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Discuss | Repair Videos | Articles
Discussion for the Milwaukee 6538-21 (SER B36A) 1-1/4" Stroke Sawzall
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The Milwaukee Armature, part number 16-30-0705 is still available for order and in stock at the factory.
Question: Removal Of Rear Bushing
I am trying to replace the spindle on my 6520-21 Milwaukee Sawzall and can't seem to find any info on how to remove the rear bushing. It appears to be pressed on to two rods but is being very stubborn. I have tried heat, and silicone both to try to loosen but have failed to remove it. Any advise???
Reply: Removal Of Rear Bushing
Give me your serial number off the tool as Milwaukee made 4 type changes on that tool.Also if you can take a few digital pictures would help also.To the best of my knowledge the front bushing sits in the housing with a zero fit and the rear sits in a cradle.The rear bushing should be the only bushing that needs to be removed if I remember right.You have a broken a shaft it could have caused other problems.Hope that helps.
Question: Brush Sparking At Full Speed
I also have this model sawzall and I am having the same problem. The arc from the brushes to armature seem normal at low speed (dial @1) and are blowing out of the case at full speed (dial @5). The brushes and armature seem fine and the variable speed control trigger is fine. Could this have anything to do with the electronic feedback module?
Question: Removing The Wobble Shaft
how do you remove the wobble shaft dowel pin reciprocating spindle from the gear cas
Reply: Removing The Wobble Shaft
If I remember right you just need to remove the blade quick release assembly and the nut on the end of the wobble drive axel and the whole assembly should come out.Hope this helps.Good luck.
Back in Oct. of 2011, I replaced the armature and brushes. The ploblem I'm having now is the variable speed does'nt work, it runs at a constent speed "fast". I also broke part#23-38-0200. By replacing the module electronic feedback part# 14-20-1040 would this correct my problem?
Reply: Sawzall Cat#6538-21
What you broke (23-38-0200) is a magnetic speed wheel.This feeds information on the armature RPM to the speed control unit. If you broke this and now the variable speed won't work Id replace this first.If the variable speed stopped working before the magnetic wheel was broken then I'd replace the speed control,magnetic wheel unit,and trigger switch to do a clean repair of the tool.Hope that helps.Good luck.
Question: Brush Spark
There is excessive spark on the lower brush with a burning smell, what is the repair required?
Reply: Brush Spark
I just replaced both brushes on this model. I was excited about putting it back into commission & even bought new rubber cover etc. to renew it's appearance. When assembled carefully to avoid pinching any wires etc. I plugged it in & it began to operate. I was stoked! Then it began to heat up and smoke & throw small sparks at the brushes (lower) & finally popped the breaker. What is up with this? I have not seen a response to your question of last year and would really appreciate input from you techies out there that are more familiar w/ this situation. I believe this machine has a componant that shuts it down to keep it from overheating. This was an expensive machine, 15amps heavy duty job. Wish I could put it right again and find out what is going on with it. Somebody write in please.