Milwaukee 6519, 6509 User Manual

Catalog No.

No de Cat.

Catálogo No.

6509 Series
Séries 6509

Serie 6509

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

Catalog No.

No de Cat.

Catálogo No.

6519 Series
Séries 6519

Serie 6519

SAWZALL
PASSE-PARTOUT SAWZALL
SIERRAS SABLE SAWZALL

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  FOR ALL POWER TOOLS

WARNING!

Failure to follow all instructions listed below may result in electric shock, fire 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-opearted (cordless) power tool.

SAVE THESE INSTRUCTIONS

READ ALL INSTRUCTIONS

WORK AREA SAFETY

1. Keep work area clean and well lit. Cluttered or 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 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. Unmodified 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.

PERSONAL SAFETY

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 bat-

tery 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 tool acci­dentally.

19. Store idle power tools out of the reach of children and do

not allow persons unfamiliar with the power tools or these
instructions to operate power tools. 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 accor-

dance 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.

POWER TOOL USE AND CARE

SERVICE

9. 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 influence 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 tools with your finger 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 footing 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 connection of dust extrac-

tion and collection facilities, ensure these are connected
and properly used. Use of these devices can reduce dust-re-

lated hazards.

page 2

23. Have your power tool serviced by a qualified repair person
using only identical replacement parts. This will ensure that

the safety of the power tool is maintained.

SPECIFIC SAFETY RULES

1. 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.

2. Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against
your body leaves it unstable and may lead to loss of control.

3. Keep hands away from all cutting edges and moving parts.

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

5. WARNING! Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause
cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

 lead from lead-based paint
 crystalline silica from bricks and cement and other masonry products, and
 arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, 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 specifically designed to filter out microscopic
particles.

Double Insulated

Canadian Standards
Association

Underwriters
Laboratories, Inc.

Symbology

Volts Alternating Current

No Load Strokes
per Minute (RPM)

Amperes

Cat.

No.

6509 Series
6519 Series

Specifications

Volts

AC

Amps

120

10

120

10

RPM

0 - 2 800
0 - 2 800

Length of

Stroke

3/4"

1-1/8"

FUNCTIONAL DESCRIPTION

2

1

4

3

5

7

3

8

6509 Series

2

1. Handle

2. Trigger

3. Quik-Lok® blade clamp

4. Blade

5. Adjustable pivot shoe

6. Shoe release lever

7. Pivot shoe access holes

10

8. Insulating boot

9. Quik-Lok® cord

10. Fixed cord

1

4

5

6

8

6519 Series

9

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
MILWAUKEE 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.

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. A

Fig. B

Fig. C

EXTENSION CORDS

Grounded tools require a three wire extension cord. Double insulated
tools can use either a two or three wire extension cord. As the distance
from the supply outlet increases, you must use a heavier gauge exten­sion cord. Using extension cords with inadequately sized wire causes a
serious drop in voltage, resulting in loss of power and possible tool
damage. Refer to the table shown to determine the required minimum
wire size.

The smaller the gauge number of the wire, the greater the capacity of the
cord. For example, a 14 gauge cord can carry a higher current than a 16
gauge cord. When using more than one extension cord to make up the
total length, be sure each cord contains at least the minimum wire size
required. If you are using one extension cord for more than one tool, add
the nameplate amperes and use the sum to determine the required mini­mum wire size.

Guidelines for Using Extension Cords

 If you are using an extension cord outdoors, be sure it is marked

with the 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

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

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

--

--

--

--

READ AND SAVE ALL INSTRUCTIONS

FOR FUTURE USE.

page 4

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 Quik-Lok® Cords (Fig. 1)
(Select Models)

MILWAUKEE's exclusive Quik-Lok® Cords provide instant field replace-
ment or substitution.

Fig. 1

1. To remove the Quik-Lok® Cord, turn the cord nut 1/4 turn to the left
and pull it out.

2. To replace the Quik-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.

Selecting a Blade

Use MILWAUKEE Sawzall® Blades for best performance. When select­ing a blade, choose the right type and length.

Many types of blades are available for a variety of applications: cutting
metal, wood, nail-embedded wood, scroll cutting, roughing-in, and
contours.

Many lengths are also available. Choose a length long enough to extend
beyond the shoe and your work throughout the stroke. For best perfor­mance and longest life, see "Accessories" to select the best blade for
the job.

Quik-Lok® Blade Clamp (Fig. 2) (Select Models)

Fig. 2

Collar

Blade

1. Unplug the tool.

2. Be sure the spindle and blade clamp areas are clean. Metal chips
and sawdust may prevent the Quik-Lok® Blade Clamp from clamping
securely (see "Maintenance").

3. To install a blade, twist the collar in the direction of the arrow while
inserting the blade into the clamp until the tang butts against the
collar.

Depending on the job, the blade may be inserted with the teeth
facing upward or downward.

4. Release the collar and the spring loaded mechanism will clamp the
blade firmly in place.

5. Twist the collar in the opposite direction of the arrow to ensure that
the blade is locked into the clamp.

6. Tug on blade to make sure it is securely locked in place.

7. To remove a blade, twist the collar in the direction of the arrow
while pulling on the blade. Be careful when handling hot blades.

®

Removing Broken Blades from the Quik-Lok

1. Unplug the tool.

2. Broken blades can be removed by the following methods.
 Point the tool downward, twist the collar, and shake the tool up and

down (DO NOT turn on the tool while your fingers are holding the
blade clamp open). The shank of the broken blade should drop out of
the clamp.

 If shaking the tool doesn't work...

In most cases, a corner of the broken blade will extend beyond the
blade clamp. Twist the collar and pull the broken blade out of the
clamp by this corner.

 If the broken stub doesn't extend far enough to be grabbed by its

corner, use a thin blade with small teeth (such as a metal cutting
blade) to hook the blade that is jammed in the clamp while twisting
the collar and pull it out.

Installing and Removing Blades
Blade Clamp (Available as accessory Cat. No. 49-22-5016 only)
(Fig. 3)

Fig. 3

1. Unplug the tool before changing blades.

2. Be sure the spindle and blade clamp area are clean. Metal chips and
sawdust may prevent the blade clamp screw from clamping se­curely.

3. To install a blade, loosen the blade clamp screw, turning it counter­clockwise. Insert the blade until the tang butts against the spindle.

NOTE: The blade must be inserted all the way into the spindle so that
the tang on the blade seats firmly in the blade clamp.

Depending on the job, the blade may be inserted with the teeth
facing upward or downward.

4. Insert the hex key into the blade clamp screw, turning it clockwise.
Tighten securely.

5. To remove a blade, insert hex key into the blade clamp screw and
turn it counterclockwise 1 full turn. Then slide the blade out of the
spindle. Be careful when handling hot blades.

Hex key

Blade clamp screw

Blade Clamp

page 5

Adjustable Pivot Shoe

The shoe can be adjusted forward or backward to take advantage of the
unused portion of the blade or for special jobs requiring low blade
clearance.

WARNING!

WARNING!

To reduce the risk of injury, be sure the blade always
extends beyond the shoe and work throughout the stroke.
Blades may shatter if they impact the work or shoe (Fig. 6).

Do not operate Sawzall without a shoe. Striking the spindle
against the work may damage the reciprocating mechanism.

6509 Series (Fig. 4)

Fig. 4

Insulating
boot

Adjusting
screws

1. To adjust the shoe, place hex wrench through access holes in
insulating boot and loosen four (4) screws.

2. Move shoe to desired position

3. Tighten screws.

4. After adjusting the shoe, slowly pull the trigger to be sure the blade
always extends beyond the shoe and your work throughout the
stroke.

6519 Series (Fig. 5)

Access holes

Hex wrench

Fig. 6

Stroke

Fig. 5

Shoe release lever

1. To adjust the shoe, pull out the shoe release lever 1/4 turn.

2. Slide the shoe forward or backward to the desired position.

3. To lock the shoe in position, push in the shoe release lever.

4. After adjusting the shoe, slowly pull the trigger to be sure the blade
always extends beyond the shoe and your work throughout the
stroke.

page 6

OPERATION

WARNING!

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

Impact Protection System (Select Models)

Select models are equipped with a unique patented gearing system that
provides efficient power transmission and extended life in the most
difficult cutting applications. This durable system will absorb impacts,
blade lock ups, and motor stalls. These models can be used for extreme
cutting applications such as large diameter pipe, thick metal, pallets, and
heavy demolition and renovation work as well as for general purpose
cutting.

Starting, Stopping and Controlling Speed

1. To start the tool, grasp the handle firmly and pull the trigger.

2. To stop the tool, release the trigger. Allow the tool to come to a
complete stop before removing the blade from a partial cut or laying
the tool down.

Trigger Speed Control Switch

MILWAUKEE Sawzalls® are equipped with a trigger speed control switch.
It may be operated at any speed from zero strokes per minute to full
speed. Always start tool before blade contacts the workpiece. To vary
the speed, simply increase or decrease the pressure on the trigger. The
further the trigger is pulled, the greater the speed. To stop the tool,
release the trigger and allow the tool to stop completely before removing
from a partial cut or before laying the tool down.

Plunge Cutting (Fig. 7)

Your MILWAUKEE Sawzall® is ideal for plunge cutting directly into sur­faces that can not be cut from an edge, such as walls or floors. Plunge
cutting may be done two ways depending on how the blade is inserted.
Column A shows how to plunge cut with the teeth of the blade facing
down. Column B shows how to plunge cut with the teeth of the blade
facing up. Do not plunge cut into metal surfaces (see Cutting Metals).

Fig. 7

General Cutting

For straight or contour cutting from an edge, line the blade up with your
cutting line. Before the blade contacts the workpiece, grasp the handle
firmly and pull the trigger. Then guide the tool along your cutting line.
Always hold the shoe flat against the workpiece to avoid excessive
vibration.

Cutting Metals

Begin cutting at a slow speed, gradually increasing speed as you cut.
When cutting into metals or hard materials that can not be cut from an
edge, drill a starting hole larger than the widest part of the blade. Extend
blade life by using a solid blade cutting lubricant such as MILWAUKEE
Band Saw Blade Lubricant Cat. No. 49-08-4206.

WARNING!

To reduce the risk of explosion, electric shock and property
damage, always check the work area for hidden gas pipes,
electrical wires or water pipes when making blind or plunge
cuts.

1. Insert the blade into the tool.
If you inserted the blade with the teeth facing downward, hold the

tool as shown in Column A, resting the edge of the shoe on the
workpiece.

If you inserted the blade with the teeth facing upward, hold the tool
as shown in Column B, resting the edge of the shoe on the work­piece as shown.

2. With the blade just above the workpiece, pull the trigger. Using the
edge of the shoe as a pivot, lower the blade into the workpiece as
shown.

3. As the blade starts cutting, raise the handle of the tool slowly until
the shoe rests firmly on the workpiece. Then guide the tool along
your cutting line to acquire the desired cut.

NOTE: To make plunge cutting easier, use a heavy gauge blade and
install the blade with the teeth facing upward as shown in Column B.

page 7

MAINTENANCE

ACCESSORIES

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

Quik-Lok® Blade Clamp Maintenance

 Periodically clean dust and debris from the Quik-Lok® Blade Clamp

with dry compressed air.
 If the collar resists twisting, twist the collar back and forth to shake

debris loose.
 Periodically lubricate Quik-Lok® Blade Clamp with a dry lubricant

such as graphite.

WARNING!

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

For a complete listing of accessories refer to your MILWAUKEE Electric
Tool catalog or go on-line to www.milwaukeetool.com. To obtain a
catalog, contact your local distributor or a service center.

8' Quik-Lok® Cord

Cat. No. 48-76-4008

25' Quik-Lok® Cord

Cat. No. 48-76-4025

1/2" Blade Clamp Kit

Cat. No. 49-22-5016

20 mm Blade Clamp Kit

Cat. No. 49-22-5004

Impact Resistant Carrying Case

Cat. No. 50-55-6506

Steel Carrying Case

Cat. No. 48-55-1535

Easy-Cut Sawzall Blade Lubricant

Cat. No. 49-08-4206

For MILWAUKEE Sawzall
of the manual.

®

Blades, refer to the blade listing at the end

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 flow
inside the tool.

Cleaning

Clean dust and debris from vents. Keep the tool handles clean, dry and
free of oil or grease. Use only mild soap and a damp cloth to clean your
tool since certain cleaning agents and solvents are harmful to plastics
and other insulated parts. Some of these include: gasoline, turpentine,
lacquer thinner, paint thinner, chlorinated cleaning solvents, ammonia
and household detergents containing ammonia. Never use flammable or
combustible solvents around tools.

Repairs

If your tool is damaged, return the entire tool to the nearest service
center.

page 8

FIVE YEAR TOOL LIMITED WARRANTY

Every MILWAUKEE tool is tested before leaving the factory and is war­ranted to be free from defects in material and workmanship. MILWAUKEE
will repair or replace (at MILWAUKEEs discretion), without charge, any
tool (including battery chargers) which examination proves to be defec­tive in material or workmanship from five (5) years after the date of
purchase. Return the tool and a copy of the purchase receipt or other
proof of purchase to a MILWAUKEE Factory Service/Sales Support
Branch location or MILWAUKEE Authorized Service Station, freight pre­paid and insured. This warranty does not cover damage from repairs
made or attempted by other than MILWAUKEE authorized personnel,
abuse, normal wear and tear, lack of maintenance, or accidents.

Battery Packs, Flashlights, and Radios are warranted for one (1) year
from the date of purchase.

THE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN ARE
EXCLUSIVE. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY
INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES, INCLUDING
LOSS OF PROFITS.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRAN­TIES, OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED FOR
MERCHANTABLILITY OR FITNESS FOR PARTICULAR USE OR PURPOSE.

This warranty gives you specific legal rights. You may also have other
rights that vary from state to state and province to province. In those
states that do not allow the exclusion of implied warranties or limitation
of incidental or consequential damages, the above limitations or exclu­sions may not apply to you. This warranty applies to the United States,
Canada, and Mexico only.