SERVICE PARTS LIST DEEP CUT BANDSAW D51C BULLETIN NO CATALOG NO SEE PAGE 3 FOR FASTENER TORQUE CHART

Transcription

1 = Part number change from previous service parts list. SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS DEEP CUT BANDSAW CATALOG NO SERVICE PARTS LIST STARTING SERIAL NO. D5C REVISED BULLETIN BULLETIN NO DATE Apr. 205 WIRING INSTRUCTION See Page thru LUBRICATION NOTES: Type J Grease, No When replacing Idler Gear Kit (5), place g, (. oz.) of grease around gear teeth and ID of Idler Gear (3) Apply Loctite 23 to threads of screws 3 and (2x) When replacing Bevel Pinion Assembly (33), place 3. g, (.3 oz.) grease around Helical Gear (35). Coat teeth and end of Bevel Pinion (30). Place a heavy coating of grease in the bevel pinion bore of Gearcase (2) x /2" Pan Hd. Tapt. T- (5 of 23) (23) Washer ( of 2) (2) Needle Bearing ( of 3) (3) Washer () x.33" Pan Hd. Taptite T-20 (3) Gearcase (See Page 3) () x " Pan Hd. Taptite T-2 () Seal Gasket () Pin (2) Bevel Pinion () Ball Bearing () Bearing Plate () Washer () Spring Washer () Helical Gear () Ball Bearing (2) x 3/" Pan Hd. Taptite T-2 () Idler Gear () Washer () Pin () x " Pan Hd. Plastite T-20 () Diaphragm () Ball Bearing ( of 2) (2) Baffl e () Rubber Block (2) Power Cord () x /2" Pan Hd. Plastite T-20 (2) Terminal Block () Rubber Switch Cover () Leadwire Assembly-Black (Not Shown) () Leadwire Assembly-White (Not Shown) () Leadwire Assembly-Red (Not Shown) () On-Off Switch () LED Switch () x 5/" Pan Hd. Plastite T-20 () /-20 x.5" Pan Hd. Taptite T-30 () Handle Cover () /-2 x 5/" Pan Hd. Taptite T-30 (3) PCB Assembly () Support Handle () Isolator Support () Outer Motor Housing () Pulley Support (See Page 2) () Coiled Pin ( of 3) (3) Service Nameplate () Nameplate Screw (2) Brush Cap (2) Carbon Brush (2) M x 3.5mm ST Screw () Brush Holder Assembly (2) Sensor Assembly () Inner Motor Housing () Bearing Cap () Ball Bearing () Magnetic Ring () Service Field Kit () Armature () x " Pan Hd. Taptite T- () T-Block () x 5/" Pan Hd. Taptite T- (2) Lever Release Spring () Release Button () Shoe Bumper () Blade Guard () Diaphragm Kit () Fan Baffl e Kit () Service Armature Kit () Bevel Pinion Assembly () Shoe Bumper Kit () Handle Assembly Kit () Idler Gear Kit () Outer Motor Housing Kit () SEE PAGE 3 FOR FASTENER TORQUE CHART MILWAUKEE ELECTRIC TOOL CORPORATION 335 W. Lisbon Road, Brookfi eld, WI Drwg. 2

2 00 0 EXAMPLE: Component Parts (Small #) Are Included When Ordering The Assembly (Large #). 3 FIG. NOTE: 3 Use Loctite 23 or the equivalent to the threads of Screw (3) prior to installing T-Handle () onto Pulley Support (5) FIG. NOTE: 5,0 Use Loctite 32 or the equivalent to secure the Blade Backing Pad (0) to the Pulley Support (5) x /2" Pan Hd. Tapt. T- ( of 23) (23) Pulley Cover ( of 2) (2) Pulley Tire ( of 2) (2) UNC x." Slotted (2 of ) () Washer (2 of ) () Ball Bearing ( of ) () Washer (2 of ) () Ball Bearing ( of 2) (2) Pin ( of 2) (2) x /" Pan Hd. Tapt. T- (2 of ) () x.3" Pan Hd. Taptite T-20 (2) Tension Release Lever () /"- UNC x " Socket Hd. Cap Screw () Front T-Handle () Pulley Support () Front Pulley Shroud () Cam Shaft () Cam Bushing () /- x /" Screw () Washer () Coil Pin (2 of 3) (3) Driver Plate () Front Pulley Shaft () 5--5 Washer (2) Sleeve Bearing (2) Front Pulley () Snap Ring () Blade Backing Pad () Needle Bearing () Front Roller Block () Shoulder Screw (3) Tension Bushing (3) Wear Plate () Support Plate () Blade Tension Spring (2) Contact Plate () LED Assembly () M3 x mm Screw () LED Cover () Front Guide Roller Kit () Guide Roller Kit () Tensioning Mechanism Assembly () Pulley Support Kit () x." Pan Hd. M Screw T-20 () SEE PAGE 3 FOR FASTENER TORQUE CHART

3 LUBRICATION NOTES: Type J Grease, No When installing Gearcase Cover Kit (2), place. g, (. oz) grease to the Bevel Gear (20). Place g (.2 oz.) to the large Spur Gear (2). Coat all of the gear teeth on small Spur Gear (2) with grease. Coat Washer (3) and ends of shafts ( & 22) with J Grease Dowel 0 To properly tighten hex head screw (3), use a wooden dowel or a nylon rod in the opening between the rear pulley () and gearcase (2). Be careful not to damage pulley tire (). Apply enough pressure to prevent rear pulley from turning. Torque hex head screw (3) to 32 in/lbs. Service Tool can be ordered to secure rear pulley to tighten hex hd. screw. SCREW TORQUE CHART Torque Fig. Part No. Location (In/Lbs.) Rear Pulley Front Roller Block Rear Roller Block Bearing Plate Ground Terminal Gearcase Pulley Support Diaphragm Diaphragm Handle Cover Handle Cover Handle Cover Handle Cover Support Handle LED Cover Front T-Handle Support Plate Support Plate LED Assembly Brush Holder Assembly T-Block T-Block Tire Cleaning Brush Cover Tension Release Lever NOTE: 32 in/lbs. or 2 ft/lbs. Use screws () to temporarily attach service tool to rear pulley. Hold tool and tighted hex head screw (3) to 32 in/lbs. 5 Lightly coat both sides of Washers (5) and Clutch Plates () with J Grease EXAMPLE: Component Parts (Small #) Are Included When Ordering The Assembly (Large #). 3 2 Service Tool x /2" Pan Hd. Tapt. T ( of 23) (23) Pulley Cover ( of 2) (2) M Screw, 3/"- UNC 5/" Hex Hd. () Disc Spring () Clutch Washer (2) Clutch Plate (2) Rear Pulley () Pulley Tire ( of 2) (2) Spindle () Gearcase Cover () Ball Bearing () Spur Gear () Washer ( of 2) (2) UNC x." Slotted (2 of ) () Washer (2 of ) () Ball Bearing ( of ) () Washer (2 of ) () Ball Bearing ( of 2) (2) Pin ( of 2) (2) x /" Pan Hd. Tapt. T- (2 of ) () Rear Roller Block () Needle Bearing (2 of 3) (3) Rear Pulley Shroud () Gearcase () Pin ( of 2) (2) Ball Bearing ( of 2) (2) Bevel Gear () Spur Gear () Shaft () Tire Cleaning Brush () Tire Cleaning Brush Cover () x 3/" Pan Hd. Taptite T-20 (2) Gearcase Cover Kit () Rear Guide Roller Kit () Gearcase Top Assembly () Guide Roller Kit () Tire Clearing Brush Kit () Washer () Blow Molded Carrying Case (Not Shown) ()

4 0 AS AN AID TO REASSEMBLY, TAKE NOTICE OF WIRE ROUTING AND POSITION IN WIRE GUIDES AND TRAPS WHILE DISMANTLING TOOL. BE CAREFUL AND AVOID PINCHING WIRES BETWEEN HANDLE HALVES WHEN ASSEMBLING. 5 SWITCH LED Switch PCB Assembly Support Handle Route red leadwire assembly # from terminal block (T) to the LED switch as shown. Solder to post marked '' on LED switch. 5 Terminal Block (T) Black wire # from the PCBA is to be soldered to the post marked '2' on the LED switch. See page for wire routing and placement of wire # in traps of support housing. On-Off Switch 2 Ground Screw 3 Power Cord No. Color Origin or Gauge Length Terminals, Connectors and or 2 End Preparation Black Cord Component of the cord set. Connect to lower right of terminal block (T). 2 White Cord Component of the cord set. Connect to lower left of terminal block (T). 3 Green Cord Component of the cord set. Connect to grounding area on surface of gearcase. Black Leadwire assembly. On one end twist strands together with red wire # and connect with the upper right of terminal block (T). Connect the other end to the '2 ' position of the switch. 5 White Leadwire assembly. Connect one end to the upper left of terminal block (T). Connect the other end to the ' ' position of the switch. Red Leadwire assembly. On one end twist strands together with black wire # and connect with the upper right of terminal block (T). Solder other end to position '' on LED switch.

5 0 AS AN AID TO REASSEMBLY, TAKE NOTICE OF WIRE ROUTING AND POSITION IN WIRE GUIDES AND TRAPS WHILE DISMANTLING TOOL. BE CAREFUL AND AVOID PINCHING WIRES BETWEEN HANDLE HALVES WHEN ASSEMBLING. 5 SWITCH LED Switch On-Off Switch PCB Assembly Support Handle Terminal Block (T) PCB ASSEMBLY Heat Shrink Tube No (2 places) Place over connected wires and from PCB Assembly and wires 23 and 2 of Sensor Assembly. Heat over the joined connectors. (See page ). Power Cord Place over connected wires and 20 from PCB Assembly and wires 2 and 22 of LED Assembly. Heat over the joined connectors. (See page ). Origin or No. Color Gauge Length Terminals, Connectors and or 2 End Preparation Red Component of the PCB Assembly. Connect to the '2a' position on the on-off switch. 0 White Component of the PCB Assembly. Connect to the ' ' position on the on-off switch. Black Component of the PCB Assembly. Connect to the ' 2' position on the on-off switch.

6 0 AS AN AID TO REASSEMBLY, TAKE NOTICE OF WIRE ROUTING AND POSITION IN WIRE GUIDES AND TRAPS WHILE DISMANTLING TOOL. BE CAREFUL AND AVOID PINCHING WIRES BETWEEN HANDLE HALVES WHEN ASSEMBLING. 5 SWITCH LED Switch PCB Assembly Support Handle Female connector with wires and from the PCB Assembly is to be joined with male connentor of the sensor assembly (wires 23 and 2). See detail wiring below. s & s 23 & 2 Terminal Block (T) 23 Heat Shrink Tube No On-Off Switch 2 Sensor Assy. Sensor Assy. Inner Motor Housing Insulator Support Top View shown without Outer Motor Housing Route sensor assembly wires through the center slot of the inner motor housing. Note: Field wire 5 will also utilize the same center slot. Power Cord No. Color Origin or Gauge Length Terminals, Connectors and or 2 End Preparation Black Component of the PCB Assembly. Solder to position '2' on LED switch. White Component of the PCB Assembly. Connect to position '' at the on-off switch. Black Component of the PCB Assembly. Connect to position '' at the on-off switch. Black Components of the PCB Assy. s and are joined together with a female connector. White The female connector is to connect with the male terminal of sensor assembly Red Components of the Sensor Assy. s 23 and 2 are joined together with a male connector. 2 White The male connector is to connect with female terminal of wires and.

7 s 2 & 22 s & 20 Heat Shrink Tube No Connect male terminal of wire 2 with female terminal of field wire Place connected terminals of wires 2 & and 3 & 5 here. Connect male terminal of wire 3 with female terminal of field wire Insulating Sleeve Connect to red #3 on PCBA Connect to blue #2 on PCBA 2 5 Connect to male terminal with wires and 20 from PCBA LED Assembly Insulating Sleeve Pulley Support Right Brush Left Brush Route black field lead # around the outside of the inner motor housing, trapping the wire in the outside slot 2 at the top. Route # out the insulator support and connect with blue wire #2 of the PCBA. Trap black field lead #5 in the center slot of the inner motor housing and route out the insulator support and connect with red wire #3 of the PCBA. Route and trap white field leads as shown and connect to brush holder assemblies. BACK VIEW (INSIDE) OF PULLEY SUPPORT FRONT VIEW (BRUSH END) OF OUTSIDE MOTOR HOUSING No. Color Origin or Gauge Length Terminals, Connectors and or 2 End Preparation 2 Blue Component of PCB Assembly. Connect male terminal with female terminal of wire. 3 Red Component of PCB Assembly. Connect male terminal with female terminal of wire 5. Black Component of the fi eld. Connect female terminal to the male terminal of blue wire #2. 5 Black Component of the fi eld. Connect female terminal to the male terminal of red wire #3. Black Components of PCB Assembly. s and 20 are joined together with a male terminal. 20 White Connect the male terminal to the female terminal of wires 2 and 22 of the LED assembly. 2 Black Components of the LED assy. s 2 and 22 are joined together with a female terminal. 22 White Connect the female terminal to the male terminal of wires and 20 of the PCB Assembly. 2 White Component of the fi eld. From top of fi eld, connect to the right brush holder tab. 2 White Component of the fi eld. From bottom of fi eld, connect to the left brush holder tab.