Milwaukee 6242-6 OPERATOR'S MANUAL
Cat. No.
No de Cat.
6242-6
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
COMPACT BAND SAW
SCIE À RUBAN COMPACTE
SIERRA DE BANDA COMPACTA
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S
MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE ET BIEN
COMPRENDRE LE MANUEL DE L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER Y ENTENDER EL
MANUAL DEL OPERADOR.
GENERAL POWER TOOL SAFETY WARNINGS
WARNING READ ALL SAFETY WARNINGS AND INSTRUCTIONS.
Failure to follow the warnings and instructions may result in electric shock, fi re and/or
serious injury.
Save all warnings and instructions for future reference
The term "power tool" in the warnings refers to your mains-operated (corded) power tool
or battery-operated (cordless) power tool.
WORK AREA SAFETY
• Keep work area clean and well lit. Cluttered or
dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the presence of fl ammable
liquids, gases or dust. Power tools create
sparks which may ignite the dust or fumes.
• Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
ELECTRICAL SAFETY
• Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power
tools. Unmodifi ed plugs and matching outlets will
reduce risk of electric shock.
• Avoid body contact with earthed or grounded
surfaces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of elec-
tric shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. W ater entering a power tool will increase
the risk of electric shock.
• Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords
increase the risk of electric shock.
• When operating a power tool outdoors, use
an extension cord suitable for outdoor use.
Use of a cord suitable for outdoor use reduces
the risk of electric shock.
• If operating a power tool in a damp location
is unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD reduces
the risk of electric shock.
PERSONAL SAFETY
• Stay alert, watch what you are doing and use
common sense when operating a power tool.
Do not use a power tool while you are tired or
under the infl uence of drugs, alcohol or medi-
cation. A moment of inattention while operating
power tools may result in serious personal injury.
• Use personal protective equipment. Always
wear eye protection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions
will reduce personal injuries.
• Prevent unintentional starting. Ensure the
switch is in the off-position before connecting
to power source and/or battery pack, picking
up or carrying the tool. Carrying power tools
with your fi nger on the switch or energising power
tools that have the switch on invites accidents.
• Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key
left attached to a rotating part of the power tool
may result in personal injury.
• Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or
jewellery. Keep your hair , clothing and gloves
away from moving parts. Loose clothes, jewel-
lery or long hair can be caught in moving parts.
• If devices are provided for the connection of
dust extraction and collection facilities, ensure
these are connected and properly used. Use of
dust collection can reduce dust-related hazards.
POWER TOOL USE AND CARE
• Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the
rate for which it was designed.
• Do not use the power tool if the switch does
not turn it on and off. Any power tool that cannot
be controlled with the switch is dangerous and
must be repaired.
• Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
• Store idle power tools out of the reach of children and do not allow persons unfamiliar with
the power tool or these instructions to operate
the power tool. Power tools are dangerous in the
hands of untrained users.
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• Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts
and any other condition that may affect the
power tool’s operation. If damaged, have the
power tool repaired before use. Many accidents
are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
• Use the power tool, accessories and tool bits
etc., in accordance with these instructions,
taking into account the working conditions
and the work to be performed. Use of the power
tool for operations different from those intended
could result in a hazardous situation.
SERVICE
• Have your power tool serviced by a qualifi ed
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
SPECIFIC SAFETY RULES
• Hold power tool by insulated gripping surfaces, when performing an operation where the
cutting accessory may contact hidden wiring
or its own cord. Cutting accessories contacting
a “live” wire may make exposed metal parts of
the power tool “live” and could give the operator
an electric shock.
• Maintain labels and nameplates. These carry
important information. If unreadable or missing,
contact a MILWAUKEE service facility for a free
replacement.
FUNCTIONAL DESCRIPTION
1. Trigger
2. Handle
3. Material guide
4. Blade
5. Tension lock handle
6. Blade release button
7. Front handle
8. Speed dial
9. LED On/Off switch
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• WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause
cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:
• lead from lead-based paint
• crystalline silica from bricks and cement and other
masonry products, and
• arsenic and chromium from chemically-treated
lumber.
Your risk from these exposures varies, depend-
ing on how often you do this type of work. To
reduce your exposure to these chemicals: work
in a well ventilated area, and work with approved
safety equipment, such as those dust masks that
are specially designed to fi lter out microscopic
particles.
Symbology
FPM
9
4
3
No Load Surface Feet per Minute
Volts Alternating Current
Amps
Underwriters Laboratories, Inc.,
United States and Canada
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2
3
GROUNDING
WARNING Improperly connecting the
grounding wire can result in the risk of electric shock. Check with a qualifi ed electrician
if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug
provided with the tool. Never remove the
grounding prong from the plug. Do not use
the tool if the cord or plug is damaged. If
damaged, have it repaired by a MILWAUKEE
service facility before use. If the plug will not
fi t the outlet, have a proper outlet installed by
a qualifi ed electrician.
Grounded Tools: Tools with Three Prong Plugs
Tools marked “Grounding Required” have a three
wire cord and three prong grounding plug. The
plug must be connected to a properly grounded
outlet (See Figure A). If the tool should electrically
malfunction or break down, grounding provides a
low resistance path to carry electricity away from
the user, reducing the risk of electric shock.
The grounding prong in the plug is connected
through the green wire inside the cord to the
grounding system in the tool. The green wire in the
cord must be the only wire connected to the tool's
grounding system and must never be attached to
an electrically “live” terminal.
Your tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes
and ordinances. The plug
and outlet should look like
those in Figure A.
Double Insulated Tools:
Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require
grounding. They have a special double insulation system which satisfi es OSHA requirements
and complies with the applicable standards of
Underwriters Laboratories,
Inc., the Canadian Standard Association and the
National Electrical Code.
Double Insulated tools may
be used in either of the
120 volt outlets shown in
Figures B and C.
Fig. A
Fig. B
Fig. C
EXTENSION CORDS
Grounded tools require a three wire extension
cord. Double insulated tools can use either a two
or three wire extension cord. As the distance from
the supply outlet increases, you must use a heavier
gauge extension cord. Using extension cords with
inadequately sized wire causes a serious drop in
voltage, resulting in loss of power and possible tool
damage. Refer to the table shown to determine the
required minimum wire size.
The smaller the gauge number of the wire, the
greater the capacity of the cord. For example, a 14
gauge cord can carry a higher current than a 16
gauge cord. When using more than one extension
cord to make up the total length, be sure each cord
contains at least the minimum wire size required. If
you are using one extension cord for more than one
tool, add the nameplate amperes and use the sum
to determine the required minimum wire size.
Guidelines for Using Extension Cords
• If you are using an extension cord outdoors,
be sure it is marked with the suffi x “W-A” (“W”
in Canada) to indicate that it is acceptable for
outdoor use.
• Be sure your extension cord is properly wired
and in good electrical condition. Always replace
a damaged extension cord or have it repaired by
a qualifi ed person before using it.
• Protect your extension cords from sharp objects,
excessive heat and damp or wet areas.
Recommended Minimum Wire Gauge
Nameplate
* Based on limiting the line voltage drop to
fi ve volts at 150% of the rated amperes.
for Extension Cords*
Amperes
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
Extension Cord Length
25'
18
18
18
18
16
14
12
50'
18
18
18
16
14
12
10
75'
18
18
16
14
12
10
100'
18
16
14
12
10
150'
16
14
12
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READ AND SAVE ALL
INSTRUCTIONS FOR
FUTURE USE.
ASSEMBLY
WARNING T o reduce the risk of injury ,
always unplug tool before attaching or removing accessories or making adjustments. Use
only specifi cally recommended accessories.
Others may be hazardous.
Blades and Blade Selection
The blade dimensions required for the band saws
are: .020" thickness, 1/2" width and 35-3/8" in
length. The special .020" thickness reduces fl exure
fatigue and provides maximum tooth life. To maximize cutting life, use a blade with the correct pitch
(teeth per inch) for the specifi c cutting job.
Blades are available in several pitches. T o select the
proper blade, three factors should be considered:
The size, shape, and type of material to be cut.
The following suggestions are for selecting the
right blade for various cutting operations. Keep in
mind that these are broad guidelines and that blade
requirements may vary depending upon the specifi c
size, shape and type of material to be cut. Generally, soft materials require coarse pitch blades and
hard materials require fi ne pitch blades. Use coarse
pitch blades for thick work and fi ne pitch blades for
thin work. It is important to keep at least three teeth
in the cut (see "Typical Application").
Fig. 1
10 Teeth per Inch
14 Teeth per Inch
18 Teeth per Inch
24 Teeth per Inch
• For tough stock 3/16" up to
3-1/4" in diameter or width.
• For tough stock 5/32" to 3/4" in
diameter or width.
• For thin-wall tubing and thin
sheets heavier than 21 gauge.
• For thin-wall tubing and thin
sheets heavier than 21 gauge.
Adjusting the 2-Position Material Guide
1. Unplug the tool.
2. T o raise the guide to the upper position, press up
fi rmly to disengage the bottom position detent.
Slide the guide to the upper position.
3. To lower the guide, pull down fi rmly to engage
the bottom-position detent.
WARNING Do not touch blade
immediately after use. Blade will be hot.
Changing Blades
1. UNPLUG THE TOOL BEFORE REMOVING OR
INSTALLING BLADES.
2. Raise the material guide to the upper position.
3. Turn the tension lock handle located on the front
of the saw 180° counterclockwise.
4. To remove the blade:
a. Pull the blade out of the guides.
b. Then, press the Blade Release Button to lift
the blade above the blade guard and remove
completely.
5. To install a blade:
a. Fit the blade around the pulleys.
NOTE: Be sure the teeth face out.
b. Firmly press the blade between the guides.
6. Turn the tension lock handle 180° clockwise to
secure the blade on the pulleys.
7. Adjust the material guide to the desired position.
8. Be sure that the blade lies freely within the guard
channel before starting the tool motor.
BE SURE THAT THE BLADE IS PROPERLY
SEATED ON THE PULLEYS BEFORE ST ART ING THE CUT.
Blade LED
To line-up a cut or light-up the workpiece, use the
LED On/Off Switch.
Specifi cations
Tool Capacities
Cat. No. Volts Amps FPM Recommended Blades
6242-6 120 AC 7 200 - 360 35-3/8" X 1/2" X .020 Bi-Metal 3-1/4" 3-1/4" x 3-1/4"
4
Round
Stock
Rectangular
Stock
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OPERATION
WARNING T o reduce the risk of injury ,
always unplug tool before attaching or removing accessories or making adjustments. Use
only specifi cally recommended accessories.
Others may be hazardous.
WARNING T o reduce the risk of injury ,
wear safety goggles or glasses with side
shields. Keep hands away from the blade and
all moving parts.
Speed Dial
To set the top speed, rotate the speed dial. Set
the dial to “4” for maximum speed (360 FPM), “1”
for minimum speed (200 FPM).
Starting and Stopping
1. To start the tool, grasp the handles fi rmly and
pull the trigger. The speed is determined by the
speed dial setting.
2. To stop the tool, release the trigger. Allow the tool
to come to a complete stop before removing the
blade from a partial cut or laying the tool down.
Typical Application
1. Keep the blade off the workpiece until the motor
has reached the selected speed.
2. Start cutting on a surface where the greatest
number of teeth will be in contact with the workpiece at one time (Fig 2).
Fig. 2
3. Place the material guide against the workpiece
and lower the moving saw blade into the cut.
4. Do not bear down while cutting. The weight of
the tool will supply adequate pressure for the
fastest cutting.
5. When completing a cut, hold the tool fi rmly so it
will not fall against the workpiece (Fig. 3).
Fig. 3
MAINTENANCE
WARNING 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 program. 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 mounting, broken parts and any other condition that may affect
its safe operation. If abnormal noise or vibration
occurs, turn the tool off immediately and have the
problem corrected before further use. Do not use a
damaged tool. T ag 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
WARNING T o reduce the risk of injury ,
electric shock and damage to the tool, never
immerse your tool in liquid or allow a liquid
to fl ow 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 fl ammable or combustible
solvents around tools.
Repairs
If your tool is damaged, return the entire tool to the
nearest service center.
Correct Incorrect
ACCESSORIES
WARNING T o reduce the risk of injury ,
always unplug the tool before attaching or
removing accessories. Use only specifi cally
recommended accessories. Others may be
hazardous.
For a complete listing of accessories refer to your
MILWAUKEE Electric Tool catalog or go on-line
to www.milwaukeetool.com. To obtain a catalog,
contact your local distributor or a service center.
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