Maintenance - Milwaukee 4004 20A Operator's Manual

To reduce the risk of injury, always unplug
your tool before performing any maintenance.
Never disassemble the tool or try to do any
rewiring on the tool's electrical system. Contact
a MILWAUKEE service facility for ALL repairs.
Maintaining Tools
Keep your tool in good repair by adopting a regular maintenance pro-
gram. Before use, examine the general condition of your tool. Inspect
guards, switches, tool cord set and extension cord for damage. Check
for loose screws, misalignment, binding of moving parts, improper mount-
ing, broken parts and any other condition that may affect its safe opera-
tion. If abnormal noise or vibration occurs, turn the tool off immediately
and have the problem corrected before further use. Do not use a dam-
aged tool. Tag damaged tools "DO NOT USE" until repaired
(see "Repairs").
Under normal conditions, relubrication is not necessary until the motor
brushes need to be replaced. After six months to one year, depending on
use, return your tool to the nearest MILWAUKEE service facility for the
following:
• Lubrication
• Brush inspection and replacement
• Mechanical inspection and cleaning (gears, spindles, bearings,
housing, etc.)
• Electrical inspection (switch, cord, armature, etc.)
• Testing to assure proper mechanical and electrical operation
Lubricating Rack and Pinion
Maintain a light coat of MILWAUKEE Type "E" Grease on the rack and
pinion gears to reduce friction and wear.
Lubricating the Spindle for Dymodrills with a Shear Pin
Before each use, clean and lubricate the spindle or spindle sleeve with
MILWAUKEE Type "E" Grease to prevent the spindle from seizing during
coring.
1. To maintain the spindle on shear pin models, remove the retaining
ring with a screwdriver. Then remove the spindle sleeve.
2. Remove dust and debris from the inside and outside diameter of the
spindle and spindle sleeve and from the water hole in the spindle.
Place a light coating of MILWAUKEE Type "E" grease on the spindle.
3. Replace the spindle sleeve onto the spindle. Make sure the spindle
sleeve rotates freely on the spindle. Then replace the retaining ring.
Replacing Vacuum Pad Gaskets
For Cat. No. 4115, 4125 & 4130 only.
Through normal use, the rubber gaskets on the underside of the vacuum
pads can become worn, requiring replacement. If replacement is re-
quired, take the pad to an authorized service center or replace the
gasket as follows:
1. Remove the old gasket and thoroughly remove the old glue from the
groove.
2. Squeeze a continuous bead of rubber cement (Cat. No. 44-22-0060)
in the entire bottom of the groove.
3. Immediately place a new gasket (Cat. No. 43-44-0570) in the groove
and press firmly in place.
4. Turn the pad over and place the gasket side on a smooth flat surface
and apply pressure to all edges of the pad.
5. Allow cement to dry for 24 hours before using.
For Cat. No. 4120 only.
With normal use, the rubber gasket on the underside of the base can
become worn, requiring replacement. If replacement is required, take the
base to an authorized service center or replace the gasket as follows:

MAINTENANCE

WARNING!
1. Remove the motor and bit.
2. Tip the Dymorig on its back so that the wheels point down.
3. Remove the old gasket.
4. Squeeze a continuous bead of rubber cement (Cat. No.
44-22-0060) in the entire bottom of the groove.
5. Place the new gasket (Cat. No. 43-44-0605) into the groove making
sure it is pushed in completely.
6. Stand the Dymorig upright again.
7. Reinstall the motor and bit.
Cleaning the Filter on the Vacuum Pump
Periodically clean the filter felts to keep the vacuum pump operating
efficiently. To clean the filter felts, remove the plastic jar and remove the
felts from the plastic tube. Remove dust and debris from the felts and
clean the plastic jar. Then replace the felts on the plastic tube and posi-
tion the jar onto the filter assembly.
To reduce the risk of injury, electric shock and
damage to the tool, never immerse your tool in
liquid or allow a liquid to flow inside the tool.
Cleaning
Clean dust and debris from vents. Keep the tool handles clean, dry and
free of oil or grease. Use only mild soap and a damp cloth to clean your
tool since certain cleaning agents and solvents are harmful to plastics
and other insulated parts. Some of these include: gasoline, turpentine,
lacquer thinner, paint thinner, chlorinated cleaning solvents, ammonia
and household detergents containing ammonia. Never use flammable or
combustible solvents around tools.
Repairs
If your tool is damaged, return the entire tool to the nearest service
center.
FIVE YEAR TOOL LIMITED WARRANTY
Every MILWAUKEE tool is tested before leaving the factory and is war-
ranted to be free from defects in material and workmanship. MILWAUKEE
will repair or replace (at MILWAUKEE's discretion), without charge, any
tool (including battery chargers) which examination proves to be defec-
tive in material or workmanship from five (5) years after the date of
purchase. Return the tool and a copy of the purchase receipt or other
proof of purchase to a MILWAUKEE Factory Service/Sales Support
Branch location or MILWAUKEE Authorized Service Station, freight pre-
paid and insured. This warranty does not cover damage from repairs
made or attempted by other than MILWAUKEE authorized personnel,
abuse, normal wear and tear, lack of maintenance, or accidents.
Battery Packs, Flashlights, and Radios are warranted for one (1) year
from the date of purchase.
THE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN ARE
EXCLUSIVE. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY
INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES, INCLUDING
LOSS OF PROFITS.
THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRAN-
TIES, OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED FOR
MERCHANTABLILITY OR FITNESS FOR PARTICULAR USE OR PURPOSE.
This warranty gives you specific legal rights. You may also have other
rights that vary from state to state and province to province. In those
states that do not allow the exclusion of implied warranties or limitation
of incidental or consequential damages, the above limitations or exclu-
sions may not apply to you. This warranty applies to the United States,
Canada, and Mexico only.
WARNING!
page 13