BULLETIN NO.
SERVICE PARTS LIST 54-24-5200
SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS REVISED BULLETIN DATE
Sept. 2013
5/8" (16mm) SDS Rotary Hammer
WIRING INSTRUCTION
STARTING
CATALOG NO. 5263-20 SERIAL NO. C59A SEE PAGE 4
EXAMPLE: Item 87 is used once
00 0 Component Parts (Small #) Are Included in each handle
When Ordering The Assembly (Large #).
4 4a 4b
87
halves
FIG. PART NO. DESCRIPTION OF PART NO. REQ. 87 (2x)
1 05-73-0010 Screw (1) 4b
2 22-64-0575 Cord Set (1)
3 12-20-5263 Service Nameplate (1)
4 14-38-0010 Handle Housing Assembly (1)
4a --------------- Right Handle Housing Halve (1) 1
4b --------------- Left Handle Housing Halve (1)
5 18-07-0065 Service Field (1) 58
6 16-07-0045 Service Armature (1)
7 --------------- Fan (1)
8 --------------- Ball Bearing (1)
9 --------------- External Snap Ring (1) 6 7 8
9 10
14
24
2
21 69
29 21 22 23 24 25
26 27 28 65 67
4a 46 7
1 26 22 65 10 Install / place rubber slugs (69)
into position shown once field has
been placed in housing halve.
67 8
25 9
14-46-0085
SERVICE MAINTENANCE KIT
11 27 23 63
FIG. PART NO. DESCRIPTION QTY.
62 22-18-0030 Carbon Brush Set (1)
63 45-22-0540 Bearing Cup (1)
3 28 12 5
65 43-44-0035 Gasket (1)
67 43-84-0010 Felt (1)
FIG. PART NO. DESCRIPTION OF PART NO. REQ. 69 45-30-0045 Rubber Slug (2)
62 64 42-52-5262 Dust Cap (1)
10 --------------- Insulating Disc (1)
11 05-81-5262 M4 x 18 Pan Hd. Plast. T-15 Screw (7) 66 44-90-5262 External Snap Ring (1)
12 44-10-0055 Lever (1) 68 44-90-0085 Protection Washer (1)
13 22-22-0115 Brush Card (1) 70 34-40-0285 O-Ring (1)
14 44-76-5385 Cord Protector (1) 71 44-90-0185 Retaining Ring (1)
21 28-14-0095 Housing Cover (1) 72 44-90-0195 Retaining Ring (1)
22 31-10-0010 Hammer Switch Carriage (1) 73 44-90-0205 Protection Washer (3)
23 31-88-0070 Pivot (1) 74 34-40-1510 O-Ring (1)
24 44-10-0175 Lever (1) 75 34-40-0305 O-Ring (1)
76 42-76-0095 Thrust Collar (2)
25 34-40-0235 O-Ring (1) 13 12
62 77 45-88-0985 Backing Flange (1)
26 44-86-0025 Fastening Bow (2)
27 31-88-0080 Disc (1) 78 45-88-1060 Spacer (1)
28 05-81-0210 M4 x 18 Pan Hd. Plast. T-15 Screw (1) = Component of the 79 45-88-1115 Stop Washer (1)
14-46-0085 5263-20 80 45-88-1145 Bearing Washer (1)
29 31-40-0125 Housing Cover Assembly (1) Service Maintenance Kit
46 05-74-0105 Screw (4) 81 45-88-1155 Disc Washer (1)
58 23-66-0655 Switch Assembly (1) 82 42-36-0175 Backing Flange (1)
60 42-55-0235 Carrying Case (1) 83 05-74-0480 M5 x 25 Screw (2)
60 84 34-40-0320 Seal Ring (1)
62 22-18-0030 Carbon Brush (Set of 2) (1)
63 45-22-0540 Bearing Cup (1) 85 34-40-0325 O-Ring (1)
65 43-44-0035 Gasket (1) 49-08-5350 P' Grease (100g tube) (1)
67 43-84-0010 Felt (1) 49-08-5345 Q2' Grease (45g tube) (1)
69 45-30-0045 Rubber Slug (2)
87 43-84-5200 Housing Insert (2)
MILWAUKEE ELECTRIC TOOL CORPORATION
23-94-0330 Leadwire Assembly (See wiring on page 4) (1)
13135 W. Lisbon Road, Brookfield, WI 53005
23-94-0335 Leadwire Assembly (See wiring on page 4) (1) Drwg. 5
68 59
19 61
= Component of the
14-46-0085 5263-20
20 17 18
19 68 Service Maintenance Kit
83 15
74 56 84
35 74 72 86 40 30
SEE NOTE
BELOW 44
78
66
18
NOTE:
Install snap ring
17 16 15
84
#66 with opening
180º from steel ball #44.
53
39
55
37
54 82
36
41
52
73 42
51
33 43
50 38
NOTE: 75 66
49 Item 78 (45-88-1060)
Spacer, has two alternate 73
81 components included in the 85 45
Maintenance Kit (14-46-0085) 77
48 that can be used based on the fit 79 64
with the assembly. 70
80 Those alternate components are: 31
1. 45-88-1168 Spacer
47 2. 45-88-1345 Spacer 71
44
76
FIG. PART NO. DESCRIPTION OF PART NO. REQ.
15 02-50-0040 Needle Bearing (1) 32
16 34-40-0215 Gearcase Cover (1)
17 34-40-0225 Seal Ring (1) 34 30 31 32 33 36 37 38 39 70 71
72 73 75 76 77 78 79 85 86 88
18 02-50-0020 Needle Bearing (1) 30
19 02-04-0310 Ball Bearing (1)
20 28-14-0085 Gearcase (1)
30 32-75-0075 Spindle Sleeve (1) FIG. PART NO. DESCRIPTION OF PART NO. REQ.
31 02-02-1230 Steel Ball (3) 70 34-40-0285 O-Ring (1)
32 45-08-0075 Striker (1) 71 44-90-0185 Retaining Ring (1)
33 45-08-0080 Ram (1) 72 44-90-0195 Retaining Ring (1)
34 32-75-0095 Spindle Sleeve Assembly (1) 73 44-90-0205 Retaining Ring (3)
35 44-62-0020 Piston Assembly (See Note Below) (1) 74 34-40-1510 O-Ring (1)
36 40-50-0855 Spring (1) 75 34-40-0305 O-Ring (1)
37 42-70-0020 Clutch Disc (1) 76 42-76-0095 Thrust Collar (2)
38 02-02-1300 5mm Steel Ball (3) 77 45-88-0985 Flange Washer (1)
39 32-75-0125 Gear Wheel (1) 78 45-88-1060 Spacer (1)
40 34-40-0245 O-Ring (2) 79 45-88-1115 Stop Washer (1)
41 40-50-5262 Pressure Spring (1) 80 45-88-1145 Bearing Washer (1)
42 42-36-5262 Support Plate (1) 81 45-88-1155 Disc Washer (1)
43 44-90-5265 Holding Ring (1) 82 42-36-0175 Backing Flange (1)
44 02-02-0275 Steel Ball (1) 83 05-74-0480 M5 x 25 Screw (2)
45 42-76-5262 Sleeve (1) 84 34-40-0320 Seal Ring (1)
47 34-40-0265 O-Ring (1) 85 34-40-0325 O-Ring (1)
48 02-50-0045 Needle Bearing (1) 86 45-88-0975 Washer (1)
49 32-75-0130 Gear (1) 14-46-0085 Maintenance Kit (1)
50 02-50-0055 Needle Bearing (1)
51 42-70-0025 Clutch Ring (1)
52 40-50-0865 Spring (1) NOTE: The original design of
53 44-60-0280 Pin (1) the Piston Assembly (35)
54 45-88-0965 Washer (1) utilized a connecting rod made
of nylon. The connecting rod is
55 43-16-0025 Eccentric Shaft (1) now made of aluminum and is a
56 30-20-0020 Bearing Pin Clamp (1) direct replacement.
59 44-94-5381 Depth Gauge (1)
61 31-05-5265 Side Handle Assembly (1) 35 74
64 42-52-5262 Dust Cap (1) Connecting
66 44-90-5262 External Snap Ring (1) Rod 74
68 44-90-0085 Retaining Ring (1)
LUBRICATION NOTES: Type ‘Q2’ Grease
No. 49-08-5345, 1.5 oz. / 45g tube
Type ‘P’ Grease
No. 49-08-5350, 3.5 oz. / 100g tube
NOTE:
Apply a drop of Blue Loctite®
to the threads of each screw.
Lightly coat all parts
highlighted here with ‘Q2’ grease
unless directed otherwise.
Place approx. Prior to reinstalling,
1/8 oz. of ‘P’ grease clean gear assemblies
in cavity of housing cover with a clean, dry cloth.
Lightly coat all parts highlighted here
with ‘P’ grease. Apply a greater amount
of grease to all internal and external gear teeth.
Fill the back of the
piston and coat the
outside with grease.
Prior to installing into gearcase,
place approx. 1/8 oz. of ‘P’ grease
over and around the gear wheel and
clutch disc. Be sure to have a heavy
coating over all of the gear wheel teeth.
No grease
on the face
of piston.
Coat the inside cavity of the spindle
sleeve and the area that is indicated
on the outside of the
spindle sleeve
No grease with ‘Q2’ grease.
on face of ram
Be sure to place a
heavy coating of
‘P’ grease over all
of the gear teeth.
3 2 6 7 4
1 3 BLACK from switch
5 to field
SWITCH
FIELD 5 BLUE
SET COLLAR from switch
ASSEMBLY 6 RED
to heat sink
with BRUSHES
7 BLACK
THERMAL
HEAT SINK
4 BLACK from switch
to field
2 WHITE from cord
to switch
4
1 BLACK from cord
to switch
= WIRE TRAPS
or GUIDES
CORD PROTECTOR
AS AN AID TO REASSEMBLY, TAKE
NOTICE OF WIRE ROUTING AND
POSITION IN WIRE GUIDES AND
POWER CORD SET TRAPS WHILE DISMANTLING TOOL.
BE CAREFUL AND AVOID PINCHING
WIRES BETWEEN HANDLE HALVES
WHEN ASSEMBLING.
WIRING SPECIFICATIONS
Wire Wire Origin or
No. Color Gauge Length Terminals, Connectors and 1 or 2 End Wire Preparation
1 Black 22-64-0575 ----- Component of cord set. Connect to switch as shown.
2 White 22-64-0575 ----- Component of cord set. Connect to switch as shown.
3 Black 23-94-0335 ----- Leadwire assembly. Connect to switch and front right position of the field as shown.
4 Black 23-94-0330 ----- Leadwire assembly. Connect to switch and rear left position of the field as shown.
5 Blue 23-66-0655 ----- Component of the switch assembly. Wired between the switch and the thermal heat sink.
6 Red 23-66-0655 ----- Component of the switch assembly. Wired between the switch and the thermal heat sink.
7 Black 23-66-0655 ----- Component of the switch assembly. Wired between the switch and the thermal heat sink.
