BULLETIN NO.

SERVICE PARTS LIST 54-24-0680

SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS REVISED BULLETIN DATE
54-24-0679 May 2011
1/2" HAMMER-DRILL
WIRING INSTRUCTION
STARTING
00 EXAMPLE: CATALOG NO. 5378-20 SERIAL NO. 897G SEE PAGE 3
0 Component Parts (Small #)
Are Included When Ordering 63
The Assembly (Large #).
47
= Part number change from 41 42 63
64 SEE REVERSE SIDE FOR
previous service parts list. 35 SERVICE & GREASE NOTES
36

37 27
26
25 7
24 21
64
22
13
45 33
11
10 17
46
16
38 12
9
36 34 8
53
35 32 15
52 28 14
43 48 6
51 30 28 28
62
54 48 49 50
51 52 53
31 61
62 23
61 4
50 56 5
29
55
49 44
20
19
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
1 05-88-1500 M6 x 27 Chuck Screw (1) 18
2 48-66-3280 Chuck Key (1) Apply a drop of Blue Loctite®
thread locking adhesive to chuck 2
3 48-66-1355 Chuck (Incl. Chuck Key) (1)
screw (1) prior to installing onto
4 28-14-5382 Gearcase Assembly (Incl. Needle Bearing, spindle (44). 1
Fixed Ratchet and Shifting Assy.) (1)
5 06-81-5380 M4 x 52 ST T-20 Screw (3) 3 2
6 45-88-5381 Washer (1)
7 44-94-5380 Pin (1) FIG. PART NO. DESCRIPTION OF PART NO. REQ.
8 14-29-5378 1st and 2nd Spindle Gear Assembly (1) 41 23-66-5380 Switch (1)
9 45-88-5378 Washer (3) 42 14-34-5378 Rear Handle Assembly (1)
10 02-80-5380 Thrust Bearing (1) 43 05-88-1200 M4 x 16 Pan Hd. T-20 Screw (7)
11 40-50-5380 Spring (1) 44 38-50-5380 Spindle Shaft (1)
12 02-02-5380 Ball (1) 45 44-76-0210 Cord Protector (1)
13 44-60-5381 Pin (1) 46 22-64-5378 Cord Set (1)
14 14-29-5379 Gear Shaft Assembly (1) 47 42-55-5378 Carrying Case (1)
15 02-02-0165 Ball (1) 48 31-05-5379 Side Handle (1)
16 43-44-5381 Rubber Seal (1) 49 45-88-5377 Washer (1)
17 14-34-5382 Selector Housing Assembly (1) 50 14-34-5374 Side Handle Carrier Assembly (1)
18 34-80-5380 Retaining Ring (1) 51 44-94-5381 Depth Gauge (1)
19 43-44-5380 Seal (1) 52 05-81-5378 M8 x 53 Bolt (1)
20 45-88-5380 Washer (1)  53 40-50-5375 Side Handle Clamping Band (1)
21 43-44-5378 Felt Seal (1)  54 14-34-5373 Side Handle Assembly (1)
22 43-96-5380 Speed Selector Key (1) 55 02-04-5380 Ball Bearing (1)
23 44-66-5381 Grease Plate (1) 56 44-84-5380 Rotating Ratchet (1)
24 43-44-5379 Gasket (1) 61 02-04-5381 Ball Bearing (1)
25 05-88-5380 M3.5 x 12 T-10 Screw (2) 62 02-04-5382 Ball Bearing (1)
26 42-36-5378 Pinion Support (1) 63 --------------- Left Handle Halve (1)
27 28-14-5378 Diaphragm Assy. (Incl. Washer & Bearings) (1) 64 --------------- Right Handle Halve (1)
28 42-34-5380 Rubber Slug (3) 12-20-5378 Service Nameplate Kit (Not Shown) (1)
29 43-44-5377 Seal Ring (1) 48-66-4040 Chuck Key Holder (Not Shown) (1)
30 14-34-5383 Baffle Assembly (1) 23-94-5381 Red Brush Leadwire Assembly (Not Shown) (1)
31 16-07-5376 Service Armature Assembly (1) 23-94-5379 Black Brush Leadwire Assy. (Not Shown) (1)
32 18-07-5376 Service Field (1)
33 44-66-5378 Shifting Clip (1)
34 31-50-5378 Motor Housing (1)
35 06-81-5381 M3 x 6 Pan Hd. Phillips Screw (2)
36 44-66-5379 Brush Holder Retaining Plate (2)
37 22-22-5380 Brush Assy.-w/pop-off (Incl. Spring & Holder) (1)
38 22-22-5381 Brush Assy.-regular (Incl. Spring & Holder) (1) MILWAUKEE ELECTRIC TOOL CORPORATION
13135 W. Lisbon Road, Brookfield, WI 53005
Drwg. 1
Service Notes
17
DO NOT attempt to disassemble selector housing assembly (17).
16
NOTE: Gasket (24), selector housing assembly (17), speed selector key (22), 17 Slotted
2 opening
rubber seal (16) and felt seal (21) must be assembled onto the diaphragm
22
assembly (27) prior to installing onto gearcase assembly (4).
16
1. Place gasket (24) onto diaphragm assembly (27). 27 22 21

2a. Assemble speed selector key (22) onto selector housing assembly 24
(17). The speed selector key will be seated on a pin in a like-shaped
cavity of the selector housing assembly.

2b. Saturate felt seal (21) with a lightweight oil and place in selector housing 1
assembly (17) over selector key (22).

2c. Place rubber seal (16) onto other side of selector housing assembly (17).

2d. Orient the selector housing assembly (17) and the assembled 1/4 oz. ‘P’ Grease 27
components (16, 21 and 22) above the diaphragm assembly (27).
All element should slide straight down onto the diaphragm with 24
the speed selector key (22) sliding into slotted opening.
12
3. Assemble above listed parts onto gearcase 11
assembly (4). 26
10

21 13
22 9
17 8

16 33
7
4
57 15 8
14 33
56
6
7
55

44

1/16oz. 1/8 oz. ‘P’ Grease

‘U’ Grease

17
1/16oz.
‘P’ Grease
When servicing, remove 90-95% 21
of the existing grease prior to
Lubrication Instructions installing Type 'P' grease.
Original grease maybe similar in 22
Type “P” (49-08-4250) color but not compatible with 'P'.
Type “U” (49-08-0150)
14
1. Coat ratchets (56,57) with 1/16 oz. of Type “U” grease, No. 49-08-0150.
7
2. Coat spindle spline (44), ball (12) and pin (13) with 1/16 oz. of Type “P”
grease, No. 49-08-4250. 23

3. Place 1/8 oz. of Type “P” grease, No. 49-08-4250, around the gear shaft 33
assembly (14) area of gearcase (4) . 4

4. Lubricate gear assembly (parts 6,7,8,9,10,11,12,13,14,15,24,25,26,33,58,

59 and 60) using 1/4 oz. of Type “P” grease, No. 49-08-4250.

Total amount of lubrication: approximately 1/2 oz.

Back View of Gearcase Assembly
Saturate felt seal (21) with lightweight oil before assembling onto selector (Shown without Diaphragm to illustrate
housing assembly (17). component placement)

Do not place gear shaft assembly (14) in solvent solution. Wipe off with a
clean dry cloth.
 WIRING INSTRUCTIONS
TITLE 1/2" HAMMER-DRILL BULLETIN
MILWAUKEE ELECTRIC TOOL CORP. 13135 WEST LISBON RD. BROOKFIELD, WIS. DATE

= WIRE TRAPS

3 3

2 4
3
1 2
2
5
5
3

1
1
4

6 6
7
7

4
1

4
7
6

SCHEMATIC
AC SWITCH 10A 125V AC with FWD/REV
RED

6 1
BLACK 2 BLACK

BLACK 5

ARM
NOTE: As an aid to reassembly,
take note of the wire routings and
position of the wires in the wire guides
and traps prior to dismantling the tool.

Watch for pinched wires when placing 7 3 RED

WHITE
the handle cover back over the
housing assembly. 4
WHITE

WIRING SPECIFICATIONS
NOTE:
Wire Wire Origin or All leads must be held to ± 1/8".
No. Color Gauge Length Terminals, Connectors and 1 or 2 End Wire Preparation All lead lengths are before stripping.
1 Red Switch ----- Non-terminated end to '2' and terminated end to '8' on switch.
TERMINAL DESCRIPTION
2 Black Field ----- Route from field to '7' on switch.
Code Part No. Qnty.
3 Red 23-94-5381 ----- Connect to '6' on switch and route to top brush assembly.
4 White Field ----- Route from field to '1' on switch.
5 Black 23-94-5379 ----- Connect to '5' on switch and route to bottom brush assembly.
6 Black Cord ----- Connect to '2' on switch.
7 White Cord ----- Connect to '1' on switch.
BULK LEAD WIRE - BULLETIN NO. 58-01-0003