Milwaukee 6391 User Manual
OPERATOR’S MANUAL
MANUEL de L’UTILISATEUR
MANUAL del OPERADOR
Cat. No.
No de cat.
6391
HEAVY DUTY LEFT BLADE CIRCULAR SAW WITH TILT-LOK™
HANDLE
ROBUSTE SCIE CIRCULAIRE À POIGNÉE TILT-LOK™ ET LAME À
GAUCHE
SIERRA CIRCULAR DE CUCHILLA IZQUIERDA PARA TRABAJO
PESADO CON EMPUÑADURA TILT-LOKTM (INCLINABLE-FIJABLE)
TO REDUCE THE RISK OF INJURY, USER MUST READ OPERATOR’S MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L’UTILISATEUR DOIT LIRE LE
MANUEL DE L’UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER EL MANUAL
DEL OPERADOR.
GENERAL SAFETY RULES — FOR ALL POWER TOOLS
POWER TOOL USE AND CARE
SPECIFIC SAFETY RULES
WARNING
READ ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in electric shock, fi re and/or
serious injury. The term “power tool” in all of the warnings listed below refers to your
mains-operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
WORK AREA SAFETY
1. Keep work area clean and well lit. Clut-
tered or dark areas invite accidents.
2. 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.
3. Keep children and bystanders away
while operating a power tool. Distractions can cause you to lose control.
ELECTRICAL SAFETY
4. 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.
5. 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.
6. Do not expose power tools to rain
or wet conditions. Water entering a
power tool will increase the risk of electric
shock.
7. 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.
8. 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.
2 3
PERSONAL SAFETY
9. Stay alert, watch what you are do-
ing 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.
10. Use safety equipment. Always wear
eye protection. Safety equipment such
as dust mask, non-skid safety shoes,
hard hat, or hearing protection used
for appropriate conditions will reduce
personal injuries.
11. Avoid accidental starting. Ensure the
switch is in the off-position before
plugging in. Carrying power tools with
your fi nger on the switch or plugging
in power tools that have the switch on
invites accidents.
12. 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.
13. Do not overreach. Keep proper foot-
ing and balance at all times. This
enables better control of the power tool
in unexpected situations.
14. Dress properly. Do not wear loose
clothing or jewellery. Keep your hair,
clothing and gloves away from moving
parts. Loose clothes, jewellery, or long
hair can be caught in moving parts.
15. If devices are provided for the connec-
tion of dust extraction and collection
facilities, ensure these are connected
and properly used. Use of these de-
vices can reduce dust-related hazards.
16. 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.
17. 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.
18. 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 preven-
tive safety measures reduce the risk of
starting the power tool accidentally.
19. 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 danger-
ous in the hands of untrained users.
20. 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.
21. Keep cutting tools sharp and clean.
Properly maintained cutting tools with
sharp cutting edges are less likely to
bind and are easier to control.
22. Use the power tool, accessories and
tool bits etc., in accordance with
these instructions and in the manner
intended for the particular type of
power tool, 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
23. 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.
DANGER:
1. 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.
2. Do not reach underneath the work-
piece. The guard cannot protect you from
the blade below the workpiece.
3. Adjust the cutting depth to the thick-
ness of the workpiece. Less than a full
tooth of the blade teeth should be visible
below the workpiece.
4. 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.
5. Hold power tool 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 also make exposed
metal parts of the power tool “live” and
shock the operator.
6. When ripping always use a rip fence or
straight edge guide. This improves the
accuracy of cut and reduces the chance
of blade binding.
7. 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.
8. 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.
9. 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:
a. 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.
b. When blade is binding, or when inter-
rupting 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 take cor-
rective actions to eliminate the cause
of blade binding.
c. When restarting a saw in the work-
piece, 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.
d. 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.
e. Do not use dull or damaged blades.
Unsharpened or improperly set blades
produce narrow kerf causing excessive
friction, blade binding and kickback.
f. 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.
g. 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.
10. 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 acciden-
tally 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.
11. 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.
12. 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 saw-
ing, the lower guard should operate
automatically.
13. 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.
14. Do not use abrasive wheels with
circular saws. Dust and grit can cause
lower guard to hang up and not operate
properly.
15. Maintain labels and nameplates.
These carry important information.
If unreadable or missing, contact a
MILWAUKEE service facility for a free
replacement.
16. 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 ce-
ment and other masonry products,
and
• arsenic and chromium from chemi-
cally-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.
4 5
Improperly connecting the grounding
wire can result in the risk of electric
shock. Check with a qualifi ed electri-
cian 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.
Fig. A
WARNING
GROUNDING
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 satisfies
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. 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 out-
doors, 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 prop-
erly 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
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.
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
12
FUNCTIONAL DESCRIPTION
4
3
1. Handle release lever
2. Handle lever release button
3. Bevel scale
4. Bevel pointer
5. Depth adjusting lever
6. Trigger
7. Depth setting gauge
(not shown)
8. Spindle lock button
9. Bevel adjusting lever
10. Tilt-Lok™ handle
11. Upper guard
1
6
5
12. Lower guard lever
13. Blade
14. Shoe
15. Lower guard
16. Blade bolt
2
7
8
9
17. Outer blade fl ange
18. Inner fl ange (not shown)
19. Sight line
20. Rip fence slot
21. Front handle
10
Cat.
No.
6391
Specifi cations
15
No Load
RPM
5800
Volts
AC/DC
120
Amps
Symbology
Double Insulated
Underwriters Laboratories, Inc.,
United States and Canada
Amps
21
Blade
Size
Arbor
7-1/4”
5/8”
6 7
Depth of Cut
at 90°
0 to 2-15/32”
Volts Alternating Current/
Direct Current
No Load Revolutions per
Minute (RPM)
Depth of Cut
at 45°
0 to 1-13/16”
20
19
18
17
11
12
13
14
15
16
TOOL 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.
WARNING
Only use accessories with maximum speed rating at least as high
as nameplate RPM of tool.
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. Only use blades with diamond
arbors, and read the manufacturer’s instructions before use.
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 facing upwards. T o remove the bolt
from the spindle, push in the spindle lock
button. While holding the spindle lock
button in, use the wrench provided with
the tool to turn the bolt clockwise (Fig. 2).
Remove the bolt and outer blade fl ange.
Do not remove inner blade fl ange.
Fig. 2
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.
4. T o 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. 3). Larger diameter of inner fl ange
(Fig. 4) should rest on blade. Release the
lower guard lever.
Fig. 3
5. Place the outer blade flange on the
spindle and hand tighten the bolt. Larger
diameter of outer fl ange (Fig. 4 ) should
rest on blade.
Fig. 4
Inner fl ange
Outer fl ange
6. While holding the spindle lock button in,
use the wrench to turn the bolt counterclockwise and tighten.
Adjusting Depth
1. Unplug tool.
2. To 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).
Fig. 6
Adjusting Bevel Angle
1. Unplug tool.
2. To 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. 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).
Fig. 8
4. Move the bevel adjusting lever away from
the blade and push down to secure the
position.
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.
1. Unplug tool.
2. Press and hold the handle lever release
button in.
1/4”
4. Move the depth adjusting lever towards
the shoe and push down to secure the
position.
8 9
3. Loosen the handle release lever by lifting
it up and away from the Tilt-Lok™ handle
(Fig. 9).
Fig. 9
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. 10). The Tilt-Lok™ feature has
eight (8) detents which allow the handle
to snap into position. Allow the detent to
snap into place.
Fig. 10
NOTE: The blade depth setting will de-
termine 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.
WARNING
Do not operate saw with handle lever
release button pressed in or with
handle not locked into position.
NOTE: The saw will not operate if the
handle release lever is not properly secured.
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 MILWAUKEE
service facility for repair immediately.
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 (Fig. 11).
Fig. 11
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. 12).
Fig. 12
Bevel adjustment screw
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.
10 11
To reduce the risk of injury, wear
safety goggles or glasses with side
shields. Unplug the tool before
changing accessories or making
adjustments.
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, or cutting slot, 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 operator.
KICKBACK is the result of tool misuse
and/or incorrect operating procedures or
conditions and can be avoided by taking
proper precautions as given below:
1. Maintain a fi rm grip with both hands
on the saw and position your body
and arm to allow you to resist KICKBACK forces. KICKBACK forces can
be controlled by the operator, if proper
precautions are taken.
2. When blade is binding, or when inter-
rupting 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 take corrective
actions to eliminate the cause of blade
binding.
WARNING
OPERATION
3. When restarting a saw in the work-
piece, center the saw blade in the
kerf, or cut, 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.
4. Support large panels to minimize 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.
5. Do not use dull or damaged blades.
Unsharpened or improperly set blades
produce narrow kerf causing excessive
friction, blade binding and KICKBACK.
6. Blade depth and bevel adjusting lock-
ing levers must be tight and secure
before making cut. If blade adjustment
shifts while cutting, it may cause binding
and KICKBACK.
7. Use extra caution when making a
“Pocket Cut” into existing walls or
other blind areas. The protruding blade
may cut objects that can cause KICKBACK.
8. Set the depth of cut for no more than
1/8" to 1/4" greater than the thickness
of the stock. The less blade exposed, the
less chance of binding and KICKBACK.
Before cutting, be sure depth and bevel
adjustments are tight.
9. Be cautious of pitchy, knotty, wet or
warped stock. These are most likely to
create pinching conditions and possible
KICKBACK. Do not rip warped lumber.
Avoid cutting nails.
10.Use a rip fence or edge guide when rip-
ping. Guides improve control and reduce
blade binding.
11.Stay alert. Any distraction can cause
twisting or binding. Repetitive cuts may
lull the user into careless movements.
General Operation
Always clamp the workpiece securely on a
saw horse or bench (Fig. 13). See “APPLICATIONS” for the correct way to support your
work in different situations.
Fig. 13
1. Draw a cutting line. Place the front of the
shoe on the edge of the workpiece without
making blade contact. Hold the Tilt-Lok™
handle with one hand and the front handle
with the other (Fig. 14).
Fig. 14
2. Line up the sight line with your cutting
line. Position your arms and body to resist
KICKBACK. Pull the trigger, allowing the
motor to reach full speed before beginning to cut.
3. While cutting, keep the shoe fl at against
the workpiece and maintain a fi rm grip. Do
not force the saw through the workpiece.
Forcing a saw can cause KICKBACK.
4. If making a partial cut, restarting in midcut or correcting direction, allow the blade
to come to a complete stop. To resume
cutting, center the blade in the kerf, back
the saw away from cutting edge a few
inches, pull the trigger and re-enter the
cut slowly.
5. If the saw binds and stalls, maintain a fi rm
grip and release the trigger immediately.
Hold the saw motionless in the workpiece
until the blade comes to a complete
stop.
6. After fi nishing a cut, be sure the lower
guard closes and the blade comes to
a complete stop before setting the saw
down.
Troubleshooting
If the blade does not follow a straight line:
• Teeth are dull. This is caused by hitting a
hard object such as a nail or stone, dulling
teeth on one side. The blade tends to cut
to the side with the sharpest teeth.
• Shoe is out of line or bent
• Blade is bent
• Rip fence or guide is not being used
If the blade binds, smokes or turns blue
from friction:
• Blade is dull
• Blade is on backwards
• Blade is bent
• Blade is dirty
• Workpiece is not properly supported
• Incorrect blade is being used
APPLICATIONS
Selecting Tilt-Lok™ Handle Positions
WARNING
To reduce the risk of injury, wear
safety goggles or glasses with side
shields. Unplug the tool before
changing accessories or making
adjustments.
APPLICATION SUGGESTED TILT-LOK POSITIONS*
For cuts made at or near
waist level
For shallow cuts made at
or near waist level
For cuts made below the
waist, as in fl ooring ap-
plications
For cuts made overhead,
as in ceiling applications
* These are only suggested positions; the actual optimum cutting position
may vary depending on the actual application and user preference.
Fig. 15
Handle in lower positions (Fig. 16) allows for more leverage
when pushing the saw through the workpiece.
Handle in lower positions allows the user to apply increased
downward force during shallow cuts.
Handle in higher positions (Fig. 17) reduce the amount of
“bending over” by the user. Higher handle positions allow
the user to apply an increased downward force on the saw.
Handle in higher positions reduce the amount of extended
reach by the user for overhead cuts. Higher handle positions allow the user to apply an increased upward force on
the saw.
The Tilt-Lok™ handle is a feature which
allows the user to adjust the angle of the
handle for optimum cutting positions. The
Tilt-Lok™ handle has eight (8) detents
which allow the handle to snap into position
(Fig. 15). See “Adjusting Tilt-Lok™ Handle”
for instuctions on adjusting the handle. Refer to the chart below for suggested handle
positions.
Fig. 17
Fig. 16
12 13
Cutting Large Panels
Large panels and long boards sag or bend
if they are not correctly supported. If you
attempt to cut without leveling and properly
supporting the workpiece, the blade will tend
to bind, causing KICKBACK.
Support large panels. Be sure to set the
depth of the cut so that you only cut through
the workpiece, not through the supports.
Fig. 18
WARNING
To reduce the risk of electric shock,
check work area for hidden pipes
and wires before making pocket
cuts.
Pocket Cutting
Pocket cuts are made in the middle of the
workpiece when it can not be cut from an
edge. We recommend using a Sawzall®
reciprocating saw or jig saw for this type
of cut. However, if you must use a circular
saw to make a pocket cut, USE EXTREME
CAUTION. To maintain control of the saw
during pocket cutting, keep both hands on
the saw (Fig. 20).
Fig. 20
Cutting Masonry and Metal
MILWAUKEE circular saws are not intended
for continuous use in cutting metal or masonry. When cutting these materials, use
the correct blade. MILWAUKEE does not
recommend using bonded abrasive wheels
on circular saws for any application.
WARNING
Dust, chips, and grit can cause
guard to hang up at any time. If saw
is used to cut masonry or metal,
reserve and mark it for that purpose
only and return it to a MILWAUKEE
service facility for cleaning and
testing before using it for wood
cutting.
WARNING
Ripping Wood
Ripping is cutting lengthwise with the grain.
Select the proper blade for your job. Use a
rip fence for rips 4" wide or less. T o install the
rip fence, slide the bar through the rip fence
slot in either side of the shoe. The width of
the cut is the distance from the inside of the
blade to the inside edge of the rip fence.
Adjust the rip fence for the desired width,
and lock the setting by tightening the rip
fence screws.
When ripping widths greater than 4", clamp
or tack 1" lumber to workpiece and use the
inside edge of the shoe as a guide.
Cross-Cutting Wood
Cross-cutting is cutting across the grain.
Select the proper blade for your job. Advance the saw slowly to avoid splintering
the wood.
Fig. 19
1. Beginning at a corner, line up the sight
line with your cutting line. Tilt the saw
forward, fi rmly fi xing the front of the shoe
on the workpiece. The blade should be
just above cutting line, but not touching
it. Raise the lower guard using the lower
guard lever.
2. Pull the trigger, allowing the blade to come
up to full speed. Using the front of the
shoe as a hinge point, gradually lower the
back end of the saw into the workpiece.
3. When the shoe rests fl at against work-
piece, release the lower guard lever. Advance the saw to the far corner. Release
the trigger and allow the blade to come to
a complete stop before removing it from
workpiece. Repeat the above steps for
each side of the opening. Use a Sawzall
reciprocating saw, jig saw or small hand
saw to fi nish the corners if they are not
completely cut through.
Only use accessories with maximum speed rating at least as high
as nameplate RPM of tool.
When cutting masonry, use a diamond blade.
Make successive passes at depths of less
than 1/4" to achieve the desired depth. Cutting at a depth of more than 1/4" will damage
wheel. Unplug the tool and frequently clean
dust from air vents and guards.
WARNING
Do not use tool for cutting metal
near fl ammable material. Sparks
may cause fi re.
When cutting metal, use a metal cutting
blade. Set depth of cut to full depth. Protect
everyone in the area from sparks.
®
14 15
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. 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
WARNING
To 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.
ACCESSORIES
WARNING
To reduce the risk of injury, always
unplug the tool before attaching or
removing accessories. Use only specifi cally recommended accessories.
Others may be hazardous.
FIVE YEAR TOOL LIMITED WARRANTY
Every MILWAUKEE electric power tool (including battery charger) is warranted to the original
purchaser only to be free from defects in material and workmanship. Subject to certain exceptions, MILWAUKEE will repair or replace any part on a electric power tool which, after examina-
tion, is determined by MILWAUKEE to be defective in material or workmanship for a period of
fi ve (5) years* after the date of purchase. Return the electric power tool and a copy of proof
of purchase to a MILWAUKEE factory Service/Sales Support Branch location or MILWAUKEE
Authorized Service Station, freight prepaid and insured, are requested for this warranty to be
effective. This warranty does not apply to damage that MILWAUKEE determines to be from
repairs made or attempted by anyone other than MILWAUKEE authorized personnel, misuse,
alterations, abuse, normal wear and tear, lack of maintenance, or accidents.
* The warranty period for Hoists (lever, hand chain, & electric chain hoists), all Ni-CD battery
packs, Work Lights (cordless fl ashlights), Job Site Radios, and Trade Titan™ Industrial W ork
Carts is one (1) year from the date of purchase. *The warranty period for Li-Ion battery packs
that do not contain V™-technology – 4.0 volts through 18.0 volts - is two (2) years from the
date of purchase.
*There is a separate warranty for V™-technology Li-Ion Battery Packs V™18 volts and above
that accompany V™-technology cordless power tools:
*Every MILWAUKEE V™-technology Li-Ion Battery Pack 18 volts or above is covered by an
initial 1000 Charges/2 Years free replacement warranty. This means that for the earlier of
the fi rst 1000 charges or two (2) years from the date of purchase/fi rst charge, a replacement
battery will be provided to the customer for any defective battery free of charge. Thereafter,
customers will also receive an additional warranty on a pro rata basis up to the earlier of the
fi rst 2000 charges or fi ve (5) Years from the date of purchase/fi rst charge. This means that
every customer gets an additional 1000 charges or three (3) years of pro rata warranty on
the V™-technology Li-Ion Battery Pack 18 volts or above depending upon the amount of use.
During this additional warranty period, the customer pays for only the useable service received
over and above the fi rst 1000 Charges/2 years, based on the date of fi rst charge and number
of charges found on the battery pack via Milwaukee’s V™-technology Service Reader.
Warranty Registration is not necessary to obtain the applicable warranty on a MILWAUKEE
product. However, proof of purchase in the form of a sales receipt or other information deemed
suffi cient by MILWAUKEE, is requested.
ACCEPTANCE OF THE EXCLUSIVE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN IS A CONDITION OF THE CONTRACT FOR THE PURCHASE OF
EVERY MILWAUKEE PRODUCT. IF YOU DO NOT AGREE TO THIS CONDITION, YOU
SHOULD NOT PURCHASE THE PRODUCT. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY INCIDENTAL, SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES,
OR FOR ANY COSTS, ATTORNEY FEES, EXPENSES, LOSSES OR DELAYS ALLEGED
TO BE AS A CONSEQUENCE OF ANY DAMAGE TO, FAILURE OF, OR DEFECT IN ANY
PRODUCT INCLUDING, BUT NOT LIMITED TO, ANY CLAIMS FOR LOSS OF PROFITS.
THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED. WITHOUT LIMITING THE
GENERALITY OF THE FOREGOING, MILWAUKEE DISCLAIMS ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE, AND ALL
OTHER WARRANTIES.
This warranty applies to product sold in the U.S.A., Canada and Mexico only.
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.
16 17
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