Milwaukee 6394, 6390 User Manual

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

Catalog No.

No de Cat.

Catálogo No.

6390
6394

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

TIL T-LOK™ (INCLINABLE-FIJABLE)

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 SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below, may result in
electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREA

1. Keep your work area clean and well lit. Cluttered benches and
dark areas invite accidents.

2. Do not operate power tools in explosive atmospheres, such
as in the presence of flammable liquids, gases, or dust. Power
tools create sparks which may ignite the dust or fumes.

3. Keep bystanders, children, and visitors away while operat-
ing a power tool. Distractions can cause you to lose control.
Protect others in the work area from debris such as chips and sparks.
Provide barriers or shields as needed.

ELECTRICAL SAFETY

4. Grounded tools must be plugged into an outlet properly
installed and grounded in accordance with all codes and
ordinances. Never remove the grounding prong or modify
the plug in any way. Do not use any adaptor plugs. Check with
a qualified electrician if you are in doubt as to whether the
outlet is properly grounded. If the tools should electrically mal-

function or break down, grounding provides a low resistance path to
carry electricity away from the user.

5. Double Insulated tools are equipped with a polarized plug

(one blade is wider than the other). This plug will fit in a
polarized outlet only one way. If the plug does not fit fully in
the outlet, reverse the plug. If it still does not fit, contact a
qualified electrician to install a polarized outlet. Do not change
the plug in any way. Double insulation eliminates the need for the

three wire grounded power cord and grounded power supply
system.

6. Avoid body contact with grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk
of electric shock if your body is grounded.

7. Don't expose power tools to rain or wet conditions. Water
entering a power tool will increase the risk of electric shock.

8. Do not abuse the cord. Never use the cord to carry the tools

or pull the plug from an outlet. Keep cord away from heat, oil,
sharp edges or moving parts. Replace damaged cords
immediately. Damaged cords increase the risk of electric shock.

9. When operating a power tool outside, use an outdoor
extension cord marked “W-A” or “W”. These cords are rated for

outdoor use and reduce the risk of electric shock.

PERSONAL SAFETY

10. Stay alert, watch what you are doing, and use common sense

when operating a power tool. Do not use tool while tired or
under the influence of drugs, alcohol, or medication. A

moment of inattention while operating power tools may result in seri­ous personal injury.

11. Dress properly. Do not wear loose clothing or jewelry.

Contain long hair. Keep your hair, clothing, and gloves away
from moving parts. Loose clothes, jewelry, or long hair can be

caught in moving parts.

12. Avoid accidental starting. Be sure switch is off before

plugging in. Carrying tools with your finger on the switch or
plugging in tools with the switch on invites accidents.

page 2

13. Remove adjusting keys or wrenches before turning the tool
on. A wrench or a key that is left attached to a rotating part of the tool
may result in personal injury.

14. Do not overreach. Keep proper footing and balance at all times.
Proper footing and balance enables better control of the tool in unex­pected situations.

15. Use safety equipment. Always wear eye protection. Dust mask,
non-skid safety shoes, hard hat, or hearing protection must be used
for appropriate conditions.

TOOL USE AND CARE

16. Use clamps or other practical way to secure and support the
workpiece to a stable platform. Holding the work by hand or

against your body is unstable and may lead to loss of control.

17. Do not force tool. Use the correct tool for your application.
The correct tool will do the job better and safer at the rate for which
it is designed.

18. Do not use tool if switch does not turn it on or off. Any tool that
cannot be controlled with the switch is dangerous and must be re­paired.

19. Disconnect the plug from the power source before making

any adjustments, changing accessories, or storing the tool.

Such preventive safety measures reduce the risk of starting the tool
accidentally.

20. Store idle tools out of reach of children and other untrained
persons. Tools are dangerous in the hands of untrained users.

21. Maintain tools with care. Keep cutting tools sharp and clean.
Properly maintained tools with sharp cutting edge are less likely to
bind and are easier to control. Do not use a damaged tool. Tag
damaged tools “Do not use” until repaired.

22. Check for misalignment or binding of moving parts, break-

age of parts, and any other condition that may affect the tool’s
operation. If damaged, have the tool serviced before using.

Many accidents are caused by poorly maintained tools.

23. Use only accessories that are recommended by the manu-
facturer for your model. Accessories that may be suitable for one
tool, may become hazardous when used on another tool.

SERVICE

24. Tool service must be performed only by qualified repair
personnel. Service or maintenance performed by unqualified per-

sonnel could result in a risk of injury.

25. When servicing a tool, use only identical replacement parts.

Follow instructions in the Maintenance section of this manual.

Use of unauthorized parts or failure to follow Maintenance Instruc­tions may create a risk of electric shock or injury.

SPECIFIC SAFETY RULES — CIRCULAR SAWS

1. Maintain labels and nameplates. These carry important information. If unreadable or missing, contact a
replacement.

2. DANGER! Keep hands away from cutting area and 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.

Keep your body positioned to either side of the saw blade, but not in line with the saw blade. KICKBACK could cause the saw to jump
backwards (See “Causes and Operator Prevention of KICKBACK” below).

Do not reach underneath the work. The guard can not protect you from the blade below the work.

3. Check lower guard for proper closing before each use. Do not operate 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 lower guard lever and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.

4. Check the operation and condition 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 buildup of debris.

5. Lower guard should be retracted manually only for special cuts such as “Pocket Cuts” and “Compound Cuts”. Raise lower guard
by lower guard lever. As soon as blade enters the material, lower guard must be released. For all other sawing, the lower guard should
operate automatically.

6. Always observe that the lower guard is covering the blade before placing saw down on bench or floor. 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.

7. NEVER hold piece being cut in your hands or across your leg. It is important to support the work properly to minimize body exposure, blade
binding, or loss of control.

8. Hold 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 tool “live” and shock the operator.

9. When ripping always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance for blade binding.

10. Always use blades with correct size and shape (diamond vs. round) arbor holes. Blades that do not match the mounting hardware of the
saw will run eccentrically, causing loss of control.

11. Never use damaged or incorrect blade washers or bolts. The blade washers and bolts were specially designed for your saw, for optimum
performance and safety of operation.

12. WARNING! Use of this tool can generate dust containing chemicals known to cause cancer, birth defects or other reproductive harm. Use appropriate
respiratory protection.

13. 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 operator.

MILWAUKEE

service facility for a free

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:

14. Maintain a firm 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.

15. 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 take corrective actions to eliminate the cause of blade binding.

16. When restarting a saw in the workpiece, center 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.

17. 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.

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

19. 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.

20. 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.

page 3

GROUNDING

WARNING!

Improperly connecting the grounding wire can
result in the risk of electric shock. Check with a
qualified 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
service facility before use. If the plug will not fit
the outlet, have a proper outlet installed by a
qualified 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.

Figure B illustrates a temporary adapter available for connecting grounded
plugs (Figure A) to two prong outlets. The green rigid ear or lug extend­ing from the adapter must be connected to a permanent ground such as
a properly grounded outlet box or receptacle. Simply remove the center
screw from the outlet, insert the adapter and reattach the screw through
the green grounding ear to the outlet. If in doubt of proper grounding, call
a qualified electrician. A temporary adapter should only be used until a
properly grounded outlet can be installed by a qualified electrician.

The Canadian Electrical Code prohibits the use of temporary adapters.

cover of
grounded
outlet box

temporary

adapter

MILWAUKEE

Fig. A

screw

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 C and D.

Fig. C

Fig. D

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 suffix “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 qualified person before using it.

• Protect your extension cords from sharp objects, excessive heat and
damp or wet areas.

Recommended Minimum Wire Gauge

Nameplate

Amperes

8.1 - 12

12.1 - 15

15.1 - 20

for Extension Cords*

25'

0 - 5

5.1 - 8

16
16
14
12
10

Extension Cord Length

100'

14
12
10
10

150'

12
10

--

--

--

--

50'

16
16
14
12
10

75'

16
14
12
10
10

200'

12

--

--

--

--

page 4

green

grounding ear

Fig. B

* Based on limiting the line voltage drop to five
volts at 150% of the rated amperes.

READ AND SAVE ALL INSTRUCTIONS FOR

FUTURE USE.

Symbology

Specifications

Double Insulated

Canadian Standards Association

Underwriters Laboratories, Inc.

Volts Alternating Current/
Direct Current

Volts Alternating Current

Amps

No Load Revolutions per Minute
(RPM)

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. Cord release button
(Cat. no. 6394 only)

11. Depth adjusting lever

12. Front handle

13. Sight line

14. Rip fence slot

15. Lower guard

16. Blade flange

17. Blade bolt

18. Blade

19. Shoe

20. Lower guard lever

21. Upper guard

22. Positive-Lok
(Cat no. 6394 only)

®

cord

Catalog

No.

6390
6394

Volts

120 AC/DC

120 AC Only

No Load

RPM

5800
5800

Blade

Size

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

Arbor

5/8"
5/8"

Depth of Cut

At 90°

0 to 2-15/32"
0 to 2-15/32"

Depth of Cut

at 45°

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

FUNCTIONAL DESCRIPTION

5

4

6

2

1

7

3

Cat. No. 6394

8

9

10

11

12

22

21

20

19

18

17

16

13

14

15

page 5

TOOL ASSEMBLY

WARNING!

To reduce the risk of injury, always unplug
tool before attaching or removing accessories
or making adjustments. Use only specifically
recommended accessories. Others may be
hazardous.

Removing and Replacing Positive-Lok® Cords (Fig. 1)
Cat. No. 6394

MILWAUKEE’S

placement or substitution. The Positive-Lok
firmly to the tool.

1. T o remove the Positive-Lok
direction shown and turn the cord nut 1/4 turn to the left. Pull the
cord out.

2. To replace the Positive-Lok
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.

exclusive Positive-Lok® Cords provide instant field re-

®

feature secures the cord

Fig. 1

2

1

Cord release button

®

Cord, push the cord release button in the

®

Cord, align the connector keyways and

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). Re­lease the lower guard lever.

Fig. 3

5. Place the blade flange on the spindle and hand tighten the bolt.

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

Adjusting Depth (Fig. 4 & 5)

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. 4).

Fig. 4

Selecting Blade

Always use sharp blades. Dull blades tend to overload the tool and
increase the chance of KICKBACK (see page 8). Only use blades with a
maximum safe operating speed greater than the no load RPM marked on
the tool's nameplate. Read the blade manufacturer's instructions before
use.

Installing and Removing Blades (Fig. 2 & 3)

1. Unplug tool before installing or removing blades.

2. Place the saw on a flat surface with the blade facing upwards. To
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 counterclockwise (Fig. 2). Remove the bolt and
blade flange.

Fig. 2

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. 5).

Fig. 5

1/4"

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

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.

page 6

Adjusting Bevel Angle (Fig. 6 & 7)

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. 6).

Fig. 6

4. To adjust the handle position, hold the front handle and rotate the Tilt­Lok™ 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.

Fig. 9

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. 7).

Fig. 7

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

Adjusting Tilt-Lok™ Handle Angle (Fig. 8 & 9)

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.

3. Loosen the handle release lever by lifting it up and away from the Tilt­Lok™ handle (Fig. 8).

Fig. 8

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.

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
vice facility for repair immediately.

Adjusting the Blade to Shoe (Fig. 10 & 11)

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. 10).

Fig. 10

MILWAUKEE

ser-

page 7

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. 11).

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

Fig.11

Bevel adjustment screw

WARNING!

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 mis-

aligned 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 firm 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 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 take corrective actions to eliminate the cause of

blade binding.

3. When restarting a saw in the workpiece, 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 locking 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 ripping. 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 (Fig. 12 & 13)

Always clamp the workpiece securely on a saw horse or bench
(Fig. 12). See “APPLICATIONS” for the correct way to support your work
in different situations.

Fig. 12

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. 13).

Fig. 13

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 flat against the workpiece and maintain a
firm grip. Do not force the saw through the workpiece. Forcing a saw
can cause KICKBACK.

page 8

4. If making a partial cut, restarting in mid-cut 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 firm grip and release the trigger
immediately. Hold the saw motionless in the workpiece until the blade
comes to a complete stop.

6. After finishing a cut, be sure the lower guard closes and the blade
comes to a complete stop before setting the saw down.

Electric Brake (Cat. No. 6394)

Select models feature an electronic brake. The brake engages when the
trigger is released, causing the blade to stop and allowing you to pro­ceed with your work. Generally, the saw blade stops within two sec­onds. However, there may be a delay between the time you release the
trigger and when the brake engages. Occasionally the brake may miss
completely. If the brake misses frequently, the saw needs servicing by
an authorized
for the guard, and you must always wait for the blade to stop completely
before removing the saw from the workpiece. The correct brush grade
must be used for proper operation of the brake. Use only the correct

MILWAUKEE

MILWAUKEE

replacement brushes when servicing the tool.

service facility. The brake is not a substitute

APPLICATIONS

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

WARNING!

To reduce the risk of injury, wear safety goggles
or glasses with side shields. Unplug the tool
before changing accessories or making
adjustments.

Selecting Tilt-Lok™ Handle Positions (Fig. 14, 15 & 16)

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. 14). See “Adjusting Tilt-Lok™ Handle” for instuctions on adjusting
the handle. Refer to the chart below for suggested handle positions.

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 flooring appli­cations

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.

Handle in lower positions (Fig. 15)
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. 16) 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.

Fig. 14

Fig. 15

Fig. 16

page 9

Cutting Large Panels (Fig. 17)

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. 17

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. To 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 (Fig. 18)

Cross-cutting is cutting across the grain. Select the proper blade for
your job. Advance the saw slowly to avoid splintering the wood.

Fig. 18

Pocket Cutting (Fig. 19)

Pocket cuts are made in the middle of the workpiece when it can not be
cut from an edge. We recommend using a Sawzall
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. 19).

Fig. 19

1. Beginning at a corner, line up the sight line with your cutting line. Tilt
the saw forward, firmly fixing 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 flat against workpiece, 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
corners if they are not completely cut through.

Cutting Masonry and Metal

Although
tended for cutting wood, they may also be used with abrasive cutting
wheels or dry cutting diamond blades for cutting metal or masonry.

®

reciprocating saw, jig saw or small hand saw to finish the

MILWAUKEE

Circular Saws are primarily designed and in-

®

reciprocating saw or

WARNING!

To reduce the risk of electric shock, check work
area for hidden pipes and wires before making
pocket cuts.

WARNING!

Only use abrasive cutting wheels with a maxi­mum safe operating speed greater than the RPM
marked on the tool's nameplate.

When cutting masonry, use a dry cutting 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 the wheel. Frequently
clean dust from air vents and guards. Always wear a dust mask.

When cutting light gauge sheet metal, use an aluminum oxide abrasive
cutting wheel or an appropriate blade designed specifically for cutting
metal. Set the depth of cut for 1/8" to 1/4" greater than the thickness of
the material you are cutting. Protect everyone in the area from sparks.

WARNING!

Dust, chips and grit can cause the guard to hang
up at any time. If the saw is used with an abrasive
cutting wheel or dry cutting diamond blade, re­serve and mark it for that use only. Before using
it for wood cutting, return it to a
service facility for cleaning and testing.

MILWAUKEE

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