SERVICE PARTS LIST SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS. M18 FUEL 1" (2Kg) SDS Plus D-Handle Rotary Hammer STARTING SERIAL NO.

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1 BULLETIN NO. SERVICE PARTS LIST M8 FUEL " (Kg) SDS Plus D-Handle Rotary Hammer CATALOG NO. 00 EXAMPLE: 0 Component Parts (Small #) Are Included When Ordering The Assembly (Large #). STARTING SERIAL NO. 7-0 DATE Aug. 0 REVISED BULLETIN SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS WIRING INSTRUCTION H9A SEE PAGE l= Components of the --7 Rotary Hammer Service Kit (See page six for a complete listing) 0 9f 9g 0 9 (x) FIG. 7 7b 7c 8 9 9c 9d 9e 9f 9g 9j 9m 9p 9s 9t 9u 9v 9w 9x 0 0a 0b a PART NO (x) (x) DESCRIPTION OF PART NO. REQ. l Dust Cap l l Chuck Sleeve Assembly 7mm Steel Ball Ball Plate Conical Spring Gearcase Assembly with Bearings and Seal Spring Locking Plate Shift Lever with Spindle Sleeve Assembly Clutch Spring nd Stage Gear Clutch Plate Steel Ball Spindle Stop l Striker (Anvil) l Sleeve (Ram Catcher) l l l Spindle Bearing Bearing Bar Mounting Bracket Spiral Retaining Ring Striker and Assembly Striker (Ram) l Piston l Wrist Pin M x mm Pan Hd. Taptite Screw l Gasket Crankcase Assembly l Felt Plug Oil Shield M x 0mm Pan Hd. Taptite T-0 Screw Rotor Assembly Ball Bearing M x mm Pan Hd. Plastite T-0 Screw Motor Housing Support - Left 9d 9c 0b 0 7m 7j (x) 7f 0a 0b 7k 7 7c 0a 8 7n 8 7 0a 0a 9e 7h 9x 9w 7g 7b 9v 9u (x) 7c 9t 9s 7e 9 (x) 9p 7d 7b 7b 7c 7d 7e 7f 7 7a 7g 7h 7j 7k 7m 7n 9m 9j 7a 9c 9d 9e 9f 9g 9j 9m 9p 9s 9t 9u 9v 9w 9x FIG. PART NO. DESCRIPTION OF PART NO. REQ Motor Housing Cover - Right M x 8mm Pan Hd. T-0 Screw Ground Wire Screw Wobble Shaft Assembly 7a b -0- Pinion 7c -- Reduction Gear Shaft 7d Coupling 7e 0-0- Spring 7f --09 Coupling Sleeve 7g Wobble Plate 7h Reduction Gear 7j M x 8mm Pan Hd. Tapt. T- Screw 7k --00 Retaining Plate 7m Ball Bearing 7n l M x 0mm Hex Head Screw D-Handle Housing Cover M x mm Pan Hd. Plastite T-0 Screw Forward / Reverse Shuttle FUEL Housing Plate D-Handle Housing Support -0-7 Electronics Assembly Terminal Spring -9-8 Depth Gauge --00 Auxiliary Side Handle Service Nameplate -0-7 Motor Housing Assembly --0 Side Handle Assembly --7 D-Handle Housing Assembly Blow Molded Carrying Case --7 Rotary Hammer Service Kit (See page ) MILWAUKEE ELECTRIC TOOL CORPORATION W. Lisbon Road, Brookfield, WI 00 Drwg.

2 LUBRICATION NOTES: Type GE 00 Urethyn Grease No ,.8 oz./80g tube Apply a very light coat of grease to the inside wall of piston. No grease to inside base of cavity. NOTE: The entire contents of the grease tube will not be used. Use a total of appoximately / oz./.g. Coat the o-ring on the shift lever with grease. No grease to the face of ram Lightly coat all parts highlighted here with GE 00 grease unless directed otherwise. Coat inside cavity of the sleeve and spindle with GE 00 grease. LUBRICATION NOTES: Type S Grease No , 7.0 oz./98g tube Place a very liberal amount of grease to the rear of the piston. NOTE: The entire contents of the grease tube will not be used. Use a total of appoximately.8 oz./80g. Place approx. 8. grams, (. oz.) of S grease in the gear cavity of the gearcase. Place approx. 8. grams, (. oz.) of S grease in the crankcase, between the bevel gear and the wobble plate. Place a liberal amount of grease along the whole length of the reduction gear shaft. Prior to reinstalling, clean gear assemblies with a clean, dry cloth. Lightly coat all parts highlighted here with S grease. Apply a greater amount of grease to all internal and external gear teeth. SERVICE NOTES on pages, and are included for general servicing of the tool and ARE NOT complete step by step instructions.

3 9p 9m Use an old piston to help squarely push the internal components into spindle. Assembled components:,9j,,9m,, 9p, and. 9g Spindle Larger end 9j 9s Modified screwdriver with notch. Flat side of towards Ram Catcher Larger end into Ram Catcher Push into spindle cavity and rotate as shown. Use the same old piston to seat into internal spindle groove. Chamfer side of facing assembly Assembly of internal Spindle components: Chamfer Deep recess. Lubricate Ram Catcher and s. Assemble s onto and into Ram Catcher.. Lubricate Striker and. Assemble onto Striker.. Assemble Striker Assembly into Ram Catcher Assembly (large end into Ram Catcher as shown).. Place the chamfered end of the Stop over the small end of the Striker.. Place the assembled components from step into the cavity of an old piston as shown. Use the old piston as an aid to push the assembled components deep into the Spindle cavity.. (9s) will be used to secure the internal components inside the spindle. It is recommended to modify a flat blade screwdriver by filing or grinding a notch into the blade. Place the upright as shown with the opening of the ring straight up. Use the modified screwdriver to push the down into the Spindle cavity. Rotate the in the spindle cavity as shown.place the old piston into the Spindle cavity and tap the piston with a mallet to secure the in the groove. Place Retaining Ring 9x in this groove Spindle Service Fixture No Place Retaining Ring in this groove 9f 9g 9e Flat 9d 9c (Retaining ring) 7 8 Assembly of external Spindle components: 7. Place 9f onto Spindle. With the aid of a snap ring pliers, work the into the rear most spindle groove and snap into place. As an aid, put a dab of grease on your finger to pick up and place the three Steel Balls 9g into the three small holes on the Spindle just above the previously installed. Lubricate and install the Clutch Plate 9e onto the Spindle. Be sure to orient the part as shown and position with the three notches on the back of the plate over the three steel balls. Lubricate and install the Clutch Gear 9d. Place the Clutch Spring 9c over the Clutch Gear and the over the Spring. Place onto Spindle. With the aid of a snap ring pliers, work the down to the other parts assembled onto spindle. 8. Place Spindle Service Fixture over the assembled parts and the spindle. Position so the fixture rests on Flat. Place the fixture and spindle assembly in an arbor press and carefully compress the Clutch Spring enough to expose the spindle groove for. While compressed, use a screwdriver to work into the groove.

4 9x Spiral Retaining Ring 9w 9v Bearing Bar Mounting Bracket Crankcase Assembly 7 Wobble Shaft Assembly Consisting of: 7a, 7b, 7c, 7d, 7e, 7f, 7g, 7h, 7j, 7k, 7m and 7n. 7j (x) 9u Spindle Bearing 9 0 s Piston Wrist Pin 0b 9. The flat side of the Bearing Bar 9v has a rounded recess area that will recieve the Spindle Bearing 9u. Coat the recess area and place the Spindle Bearing in the recess. Place the two parts onto the Spindle Assembly as shown. Next place the 9w on top of the Bearing Bar and secure with Spiral Retaining Ring 9x. Mounting the Spindle Assembly onto the Crankcase Assembly 0a Striker (Ram) 0. Lubricate the inside cavity of the Crankcase Assembly with grease. Place Wobble Shaft Assembly into Crankcase Assembly as shown. Secure assembly with screws 7j. (x) Apply Blue Loctite to the threads of these four Screws prior to securing the Spindle Assembly to the Crankcase Assembly.. Place s and Wrist Pin into rear area of Piston. While holding those parts in place, be sure the s are separated, one on each side of the hole in the Wrist Pin. Connect the Piston Assembly to the Wobble Shaft Assembly by sliding the hole on the Wrist Pin over the arm on the wobble bearing.. Lubricate 0b and Striker (Ram) 0a. Be sure not to have any lubrication on the rear (flat side) of Striker. Place onto Striker 0a. Insert assembled parts into Piston as shown.. Mount the Spindle Assembly onto The Crankcase Assembly by inserting the Piston into the Spindle. Use four Screws to secure the Spindle Assembly to the Crankcase Assembly. NOTE: Prior to installing screws, place a few drops of Blue Loctite thread locking sealant to the threads.

5 Gearcase Assembly with Shift Lever installed Crankcase Assembly with Spindle Assembly, Wobble Shaft Assembly and Piston installed. Carefully insert pinion of Rotor Assembly (0) into Crankcase bearing cavity. Wiggle Rotor Assembly until pinion meshes with gearing. Seat ball bearing in bearing cavity and secure with two Screws (9). Rotor Assembly (0) Lubricate all areas, components and assemblies per instructions on page two. Carefully slide Crankcase/Spindle Assemblies into Gearcase Assembly and seat firmly. Two M x 0mm Pan Hd. Taptite T-0 Screws (9) Dust Cap s Chuck Sleeve Assembly Motor Housing Support () Rotor Assembly (0) Stator 7mm Steel Balls Ball Plate Conical Spring Notches on bottom of Chuck Sleeve that accomodate steel balls Place small end of Conical Spring on spindle first Place Stator portion of Electronics Assembly () into Motor Housing Support (). Place Motor Housing Cover () over Stator. Secure motor housing halves with four screws (), being sure to partially tighten the rear two screws, allowing for easier installation of the Rotor Assembly. Once the rotor bearing is properly seated in the bearing cavity of motor housing halves, the rear screws can be tightened. Screw () Motor Housing Cover () 7

6 Forward/Reverse Shuttle Ground Wire Terminal = Wire Traps On-Off Switch Stator Assembly Route wires as shown being very careful to tuck all wires down into traps. Be sure that all components of the electronics assembly are firmly and squarely seated in the housing support. Be careful that there are no pinched wires when assembling housing cover. Check for proper switch and shuttle functionality before tightening all screws. l--7 Rotary Hammer Service Kit t b n Dust Cap Chuck Sleeve Assy. Gasket Felt Plug Screw Type GE 00 Urethyn Grease.8 oz Tube Type S Grease 7.0 oz Tube LED Assembly Battery Terminal Connector Block PCBA Ground Wire SCREW TORQUE SPECIFICATIONS SEAT TORQUE FIG. PART NO. WHERE USED (KG/CM) (IN/LBS) Motor Housing Assembly Bearing Bar Mounting Bracket Crankcase Assembly Bearing Retainer Gear Housing Cover Motor Housing Assembly Rotor Assembly Handle Cover - Right Halve -7 -