Milwaukee 6521 User Manual

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

Catalog No.

6521 Series

No de Cat.

Séries 6521

Catálogo No.

Serie 6521

HEAVY-DUTY ORBITAL SUPER SAWZALL
ROBUSTE PASSE-PARTOUT ORBITAL SUPER SAWZALL

®

®

SUPER SAWZALL®ORBITAL PARA TAREAS PESADAS

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.

page 2

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.

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.

page 3

SPECIFIC SAFETY RULES — SAWZALLS

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

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

4. 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 specially designed to filter out microscopic
particles.

®

Symbology

Double Insulated

Volts Alternating Current

Amps

No Load Strokes Per Minute

Underwriters Laboratories, Inc.

Canadian Standards Association

Straight Cut

Orbital Cut

Catalog

Series

FUNCTIONAL DESCRIPTION

1

No.

6521

Volts

AC Only

120

2

Specifications

Length of

Amps

Stroke

11

1-1/4"

Strokes

per Minute

0-3200

3

1. Nameplate

2. Handle

3. Trigger

4. Quik-Lok® Cord (select models)

5. Speed control dial

6. Insulating boot

7. Shoe release lever

8. Adjustable pivot shoe

9. Blade

10. Blade clamp

11. Orbit control switch

page 4

11

10

4

5

6

7

8

9

GROUNDING EXTENSION CORDS

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.

Fig. A

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

--

--

--

--

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

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

READ AND SA VE ALL INSTRUCTIONS

FOR FUTURE USE.

Fig. C

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 the Quik-Lok® Cord (Fig. 1)

Fig. 1

1. To remove the Quik-Lok
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. 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 “Accessories” to select the
best blade for the job.

®

Cord, turn the cord nut 1/4 turn to the left

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.

Removing broken blades from the Quik-Lok® Blade Clamp

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 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. 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 (Fig. 2)

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.

Fig. 2

Collar

Blade

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
firmly 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.

page 6

OPERATION

WARNING!

To reduce the risk of injury, wear safety goggles
or glasses with side shields.

Adjustable Pivot Shoe (Fig. 3)

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.

Fig. 3

1/4 Turn

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.

2. To lock the shoe in position, push the shoe release lever up.

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

DO NOT OPERATE SAWZALL WITHOUT SHOE. STRIKING THE
SPINDLE AGAINST WORK MAY DAMAGE THE RECIPROCATING
MECHANISM.

Impact Protection System

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.

Orbit Control Switch (Fig. 5)

The Orbital Super Sawzall® is equipped with an orbit control switch. The
tool may be operated in 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 optimum orbital action should be determined by the user for their
specific cutting requirements.

Fig. 5

1

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. 4).

Fig. 4

Stroke

2

1. For straight reciprocating action, move the orbit control switch to the
straight cut symbol (1).

2. For orbital action, move the orbit control switch towards the orbital
cut symbol (2).

The amount of orbital action may be adjusted by moving 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 (2). For smaller orbital action, move the orbit control switch closer
to the straight cut symbol (1).

Orbital action may be adjusted when the tool is running.
NOTE: Orbital action will not operate if the blade is installed with the teeth

facing upward.

page 7

Selecting the Speed Range

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.

Fig. 6

MATERIAL

Mild Steel

Wood

Nail-Embedded Wood

Stainless Steel

Drywall

Fiberglass

Plastics

Cast Iron

Non-Ferrous

Metals

* These are only suggested settings; the actual optimum

setting may vary depending on line voltage, blade
selected and user preference.

Trigger Speed Control Switch

Super 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.

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.

SUGGESTED DIAL SETTINGS*

2-3

5

5
1-3
4-5
1-3
1-3
2-3
2-3

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.

WARNING!

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.

Plunge Cutting (Fig. 6)

Your MILWAUKEE Sawzall® is ideal for plunge cutting directly into sur­faces that can not be cut from an edge, such as walls or floors. 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 with the
teeth facing upward.

Do not plunge cut into metal surfaces (see “Cutting Metals”).

page 8

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.

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 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.

ACCESSORIES

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.

Quik-Lok® Cord Sets

10' Quik-Lok® Cord Cat. No. 48-76-5010
25' Quik-Lok® Cord Cat. No. 48-76-5025

Select Models:

Blade Clamp Cat. No. 42-68-0682
Blade Clamp Screw Cat. No. 06-83-2975

“787” Blades:

Blade Clamp Cat. No. 42-68-0685
Blade Clamp Screw Cat. No. 06-83-2975

See Pages 24, 25 & 26 for a listing of Super Sawzall® Blades.

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 W ARRAN­TIES, OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED FOR
MERCHANTABLILITY OR FITNESS FOR P ARTICULAR 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.

page 9