OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
Cat. No. / No de cat.
6520-21, 6523-21, 6536-21, 6538-21
ORBITAL SAWZALL
SCIE ALTERNATIVE SAWZALL® ORBITAL
SIERRA DE ALTERNATIVA ORBITAL SAWZALL
WARNING To reduce the risk of injury, user must read and understand operator's manual.
AVERTISSEMENT An de réduire le risque de blessures, l'utilisateur doit lire et bien
comprendre le manuel.
ADVERTENCIA Para reducir el riesgo de lesiones, el usuario debe leer y entender el manual.
®
RECIPROCATING SAWS
®
GENERAL POWER TOOL
WARNING
SAFETY WARNINGS
Read all safety warnings, instruc-
tions provided with this power tool. Failure to follow
all instructions listed below may result in electric shock,
re and/or serious injury. Save all warnings and instructions for future reference. The term "power tool"
in the warnings refers to your mains-operated (corded)
power tool or battery-operated (cordless) power tool.
tions, illustrations and specifica-
WORK AREA SAFETY
• Keep work area clean and well lit. Cluttered or dark
areas invite accidents.
• Do not operate power tools in explosive atmo-
spheres, such as in the presence of ammable
liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
• Keep children and bystanders away while operat-
ing a power tool. Distractions can cause you to lose
control.
ELECTRICAL SAFETY
• Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any adapter
plugs with earthed (grounded) power tools. Un-
modied plugs and matching outlets will reduce risk
of electric shock.
• Avoid body contact with earthed or grounded
surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the
risk of electric shock.
• Do not abuse the cord. Never use the cord for car-
rying, pulling or unplugging the power tool. Keep
cord away from heat, oil, sharp edges or moving
parts. Damaged or entangled cords increase the risk
of electric shock.
• When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of a
cord suitable for outdoor use reduces the risk of electric
shock.
• If operating a power tool in a damp location is
unavoidable, use a ground fault circuit interrupter
(GFCI) protected supply. Use of an GFCI reduces
the risk of electric shock.
PERSONAL SAFETY
• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not
use a power tool while you are tired or under the
inuence of drugs, alcohol or medication. A moment
of inattention while operating power tools may result
in serious personal injury.
• Use personal protective equipment. Always wear
eye protection. Protective equipment such as a dust
mask, non-skid safety shoes, hard hat or hearing
protection used for appropriate conditions will reduce
personal injuries.
• Prevent unintentional starting. Ensure the switch
is in the off-position before connecting to power
source and/or battery pack, picking up or carrying
the tool. Carrying power tools with your nger on the
switch or energizing power tools that have the switch
on invites accidents.
• Remove any adjusting key or wrench before turn-
ing the power tool on. A wrench or a key left attached
to a rotating part of the power tool may result in per-
sonal injury.
• Do not overreach. Keep proper footing and balance
at all times. This enables better control of the power
tool in unexpected situations.
• Dress properly. Do not wear loose clothing or
jewelry. Keep your hair and clothing away from
moving parts. Loose clothes, jewelry or long hair can
be caught in moving parts.
• If devices are provided for the connection of dust
extraction and collection facilities, ensure these
are connected and properly used. Use of dust col-
lection can reduce dust-related hazards.
• Do not let familiarity gained from frequent use
of tools allow you to become complacent and
ignore tool safety principles. A careless action can
cause severe injury within a fraction of a second.
POWER TOOL USE AND CARE
• Do not force the power tool. Use the correct power tool
for your application. The correct power tool will do the
job better and safer at the rate for which it was designed.
• Do not use the power tool if the switch does not turn
it on and off. Any power tool that cannot be controlled
with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source and/
or remove the battery pack, if detachable, from
the power tool before making any adjustments,
changing accessories, or storing power tools. Such
preventive safety measures reduce the risk of starting
the power tool accidentally.
• Store idle power tools out of the reach of children and
do not allow persons unfamiliar with the power tool
or these instructions to operate the power tool. Pow-
er tools are dangerous in the hands of untrained users.
• Maintain power tools and accessories. Check for
misalignment or binding of moving parts, breakage
of parts and any other condition that may affect the
power tool’s operation. If damaged, have the power
tool repaired before use. Many accidents are caused
by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less
likely to bind and are easier to control.
• Use the power tool, accessories and tool bits etc.
in accordance with these instructions, taking into
account the working conditions and the work to
be performed. Use of the power tool for operations
different from those intended could result in a hazard-
ous situation.
• Keep handles and grasping surfaces dry, clean
and free from oil and grease. Slippery handles
and grasping surfaces do not allow for safe handling
and control of the tool in unexpected situations.
SERVICE
• Have your power tool serviced by a qualied repair
person using only identical replacement parts.
This will ensure that the safety of the power tool is
maintained.
SPECIFIC SAFETY RULES FOR
RECIPROCATING SAWS
•Hold power tool by insulated gripping surfaces,
when performing an operation where the cutting
accessory may contact hidden wiring or its own
cord. Cutting accessory contacting a “live” wire may
make exposed metal parts of the power tool “live” and
could give the operator an electric shock.
• Use clamps or another practical way to secure and
support the workpiece to a stable platform. Holding
the workpiece by hand or against your body leaves it
unstable and may lead to loss of control.
2
•
WARNING
WARNING
WARNING
To reduce the risk of injury in applications that produce a consid-
erable amount of dust, use an OSHA compliant
dust extraction solution in accordance with the
solution’s operating instructions.
• Always use common sense and be cautious when
using tools. It is not possible to anticipate every
situation that could result in a dangerous outcome.
Do not use this tool if you do not understand these
operating instructions or you feel the work is beyond
your capability; contact Milwaukee Tool or a trained
professional for additional information or training.
• Maintain labels and nameplates. These carry im-
portant information. If unreadable or missing, contact
a MILWAUKEE service facility for a free replacement.
•
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 specially designed to
lter out microscopic particles.
Some dust created by power sanding,
sawing, grinding, drilling, and other
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 sufx “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 qualied person before using it.
• Protect your extension cords from sharp objects,
excessive heat and damp or wet areas.
Recommended Minimum Wire Gauge
For Extension Cords*
Nameplate Amps
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
* Based on limiting the line voltage drop to ve volts at 150%
of the rated amperes.
Extension Cord Length
25' 50' 75' 100' 150'
18
18
18
18
18
18
18
16
14
12
18
18
16
14
12
10
18
16
14
12
10
--
16
14
12
10
16
14
12
12
--
--
--
--
--
READ AND SAVE FOR ALL
INSTRUCTIONS FOR FUTURE USE
GROUNDING
Improperly connecting the grounding wire can result in the risk of
electric shock. Check with a qualied electrician if
you are in doubt as to whether the outlet is prop-
erly 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 t the outlet, have a proper outlet installed
by a qualied electrician.
Grounded Tools:
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.
Tools marked “Double Insulated” do not require ground-
ing. They have a special double insulation system which
satises 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.
Tools with Three Prong Plugs
Double Insulated Tools:
Tools with Two Prong Plugs
Fig. A
Fig. B
Fig. C
SPECIFICATIONS
Cat. No. ....................................................... 6520-21
Volts ...............................................................120 AC
Amps .................................................................... 13
Length of Stroke ..............................................1-1/8"
Strokes per Minute ...................................... 0 - 2800
Cat. No. ....................................................... 6523-21
Volts ...............................................................120 AC
Amps .................................................................... 13
Length of Stroke ..............................................1-1/4"
Strokes per Minute ...................................... 0 - 3000
Cat. No. ....................................................... 6536-21
Volts ...............................................................120 AC
Amps .................................................................... 13
Length of Stroke ..............................................1-1/4"
Strokes per Minute ...................................... 0 - 3000
Cat. No. ....................................................... 6538-21
Volts ...............................................................120 AC
Amps .................................................................... 15
Length of Stroke ..............................................1-1/4"
Strokes per Minute ...................................... 0 - 2800
3
WARNING
SYMBOLOGY
C
US
WARNING
Double Insulated
Amps
Volts
Alternating Current Only
Straight Cut
Orbital Cut
No Load Strokes per Minute (SPM)
UL Listing for Canada and U.S.
FUNCTIONAL DESCRIPTION
10
9
7
9
8
1. Speed control dial
2. Orbit control switch
3. Quik-Lok® blade clamp
4. Adjustable pivot shoe
5. Shoe release lever
6. Insulating boot (gripping surface)
7. Rotating handle (6523-21)
8. Handle
9. Trigger
10. Handle rotation button (6523-21 only)
1
2
6
Cat. No. 6523-21
2
6
Cat. No. 6520-21
5
5
ASSEMBLY
To reduce the risk of injury, always
moving accessories. Only use accessories spe-
cically recommended for this tool. Others may be
hazardous.
Use MILWAUKEE Sawzall® Blades for best perfor-
mance. 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-em-
bedded wood, scroll cutting, roughing-in, and contours.
Many lengths are also available. Choose a length long
unplug tool before changing or re-
Selecting a Blade
3
4
6538-21
3
4
6536-21
enough to extend beyond the shoe and your work
throughout the stroke. Do not use blades less than
3-1/2" long since they won't extend beyond the
shoe throughout the stroke.
For best performance and longest life, see “Acces-
sories” to select the best blade for the job.
Unplug the tool before changing blades. Be sure the
spindle and blade clamp areas are clean. Metal chips
and sawdust may prevent the Quik-Lok® Blade Clamp
from clamping securely.
1. Depending on the job, the
blade may be inserted with
the teeth facing up or
down. To install a blade,
twist collar in the direction
of the arrow while inserting
the blade into the clamp
until the tang butts against
the collar.
2. Release collar and the spring loaded mechanism
will clamp the blade rmly in place.
3. Twist collar in the opposite direction of the arrow to
ensure that the blade is locked into the clamp.
4. Tug on blade to make sure it is securely locked in place.
5. To remove a blade, twist collar in the direction of the
arrow while pulling on the blade. Be careful when
handling hot blades.
• Periodically clean dust and debris from the Quik-Lok®
Blade Clamp with dry compressed air.
• If the collar resists twisting, twist it back and forth to
shake debris loose.
• Periodically lubricate Quik-Lok® Blade Clamp with dry
lubricant such as graphite.
Unplug the tool before removing blades. 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 the tool on while your
ngers 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. Simply 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.
Quik-Lok® Blade Clamp
Collar
Blade
Quik-Lok® Blade Clamp Maintenance
Removing broken blades from the
Quik-Lok® Blade Clamp
OPERATION
To reduce the risk of injury, always
to comply with ANSI Z87.1.
When working in dusty situations, wear appro-
priate respiratory protection or use an OSHA
compliant dust extraction solution.
The shoe can be adjusted forward or backward to six
positions to take advantage of the unused portion of the
blade or for special jobs requiring low blade clearance.
1. To adjust the shoe, pull the shoe release lever down
1/4 turn and slide the shoe forward or backward to
the desired position.
4
wear proper eye protection marked
Adjustable Pivot Shoe
2. To lock the shoe in
WARNING
WARNING
WARNING
position, push the
shoe release lever
up.
3. After adjusting the
shoe, slowly pull
the trigger to be
sure the blade always extends be-
yond the shoe and your work throughout the stroke.
DO NOT OPERATE SAWZALL WITHOUT SHOE.
STRIKING THE SPINDLE AGAINST WORK MAY
DAMAGE THE RECIPROCATING MECHANISM.
the shoe and work throughout the stroke. Blades
To reduce the risk of injury, be sure
the blade always extends beyond
1/4 Turn
may shatter if they impact the work or shoe.
Stroke
All models are equipped with a unique patented
gearing system that provides efcient power transmission and extended life in the most difcult 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.
with the handle not locked into position.
The 6523-21 Sawzall® handle can rotate continu-
ously in either direction, allowing the user to achieve
optimal cutting positions and comfort. The handle can
be locked into one of eight (8) detent positions, one at
every 45° angle.
To rotate the handle:
1. Unplug the tool.
2. Press in the handle rotation
3. Rotate the handle to the
4. Release the handle rotation
NOTE: Make sure the handle does not rotate before
Sawzall®. Return the Sawzall® to a MILWAUKEE
service facility immediately for repair.
To reduce the risk of personal injury, always hold
tool securely.
1. To start the tool, grasp the handle rmly and pull the
Impact Protection System
Do not operate the Sawzall® with the
handle rotation button pressed in or
Rotating the Handle
(Cat. No. 6523-21)
2
1
button.
desired position.
button. This will lock the
handle rmly into position.
using the tool.
If the handle can not be locked into
position, do not operate the
Starting, Stopping and Controlling Speed
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.
These Sawzalls® are equipped with an orbit control
switch. The tool may be operated with straight reciprocating (non orbital) or orbital action. Straight reciprocating action should be used when a smooth cut is needed.
Orbital action is recommended for fast, aggressive
cutting. The optimal orbital action should be determined
by the user for their specic cutting requirements.
1. For straight reciprocating action, move the orbit
control switch to the straight cut symbol .
2. For orbital action, move the orbit control switch towards the orbital cut symbol .
The amount of orbital action may be adjusted by mov-
ing the orbital control switch to any position between
the two symbols. For larger orbital action, move the
orbit control switch closer to the orbital cut symbol .
For smaller orbital action, move the orbit control switch
closer to the straight cut symbol .
Orbital action may be adjusted when the tool is running.
NOTE: Orbital action will not operate if the blade is
installed upside down.
The speed control dial controls
the maximum strokes per
minute. The speed will remain variable to the chosen
dial setting by use of the
trigger switch. Refer to the
chart for recommended dial
settings.
*These are only suggested set-
tings; the actual optimal setting
may vary depending on line
voltage, blade selected and
user preference.
These 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.
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 rmly and pull
the trigger. Then guide the tool along your cutting line.
Always hold the shoe at against the workpiece to avoid
excessive vibration.
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.
5
Orbit Control Switch
Selecting the Speed Range
MATERIAL
Mild Steel
Wood
Nail-Embedded
Wood
Stainless Steel
Drywall
Fiberglass
Plastics
Cast Iron
Non-Ferrous
Metals
Trigger Speed Control Switch
General Cutting
Cutting Metals
DIAL
SETTING*
2-3
5
5
1-3
4-5
1-3
1-3
2-3
2-3
WARNING
To reduce the risk of explosion,
WARNING
WARNING
WARNING
always check the work area for hidden gas pipes,
electrical wires or water pipes when making blind
or plunge cuts.
Your MILWAUKEE Sawzall® is ideal for plunge cutting
directly into surfaces that can not be cut from an edge,
such as walls or oors. Orbital action is recommended
for plunge cutting. 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.
NOTE: Orbital action will not operate if the blade is
installed upside down.
Do not plunge cut into metal surfaces (see “Cutting
Metals”).
1. Insert the blade into the tool.
If you inserted the blade with the teeth facing down-
ward, 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 rmly 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.
electric shock and property damage,
Plunge Cutting
(Cat. No. 6523-21)
A
B
(Cat. No. 6520-21, 6536-21, 6538-21)
MAINTENANCE
To reduce the risk of injury, always
any maintenance. Never disassemble the tool.
Contact a MILWAUKEE service facility for ALL
repairs.
Keep your tool in good repair by adopting a regular
maintenance program. Inspect your tool for issues
such as undue noise, misalignment or binding of
moving parts, breakage of parts, or any other condi-
tion that may affect the tool operation. Return the tool
to a MILWAUKEE service facility for repair. After six
months to one year, depending on use, return the
tool to a MILWAUKEE service facility for inspection.
never immerse your tool in liquid or allow a liquid
to ow inside it.
Clean dust and debris from vents. Keep handles
clean, dry and free of oil or grease. Use only mild
soap and a damp cloth to clean, 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 deter-
gents containing ammonia. Never use ammable or
combustible solvents around tools.
For repairs, return the tool to the nearest service
center.
unplug the tool before performing
Maintaining Tools
To reduce the risk of personal injury, electric shock and damage,
Cleaning
Repairs
ACCESSORIES
Use only recommended accesso-
For a complete listing of accessories, go online to
www.milwaukeetool.com or contact a distributor.
ries. Others may be hazardous.
6
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