Milwaukee 6390-20, 6394 Operator's Manual

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.

OPERATOR'S MANUAL MANUEL de L'UTILISATEUR MANUAL del OPERADOR

HEAVY-DUTY CIRCULAR SAW WITH TILT-LOK™ HANDLE SCIES CIRCULAIRES INDUSTRIELLES AVEC POIGNEE « TILT-LOK™ » SIERRA CIRCULAR PARA TRABAJO PESADO CON EMPUÑADURA

TILT-LOK™ (INCLINABLE-FIJABLE)

Cat. No.

No de cat.

6390-20

6394

PERSONAL SAFETY

GENERAL POWER TOOL SAFETY WARNINGS

WORK AREA SAFETY

ELECTRICAL SAFETY

WARNING READ ALL SAFETY WARNINGS AND ALL 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.

POWER TOOL USE AND CARE

SERVICE

SPECIFIC SAFETY RULES

• 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.

• 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 electric

shock if your body is earthed or grounded.

• Do not expose power tools to rain or wet conditions. Water 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.

• 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 medication. 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.

• 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.

• 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.

• 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.

take corrective actions to eliminate the cause of blade binding.

• When restarting a saw in the workpiece, centre the saw blade in the kerf and check that saw teeth are not engaged into the material. If saw

blade is binding, it may walk up or kickback from the workpiece as the saw is restarted.

• Support large panels to minimise the risk of blade pinching and kickback. Large panels tend

to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.

• Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.

• Blade depth and bevel adjusting locking levers must be tight and secure before making cut. If

blade adjustment shifts while cutting, it may cause binding and kickback.

• Use extra caution when making a “plunge cut” into existing walls or other blind areas. The

protruding blade may cut objects that can cause kickback.

• Check lower guard for proper closing before each use. Do not operate the saw if lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If saw is accidentally dropped, lower guard

may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.

• Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use.

Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.

• Lower guard should be retracted manually only for special cuts such as “plunge cuts”and “compound cuts.” Raise lower guard by retracting handle and as soon as blade enters the material, the lower guard must be released. For

all other sawing, the lower guard should operate automatically.

• Always observe that the lower guard is covering the blade before placing saw down on bench or ﬂ oor. An unprotected, coasting blade

will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.

• Do not use abrasive wheels with circular saws. Dust and grit can cause lower guard to hang up and not operate properly.

• Maintain labels and nameplates. These carry important information. If unreadable or missing, contact a MILWAUKEE service facility for a free replacement.

• 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

DANGER:

• Keep hands away from cutting area and the blade. Keep your second hand on auxiliary handle, or motor housing. If both hands are holding

the saw, they cannot be cut by the blade.

• Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.

• Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade

teeth should be visible below the workpiece.

• Never hold piece being cut in your hands or across your leg. Secure the workpiece to a stable platform. It is important to support the

work properly to minimize body exposure, blade binding, or loss of control.

• Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord.

Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.

• When ripping always use a rip fence or straight edge guide. This improves the accuracy of cut and

reduces the chance of blade binding.

• Always use blades with correct size and shape (diamond versus round) of arbour holes. Blades

that do not match the mounting hardware of the saw will run eccentrically, causing loss of control.

• Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were specially

designed for your saw, for optimum performance and safety of operation.

Causes and Operator Prevention of Kickback: KICKBACK is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator. When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator. If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator.

Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

• Maintain a ﬁ rm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade, but not in line with the blade. Kickback

could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.

• When blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur. Investigate and

SPECIFICATIONS

Cat. No. Volts

No Load

RPM

Blade Size

6390-20

6394

120 AC/DC

120 AC Only

5 800 5 800

7-1/4" 7-1/4"

Cat. No. Arbor

Depth of

Cut at 90°

Depth of

Cut at 45°

6390-20

6394

5/8"

0 to

2-15/32"

0 to

2-15/32"

0 to 1-13/16" 0 to 1-13/16"

FUNCTIONAL DESCRIPTION

SYMBOLOGY

Fig. B

Fig. C

Fig. A

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.

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.

READ AND SAVE ALL

INSTRUCTIONS FOR FUTURE USE.

* Based on limiting the line voltage drop to ﬁ ve volts at

150% of the rated amperes.

EXTENSION CORDS

Recommended Minimum Wire Gauge

For Extension Cords*

Nameplate

Amperes

Extension Cord Length

25' 50' 75' 100' 150'

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

18 18 18 18 16 14 12

18 18 18 16 14 12 10

18 18 16 14 12 10

18 16 14 12 10

16 14 12 12

Double Insulated

Volts

Alternating Current/ Direct Current

Alternating Current

Amps

No Load Revolutions per Minute (RPM)

Underwriters Laboratories, Inc., United States and Canada

Cat. No. 6394

1. Tilt-Lok™ handle

2. Handle lever release button

3. Handle release lever

4. Bevel scale

5. Bevel pointer

6. Bevel adjusting lever

7. Spindle lock button

8. Depth setting gauge (not shown)

9. Trigger

10. C

ord release button

11. Depth adjusting lever

12. Front handle

13. Sight line

14. Rip fence slot

15. Lower guard

16. Blade ﬂ ange

17. Blade bolt

18. Blade

19. Shoe

20. Lower guard lever

21. Upper guard

22. Positive-Lok

cord

(Cat. No. 6394 only)

• arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending 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 speciﬁ cally designed to ﬁ lter out microscopic particles.

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 Cana- da) 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.

ASSEMBLY

WARNING To 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.

Removing and Replacing Positive-Lok® Cords (Cat. No. 6394)

MILWAUKEE’S exclusive Positive-Lok® Cords provide instant ﬁ eld replacement or substitution. The Positive-Lok® feature secures the cord ﬁ rmly to the tool.

1. To remove the Positive-Lok® Cord, push the

cord release button in the direction shown and turn the cord nut 1/4 turn to the left. Pull the cord out.

2. To replace the Positive-Lok® Cord, align the

connector keyways and push the connector in as far as it will go. Turn the cord nut 1/4 turn to the right to lock. The cord release button will click back into place.

Cord release button

Fig. 1

Selecting Blade

Always use sharp blades. Dull blades tend to overload the tool and increase the chance of kickback (see “Preventing Kickback”). A combination blade is included with your tool for general use in wood. Select the right blade for your job. Read the manufacturer’s instructions before use.

WARNING Only use accessories with

maximum speed rating at least as high as nameplate RPM of tool.

Fig. 2

Rip & Crosscut

A multi-purpose blade for ripping, cross cutting and mitering in hardwoods, softwoods, plywood and composition materials.

Framing-Rip

Designed for fast and accurate ripping along the grain in hard-or softwoods where a smooth cross cut is not necessary.

Plywood-Veneer

Recommended for cutting plywood, composition materials and all types of wood where a slightly smoother ﬁ nish is needed.

Finish & Trim

Especially designed for cross cutting and mitering in materials where a very smooth cut is necessary. Also cuts aluminum.

Installing and Removing Blades

1. Unplug tool before installing or removing blades.

2. Place the saw on a ﬂ at surface with the blade fac- ing upwards. T o remove the bolt from the spindle, push in the spindle lock button. While holding in the spindle lock button, use the wrench provided with the tool to turn the bolt counterclockwise. Remove the bolt and outer blade ﬂ ange.

3. Slide the lower guard lever up to raise the lower guard. Remove the blade from the spindle. Always clean the spindle, upper guard and lower guard to remove any dirt and sawdust.

NOTE: Do not remove inner blade ﬂ ange. Larger di-

ameter of inner ﬂ ange (Fig. 3) should face the blade.

Fig. 4

4. To install a blade, place the blade on the spindle with the teeth pointing in the same direction as the arrow on the lower guard (Fig. 4). Release the lower guard lever.

5. Place the outer blade ﬂ ange on the spindle and hand tighten the bolt. Larger diameter of outer ﬂ ange (Fig. 3) should rest on blade.

6. While holding the spindle lock button in, use the wrench to turn the bolt clockwise and tighten.

Adjusting Depth

1. Unplug tool.

2. T o adjust the depth of the cut, hold the saw by the Tilt-Lok™ handle and loosen the depth adjusting lever by lifting it up and away from the shoe (Fig. 5).

Fig. 5

3. Raise or lower the shoe to the desired position. Markings in 1/4" increments are located on the inner side of the upper guard for depth setting. For the proper depth setting, the blade should extend no more than 1/4" below the material being cut (Fig. 6).

4. Move the depth adjusting lever towards the shoe and push down to secure the position.

1/4"

Fig. 6

Adjusting Bevel Angle

1. Unplug tool.

2. T o adjust the angle of the cut, hold the saw by the Tilt-Lok™ handle and loosen the bevel adjusting lever by lifting it up towards the blade (Fig. 7).

Fig. 8

4. Move the bevel adjusting lever away from the blade and push down to secure the position.

Fig. 7

3. Hold the front handle and rotate the saw by the Tilt-Lok™ handle to the desired angle as indicated by the markings on the bevel scale (Fig. 8).

Adjusting Tilt-Lok™ Handle Angle

This circular saw is equipped with an adjustable handle. The Tilt-Lok™ feature allows the user to adjust the angle of the handle for optimum cutting positions.

NOTE: The blade depth setting will determine the

range of Tilt-Lok™ positions available for the application. See “Adjusting Depth” for instructions on adjusting the blade depth.

5. Push the handle release lever back into the handle until it snaps into place.

Fig. 9

1. Unplug tool.

2. Press in and hold the handle lever release button.

3. Loosen the handle release lever by lifting it up and away from the Tilt-Lok™ handle.

4. To adjust the handle position, hold the front handle and rotate the Tilt-Lok™ handle to the desired angle as indicated by the handle rotation adjustment markings (Fig. 9). The Tilt-Lok™ feature has eight (8) detents which allow the handle to snap into position. Allow the detent to snap into place.

WARNING Do not operate saw with

handle lever release button pressed in or with handle not locked into position.

WARNING If the Tilt-Lok™ handle

moves with the handle release lever in the locked position, do not operate saw. Return the circular saw to a MILW AUKEE

service facil-

ity for repair immediately.

NOTE: The saw will not operate if the handle

release lever is not properly secured.

Fig.10

Bevel adjustment screw

Adjusting the Blade to Shoe

The shoe has been adjusted at the factory to a 90 degree setting. Inspect the saw regularly to make sure the blade is 90 degrees to the shoe.

1. Unplug tool.

2. Set the bevel pointer to zero.

3. To make sure the blade is 90 degrees to the shoe, place saw on the blade side and retract lower guard. Place a square against the blade and shoe to inspect the degree setting (Fig. 10).

4. To adjust the degree setting, loosen the bevel adjusting lever up by lifting it up towards the blade. Turn the bevel adjustment screw in or out until the blade is at a 90 degree angle with the shoe.

5. Check that the bevel pointer is at 0 degrees. To adjust the bevel pointer, loosen the two screws in the front handle and reposition the bevel pointer to 0 degrees.

OPERATION

WARNING To reduce the risk of injury,

wear safety goggles or glasses with side shields.

WARNING To 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.

Causes and Operator Prevention of Kickback:

KICKBACK is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator. When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator. If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator.

Bolt

Outer ﬂ ange

Inner ﬂ ange

Spindle

Fig. 3