Milwaukee 6523-21, 6536-21 User Manual
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
Cat. No.
No de cat.
Cat. No.
6523-21
6536-21
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.
®
GENERAL SAFETY RULES-FOR ALL POWER TOOLS
WARNING!
READ ALL INSTRUCTIONS
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 batteryopearted (cordless) power tool.
SAVE THESE 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 ex-
plosive 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 out-
doors, use an extension cord suitable for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock.
PERSONAL SAFETY
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 at-
tached 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 extraction and
collection facilities, ensure these
are connected and properly used.
Use of these devices can reduce dustrelated hazards.
POWER TOOL USE AND CARE
16. Do not force the power tool. Use
the correct power tool for your application. The correct power tool will
do the job better and safer at the rate
for which it was designed.
17. Do not use the power tool if the
switch does not turn it on and off.
Any power tool that cannot be controlled with the switch is dangerous
and must be repaired.
18. Disconnect the plug from the
power source and/or the battery
pack from the power tool before
making any adjustments, changing accessories, or storing power
tools. Such preventive safety mea-
sures 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 dangerous 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 acci-
dents are caused by poorly maintained
power tools.
21. Keep cutting tools sharp and
clean. Properly maintained cutting
tools with sharp cutting edges are less
likely to bind and are easier to control.
22. Use the power tool, accessories
and tool bits etc., in accordance
with these instructions and in the
manner intended for the particular type of power tool, taking into
account the working conditions
and the work to be performed. Use
of the power tool for operations different from those intended could result in
a hazardous situation.
SERVICE
23. Have your power tool serviced by
a qualified repair person using
only identical replacement parts.
This will ensure that the safety of the
power tool is maintained.
2 3
SPECIFIC SAFETY RULES — SAWZALLS
®
FUNCTIONAL DESCRIPTION
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 workpiece to a
stable platform. Holding the work by hand or against your body leaves it unstable and
may lead to loss of control.
4. Maintain labels and nameplates. These carry important information. If unreadable
or missing, contact a
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.
MILWAUKEE
service facility for a free replacement.
Symbology
Double Insulated
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
No Load Strokes Per Minute
(SPM)
Amps
1. Speed control dial
2. Handle rotation button
3. Trigger
4. Quik-Lok® cord
5. Rotating handle
6. Nameplate
7. Insulating boot
8. Shoe release lever
9. Adjustable pivot shoe
10. Blade
11. Quik-Lok® blade clamp
12. Orbit control switch
10
Cat.
No.
6523-21
11
9
Specifications
Volts
AC Only
120
Amps
13
Cat. No. 6523-21
12
8
Length of
Stroke
1-1/4"
1
7
Strokes
per Minute
0 - 3000
2
3
4
5
6
Straight Cut
Orbital Cut
4 5
1. Handle
2. Trigger
3. Cord
4. Nameplate
5. Insulating boot
6. Shoe release lever
7. Adjustable pivot shoe
8. Blade
9. Quik-Lok® blade clamp
10. Orbit control switch
9
8
7
GROUNDING
Cat. No. 6536-21
WARNING!
Improperly connecting the
grounding wire can result in the
2
1
10
4
5
6
3
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
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.
service facility
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.
Cat.
No.
6536-21
Specifications
Volts
AC Only
120
Amps
13
Length of
Stroke
1-1/4"
Strokes
per Minute
0 - 3000
Fig. A
6 7
Fig. B
Fig. C
EXTENSION CORDS
TOOL ASSEMBLY
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 for Extension Cords*
Nameplate
Amperes
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
* Based on limiting the line voltage drop to
five volts at 150% of the rated amperes.
Extension Cord Length
25'
18
18
18
18
16
14
12
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.
50'
18
18
18
16
14
12
10
75'
18
18
16
14
12
10
100'
18
16
14
12
10
150'
16
14
12
12
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) (Cat. No. 6523-21)
MILWAUKEE
provide instant field replacement 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
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.
's exclusive Quik-Lok® Cords
Sawzall® Blades for best
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
®
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.
Collar
Blade
8 9
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.
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.
• 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.
DO NOT OPERATE SAWZALL WITHOUT
SHOE. STRIKING THE SPINDLE
AGAINST WORK MAY DAMAGE THE
RECIPROCATING MECHANISM.
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
Impact Protection System
Both 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.
Do not operate the Sawzall® with
the handle rotation button
pressed in or with the handle not
locked into position.
Rotating the Handle (Fig. 5)
(Cat. No. 6523-21)
The 6523-21 Orbital Super Sawzall®
handle can rotate continuously 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 button.
3. Rotate the handle to the desired
position.
4. Release the handle rotation button. This
will lock the handle firmly into position.
Note: Make sure the handle does not
rotate before using the tool.
Fig. 5
handle rotation button
If the handle can not be locked
into position, do not operate the
Sawzall®. Return the Sawzall® to
a
Milwauke
immediately for repair.
Starting, Stopping and Controlling
Speed
1. To start the tool, grasp the handle firmly
and pull the trigger.
WARNING!
WARNING!
e service facility
10 11
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. 6)
The Orbital Super Sawzall® is 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 specific
cutting requirements.
Fig. 6
1
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 upside down.
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.
MATERIAL
Mild Steel
Wood
Nail-Embedded Wood
Stainless Steel
Drywall
Fiberglass
Plastics
Cast Iron
Non-Ferrous
Metals
SUGGESTED
DIAL SETTINGS*
2-3
5
5
1-3
4-5
1-3
1-3
2-3
2-3
* These are only suggested settings;
the actual optimal 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.
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.
Plunge Cutting (Figs. 7 & 8)
Your
MILWAUKEE
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 upside down.
Do not plunge cut into metal surfaces (see
“Cutting Metals”).
Sawzall® is ideal for
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.
Fig. 7
Cat. No. 6523-21
A
B
Fig. 8
1. Insert the blade into the tool.
2. With the blade just above the work-
3. As the blade starts cutting, raise the
Cat. No. 6536-21
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.
piece, pull the trigger. Using the edge of
the shoe as a pivot, lower the blade
into the workpiece as shown.
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.
12 13
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
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
facility for the following:
• Lubrication
• Mechanical inspection and cleaning
(gears, spindles, bearings, housing,
etc.)
• Electrical inspection (switch, cord,
armature, etc.)
• Testing to assure proper mechanical
and electrical operation
service facility for
MILWAUKEE
service
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.
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.
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
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
Carrying Case
Cat. No. 48-55-2055
Orbital Pipe Clamp System
Cat. No. 49-22-1016
Keyed Blade Clamp Kit
Cat. No. 49-22-5016
See Pages 46 & 47 for a listing of Super
Sawzall® Blades.
Electric Tool catalog
FIVE YEAR TOOL
LIMITED WARRANTY
Every
MILWAUKEE
leaving the factory and is warranted to be
free from defects in material and workmanship.
replace (at
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
MILWAUKEE
Support Branch location or
Authorized Service Station, freight prepaid
and insured. This warranty does not cover
damage from repairs made or attempted
by other than
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
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.
tool is tested before
MILWAUKEE
Factory Service/Sales
will repair or
’s discretion),
MILWAUKEE
MILWAUKEE
MILWAUKEE
authorized
BE LIABLE
14 15
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