SERVICE PARTS LIST SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS REVISED BULLETIN DATE. M18 FUEL 1-1/8 (3kg) Rotary Hammer.

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1 43a 43b 43 43c 43d 43d 43b 43a (8x) 66 65a 64 43c a SERVICE PARTS LIST BULLETIN NO SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS REVISED BULLETIN DATE M8 FUEL -/8 (3kg) Rotary Hammer Jan. 05 CATALOG NO WIRING INSTRUCTION STARTING SERIAL NO. F99B SEE PAGE 5 57c 57a 57b EXAMPLE: c 00 0 Component Parts (Small #) Are Included When Ordering The Assembly (Large #). 57b 57a 9(6x) * See note 68a below 68 68b 7a See detail on 53 page 5 for 54 replacement 5b 68a 44c 5a 7a 7b 7c d 7e 7f 44b 50 7e 5a 4b 5 5b 7b d 46 7f c *NOTE: There are two Rubber Washers (83) that are to be installed in recessed pockets on the bottom of the Gearcase Cover (). The washers are held in place by the two middle Gearcase Screws (9). 68b M4 x 7mm Pan Hd. Taptite T-0 w/nylok 6 4b O-Ring ( on Piston #4b, on Ram #4a) Gearbox Assembly M4 x 0mm Pan Hd. Taptite Screw ( of 4) Electronics Assembly 7a On-Off Switch 7b Battery Connector Block 7c Connector Assembly 7d LED Assembly 7e Stator Assembly 7f PCB Assembly M3.5 x 6mm Pan Hd. Plast. T-0 (8 of 3) Washer Crank Gear Assembly with Needle Bearing Crank Shift Ring Crank Spring Crank Assembly Crank Shim Retaining E-Ring Chisel Shifter Assembly 43a M x 7mm Dowel Pin 43b M x 40mm Dowel Pin 43c Chisel Bracket 43d Chisel Shift Driver 44a Connecting Rod 44b Piston = Part number change from previous service parts list. = Component of Rotary Hammer Service Kit No (See page three) 44c Wrist Pin Locking Plate Shift Ring Bevel Gear Thrust Washer Thrust Bearing Clutch Gear Assembly Clamp Plate Fork Assembly 5a Fork 5b Fork Spring Shifting Coupler O-Ring Gearcase Gasket (See page three) Gearcase Cover Selector Knob Assembly 57a Selector Ball 57b Selector Spring 57c Selector Knob M3.5 x 6mm Pan Hd. Plastite T-0 Screw Top Bellows Vibration Washer ( each for top & bottom AVS) Top AVS Square Guide Pipe Top AVS Spring Vibration Bumper ( each for top & bottom AVS) Bumper Holder ( each for top & bottom AVS) 4 65a Retaining Plate M4 x 5mm Scr. ( each for top & bottom AVS) Forward/Reverse Button Handle Assembly 68a Left Handle Halve 68b Right Handle Halve Compression Spring Blow Molded Carrying Case Rubber Washer MILWAUKEE TOOL W. Lisbon Road, Brookfi eld, WI 505 Drwg.

2 = Component of Rotary Hammer Service Kit No b a 35 35b 35c 70 (6x) 35c 34a 34 34b a 3a 35a 34a (6x) (4x) Dust Shield Collar with Steel Insert mm Steel Ball Ball Support Plate Conical Spring Side Handle Assembly 7a Clamp Collar 7b M8 x 53mm Screw 7c Side Handle Carrier Assembly 7d Washer 7e Side Handle 7f Depth Rod Side Handle Sleeve 9a M4 x 4mm Pan Hd. Taptite T-0 Screw Bushing Sleeve Assembly with Seals Washer Bumper Spindle Assembly 3a Spindle 3b Brake Ring 3c Anvil Ring 3d Square O-Ring 3e Anvil/Striker 3f Anvil O-Ring 3g Ram Catcher 3h Back Pressure Ring 3j Anvil 4a Ram 4b O-Ring ( on Ram #4a, on Piston #4b) Bumper/Washer Holder Spindle Collar O-Ring Retaining Plate Gearbox Assembly c 35b 34b b 8 (4x) 3j 4a 3h 3g 3f 3e 9a (4x) 8 3d 3c 6 5 3a 3b 3c 3d 3e 3 3f 3g 3h 3j 3b 7f 4 7a 7b 7c 7 7f 7g 7h 3a FIG. PART NO. DESCRIPTION NO. REQ Shroud M3 x 9.5mm Pan Hd. Taptite T-0 Screw O-Ring Rotor Assembly 3a Ball Bearing M4 x 0mm Pan Hd. Taptite Screw M3.5 x 6mm Pan Hd. Plast. T-0 (5 of 3) Bottom Cap Bottom Cap/Connector Rubber Housing Assembly 34a Housing Cover (Right Housing) 34b Housing Support (Left Housing) Motor Housing Assembly 35a Motor Housing Cover (Right Motor Housing) 35b Motor Housing Support (Left Motor Housing) 35c M5 x 5mm Taptite T-5 Screw Vibration Washer ( of ) Vibration Bumper ( of 4) Bumper Holder ( of 4) 4 65b Retaining Plate M4 x 5mm Scr. ( each for top & bottom AVS) Foam Block Bottom AVS Spring Bottom AVS Square Guide Pipe Bottom Bellows T-Bracket Service Nameplate (Not Shown) Lock Washer Motor Seal 3 7a 7b 7c 7d 7e

3 IMPORTANT: Dimpled end of connecting rod to crank assembly. Coat pin of crank assy. Dimple Fill back of piston with grease. There is to be no grease on face of piston. Coat wrist pin LUBRICATION NOTES: Urethyn GE00 Grease No ,.8oz. / 80g tube A total of approx. 60 grams will be used. Prior to reinstalling, clean gear assemblies with a clean, dry cloth. Lightly coat all parts highlighted here with Urethyn GE00 grease. Apply a greater amount of grease to all internal and external gear teeth. Coat entire clutch gear assembly with grease. Be sure to place a liberal amount on the gear teeth. Brush both sides of thrust washers and thrust bearing with grease. Coat entire crank gear assembly with grease. Be sure to place a liberal amount on the gear teeth. OLD DESIGN NEW DESIGN Coat the inside walls of gearbox and the crank gear pin with grease. Place approximately 40 grams of grease in the cavity after the gearing is installed. Place a heavy coat of grease on rotor pinion Coat o-ring Coat o-rings, ram and striker with grease. Brush the exterior and inside of the ram catcher. NOTE: No grease on the rear face of ram. Bottom View of Gear Case Cover # with Gasket #- There are two gaskets in Service Kit Visually inspect gear case cover to determine which gasket to install. Discard the other gasket Rotary Hammer Service Kit (For the M8 FUEL Rotary Hammer and the 75-0 M8 FUEL Rotary Hammer ) Dust Shield () () mm Steel Ball () Ball Support Plate () Bumper () 3d Square O-Ring () 3f Anvil O-Ring () 3h Back Pressure Ring () 3j Anvil () 4b O-Ring () O-Ring () O-Ring () Retaining E-Ring () O-Ring () Gearcase Gasket (See detail above) () Gearcase Gasket (See detail above) () Rubber Washer () Instruction Sheet () Urethyn GE00 Grease 60 grams required- (80 gram,.8oz tube) () Disregard and discard Carbon Brushes for models and V Carbon Brush (Set of ) () For model V Carbon Brush (Set of ) () For model DISCARD Place approximately grams of grease in the rear inside cavity of spindle. Lightly coat outside barrel as shown. Prior to installing the Ram Assembly, place 8 grams of grease inside of spindle between the ram catcher and the ram NOTE: It is recommended to order Motor Seal #90 ( ) at the same time that Rotary Hammer Service Kit No is installed. Prior to installing spindle assembly, place a heavy coating of grease in the interior cavity of bushing/ sleeve assembly. SCREW TORQUE SPECIFICATIONS SEAT TORQUE FIG. PART NO. WHERE USED (KG/CM) (IN/LBS) Gearcase Cover (4) Rear and Middle Gearcase Cover () Front a Bushing Sleeve Assembly Shroud Clamp Plate Rotor Bearing Plate Bottom Cap Housing Cover Motor Housing Cover Right Handle Halve c Motor Housing Assembly Selector Knob Retaining Plate (Top and Bottom) 0 7.5

4 NOTE: As an aid to working on the gearcase and spindle assemblies, a bench top fi xture can be made from a 3.5 piece of 4 PVC pipe. The contour of the pipe can be cut according to dimensions in the illustration. SERVICE TOOLS: Ring Expander Cone Seal Press Pin Cut or file a 45º Chamfer here Push Sleeve Seal Press Pin #90 Motor Seal Anvil Sleeve Snap Ring Bar #3a Spindle A B #3b Brake Ring #3c Anvil Ring #3d Square O-Ring #3e Anvil/Striker #3f Anvil O-Ring #3g Ram Catcher #3h Back Pressure Ring #3j Anvil #4a Ram #4b Ram O-Ring Prior to installing Place Retaining 3 4 components, lightly grease the inside cavity of spindle. Place the assembled components A into cavity end of service tool (Anvil Sleeve Snap Ring Bar). Push components into the spindle until parts bottom out. Use a rubber mallet to the end of the service tool to assure that the inside components are properly seated Anvil Sleeve Snap Ring Bar Secure the parts inside the Anvil with Retaining Ring #3j. See figures 3 and 4 for an installation aid. Ring #3j as shown on the spindle #3a. As an aid, it may be helpful to file or grind a notch on the bottom flat of a screwdriver to accomodate the round of the ring. As force is applied, the open end of the ring will close in on screwdriver. Once deep enough in the cavity, rotate ring horizontally Anvil Sleeve Snap Ring Bar Insert service tool into rear of spindle and push downward. Slide retaining ring into internal slot to secure components A. #3j Anvil Retaining Ring 5 #3j Anvil B A # Prior to placing the assembled components B (Ram and O-Ring) into spindle cavity, apply approximately 8 grams of Urethyn GE00 Grease into the barrel behind internal spindle components A. Insert Ram/O-Ring Assembly into barrel of spindle. #3 Collar #4 Steel Balls #5 Ball Support Plate #6 Conical Spring Push Sleeve # Ring Expander Cone

5 = WIRE TRAPS or GUIDES On-Off Switch Stator Assembly (Inside Motor Housing Assembly) Insulated Sleeve Battery Terminal Block Assembly Thick black and red wires thru ferrite bead. Thin green and blue wires are behind the bead. NOTE: In production, hot glue is used instead of heat shrink tubing over these terminals. Heat Shrink Tubing for Service PCBA Battery Connector Block NOTE: #7b Battery Connector Block is serviceable. To preserve the Black Wire wire lengths, it is not recommended to cut the wires above Blue Wire the terminal block. Solder Area Green Wire To remove the battery connector Red Wire block do the following:. The hot glue or heat shrink tubing must be carefully removed from each wire by using a knife or razor blade.. Carefully heat the solder at the terminal location to remove each wire. 3. Place a new piece of heat shrink tubing over each wire prior to resoldering onto the new Battery Connector Block. 4. Be sure the wires are place back at the correct terminal locations. Solder each wire back into place. Slide heat shrink tubing over the solder/terminal area and heat to secure. (Note: A small strip of electrical tape can be used in place of heat shrink tubing). LED Assembly Wire Ribbon AS AN AID TO REASSEMBLY, TAKE NOTICE OF WIRE ROUTING AND POSITION IN WIRE GUIDES AND TRAPS WHILE DISMANTLING TOOL. BE SURE THAT ALL COMPONENTS OF THE ELECTRONICS KIT ARE SEATED FIRMLY AND SQUARELY IN THE HOUSING RECESSES. AVOID PINCHED WIRES, BE SURE THAT ALL WIRES AND SLEEVES ARE PRESSED COMPLETELY DOWN IN WIRE GUIDES AND TRAPS. PRIOR TO INSTALLING THE HOUSING COVER ONTO THE HOUSING SUPPORT, BE SURE THAT THERE ARE NO INTERFERENCES.