milwaukee M18 Fuel Hp Sawzall Reciprocating Saw Installation Guide

milwaukee M18 Fuel Hp Sawzall Reciprocating Saw

Product Information

Specifications

• Catalog No.: 2722-20
• Starting Serial No.: J66A
• Revised Bulletin Date: Aug. 2022

Wiring Instruction

For wiring instructions, please refer to page 3 of the user manual.

Speed Dial Design

There are two speed dial designs available for this product:

• Squared Edge (87)
• Chamfered Edge (36)

Early production speed dials had a squared top edge design. A new speed dial design with a chamfered top edge is now available.

If your electronic assembly has a speed dial with a squared top edge, it is recommended to replace it with the new dial from Replacement Handle Kit 14-34-2722 (93).

Service Parts List

Product Usage Instructions

Installation of Rotor into Stator

When installing the rotor into the stator, it is important to note that the magnetic force is very strong. Extreme care must be taken to prevent damage to the tool and personal injury. Ensure that your fingers are not in front of the rotor fan during installation.

Replacing the Speed Dial

If your electronic assembly has a speed dial with a squared top edge, follow these steps to replace it with the new chamfered edge dial:

1. Obtain Replacement Handle Kit 14-34-2722 (93) which includes the new speed dial.
2. Disconnect the power supply to the tool.
3. Remove any screws or fasteners securing the electronic assembly.
4. Carefully remove the old speed dial from the electronic assembly.
5. Place the new speed dial from the kit onto the electronic assembly.
6. Secure the electronic assembly back into place with screws or fasteners.
7. Reconnect the power supply to the tool.

Replacing Other Parts

To replace other parts listed in the service parts list, please follow these general steps:

1. Disconnect the power supply to the tool.
2. Identify the part number and description from the list.
3. Remove any screws, fasteners, or components securing the old part.
4. Install the new part in the correct position.
5. Secure the new part with screws, fasteners, or components.
6. Reconnect the power supply to the tool.

Wiring Instruction (Page 3)

FAQ

Q: How do I identify the correct speed dial design?

A: The squared edge speed dial has a squared top edge design, while the chamfered edge speed dial has a beveled or angled top edge.

Q: Can I use the old speed dial if my electronic assembly has a squared top edge design?

A: It is recommended to replace the old speed dial with the new chamfered edge speed dial to ensure compatibility and optimal performance.

Q: Where can I find the wiring instructions?

A: The wiring instructions can be found on page 3 of the user manual.

SERVICE PARTS LIST

NOTE: Early production speed dial (87) had a squared top edge design. There is a new speed dial design that has a chamfered top edge. Replace-ment Handle Kit 14-34-2722 (93) comes with a new speed dial. If electronic assembly (94) has a speed dial with a squared top edge, replace with the new dial in the kit.

Concave side of disc spring (50) must face toward metal plate (49) and bevel gear (48).

NOTE: Orbit Slot #75 has been removed from this view for clarity (to reveal Connecting Rod Pin #18 and Rollers #17)

LUBRICATION: Type ‘T’ Grease No. 49-08-4290 (16 oz. can)

• Place 30g ±3g (approx. 1 ounce) on top of gear (48) and pinion gear of rotor assembly (95), being sure to cover the middle of the gear and all teeth.
• Place 15g ±3g (approx. .5 ounce) to the area where the gear (48) and the connecting rod of crank shaft assembly (91) interface.
• Coat both sides of the metal clutch plate (49).
• Lightly coat both pivot pins (80) where connections go into holes of front bushing assembly (90).
• Lightly coat both ends of pin (11) prior to installing rollers (68).

Removing Crankshaft Assembly (91) from Left Gearcase (13)
Remove, crankshaft assembly (91) from left gearcase (13) by separating / removing right housing half (58). Remove bearing retaining plate screws (18) and bearing plate (17) from left gearcase (13). Place a 3/16” diameter x 1-1/2” long steel rod through holes found in the counter balance and drive hub of crankshaft assembly (91) until it bottoms out. Next place a 3/16” hex key into drive hub bolt (16) and turn drive hub bolt slowly in a clockwise direction until 3/16” steel pin rest against crankshaft assembly connecting rod. The 3/16” hex key can now be forcibly turned clockwise to loosen and remove drive hub bolt (16).

Reinstalling Crankshaft Assembly (91) into Left Gearcase (13)
To reinstall drive hub bolt (16) to crankshaft assembly (91) apply Blue Loctite® (44-20-0090) to threads of drive hub bolt (16) and insert through spacer (15) aligning threads of drive hub bolt (16) with internal threads of crank-shaft assembly hub. Use a 3 /16” hex key to turn the drive hub bolt (16) slowly in a counter clockwise direction until 3/16” steel pin rest against crankshaft assembly connecting rod (See ‘Removing Crankshaft Assembly’ instructions above). Using an inch pound torque wrench and a 3/16” hex key, torque drive hub bolt (16) to 210-240 in. lbs. or bolt can be tightened using a ft. lbs. torque wrench to 17-20 ft. lbs.

SCREW TORQUE SPECIFICATIONS

• To properly install the Shoe Release Lever #64 onto the Shoe Pin #65 do the following:
• Insert the shoe pin through the hole in the gearcase insulator. Center the shoe pin with equal amounts of the pin protruding from each side of the tool.
• Rotate the shoe pin so the flats of the pin will align with the flats in the shoe release lever cavities.
• The shoe release lever is stiff but flexible. Place the shoe release lever over the gearcase insulator. Lift one end of the shoe release lever onto the shoe pin (with flats aligned) and press into place.
• Pull the other end of the shoe release lever over the other side of the pin and press in place.
• Place the tool on its side on a hard flat surface. Place a small wood block approximately 1-1/8” thick under the tool, between the hard surface and the shoe release lever, directly beneath the pin.
• With a rubber mallet, strike the shoe release lever several times to completely seat the lever onto the pin and to asure that the pin is properly centered within the gearcase.

REMOVING THE STEEL QUIK-LOK® BLADE CLAMP – VERSION 1

• Remove external retaining ring (6) and pull front cam (7) off.
• Pull lock pin (2) out and remove remainder of parts and discard.

REASSEMBLY OF THE STEEL QUIK-LOK® BLADE CLAMP

• Coat new lock pin with powdered graphite.

• Hold tool in a vertical position.

• Place spring cover (1) onto spindle.

• Slide torsion spring (3) onto spindle with spring leg on hole side of spindle.

• Slide sleeve (5) onto spindle aligning hole on sleeve with hole in spindle.

• Slide rear cam (4) over sleeve until it bottoms on sleeve shoulder, ensure spring leg inserts into groove of cam.

• Rotate rear cam in the direction of the arrows located on spring cover until there is clearance for lock pin (2) to be inserted into sleeve/spindle holes. Insert lock pin.

• Align front cam (7) inner ribs with rear cam outer slots and slide front cam onto sleeve until it bottoms. Retaining ring groove should be completely visible.

• Attach retaining ring (6) 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.

SEE PAGE 6 FOR ADDITIONAL WIRING VIEWS

• Prior to installing Right Handle/Housing Halve (38) onto left housing/handle halve (30), be sure that all wires are tucked down in wire traps. Be sure that wire ribbons are properly placed down in traps and channels. Make sure that all ele-ments of electronics assembly (94) are firmly and squarely in the corresponding cavities of left handle/housing halve.
• Secure right handle/housing halve to left handle/housing halve with screws (31, 39 and 40), watching out for pinched wires.
• Prior to installing battery, check for the proper functionality of the on-off switch, Speed Dial (87) and Lock-Off Shuttle (36).
• Install battery and assure the tool operates properly.

References

• Milwaukee® Tool Official Site | Nothing but HEAVY DUTY®

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