-96-0080 3/16" Hex Key (1)
23 --------------- Micro Switch with PCB (1) 58 06-82-5314 10-24 x 1/2" Pan Hd. Tapt. T-25 Screw (1)
24 14-74-0450 Shoe Assembly (1) 59 44-10-0625 Depth Lever (1)
25 06-57-1100 Lock Nut (1) 60 34-40-2425 O-Ring (1)
26 40-50-1760 Lock Out Spring (1) 61 23-66-3110 Micro-Switch/PCBA/Term. Block Assy. (1)
27 44-20-0720 Switch Lock Out (1) 62 31-44-2295 Housing Assembly (1)
28 23-66-1000 Switch (1) 63 43-78-0590 Hub Assembly (1)
29 22-74-0515 Diode (1) 64 28-14-1110 Gearcase Assembly (1)
30 45-30-0255 Rubber Pin (2) 65 44-20-0700 Spindle Lock Assembly (1)
31 --------------- Battery Terminal Block (1) 66 28-41-1180 Lower Guard Assembly (1)
32 40-50-1090 Terminal Block Spring (1) 67 16-01-1170 Service Armature Assembly (1)
33 --------------- PCB Assembly (1) 68 48-55-3500 Contractor Bag (1)
34 05-81-1170 M3.0 x 12 Screw (6) 12-20-2682 Service Nameplate (Not Shown) (1)
35 --------------- Gear Housing Cover (1)
36 --------------- Spindle (1)
37 --------------- Retaining Ring (1) MILWAUKEE ELECTRIC TOOL CORPORATION
38 --------------- Spindle Gear (1) 13135 W. LISBON RD., BROOKFIELD, WI 53005
39 --------------- Ball Bearing (1) Drwg. 8
 = WIRE TRAPS Switch
Lock-Out

Diode
22-74-0515

Micro Switch

2 Red

1 Black On/Off Switch

Brush Card
Assembly

PCB Assembly

LED
Assembly
Battery
Terminal
Block

AS AN AID TO REASSEMBLY,
TAKE NOTICE OF WIRE ROUTING
AND POSITION IN WIRE GUIDES Wires From
Brush Card
AND TRAPS WHILE DISMANTLING
Assembly 1 Black
TOOL. 2 Red

BE CAREFUL AND AVOID PINCHING

WIRES BETWEEN HANDLE HALVES
WHEN ASSEMBLING.
Red 12
Micro On/Off
Switch 3 Red
Switch
Diode
LED 13 White
Assembly White 6
4 Brown
PCB
11 10 Assy. Red
Yellow Blue 7

8 9
Yellow Blue

Battery
5 Term. Block
Black

WIRING SPECIFICATIONS
Wire Wire Origin or
No. Color Gauge Length Terminals, Connectors and 1 or 2 End Wire Preparation
1 Black 22-22-0760 ----- Component of brush card assy. Route to bottom right position on switch with # 4, under diode terminal.
2 Red 22-22-0760 ----- Component of the brush card assembly. Route to the top left position on switch.
3 Red ----- ----- Component of the terminal block assembly. Route to top right position on switch.
4 Brown ----- ----- Component of the PCB assembly. Route to bottom right position on switch With #1, under diode terminal.
5 Black ----- ----- Component of the PCB assembly that is soldered to the battery terminal block as shown.
6 White ----- ----- Component of 4 pin connector. Route to bottom left position on switch under diode terminal.
7 Red ----- ----- Component of 4 pin connector. Soldered to battery terminal block with #3 as shown.
8 Yellow ----- ----- Component of 4 pin connector. Soldered to battery terminal block as shown.
9 Blue ----- ----- Component of 4 pin connector. Soldered to battery terminal block as shown.
10 Blue ----- ----- Comp. of two 2 pin connectors. Attach to PCB at one end and the top position of micro switch at other.
11 Yellow ----- ----- Comp. of two 2 pin connectors. Attach to PCB at one end and the top position of micro switch at other.
12 Red ----- ----- Component of LED assembly. Attach connector block to bottom position of micro switch as shown.
13 White ----- ----- Component of LED assembly. Attach connector block to bottom position of micro switch as shown.