Milwaukee 6539-1, 6546-1 Operator's Manual
Catalog No.
No de Cat.
Catálogo No.
6539-1
6546-1
HEAVY-DUTY CORDLESS SCREWDRIVER
EXTRA ROBUSTES TOURNEVIS SANS CORDON
ATORNILLADORES HEAVY-DUTY DE BATERIAS, INALAMBRICOS
To extend battery pack life:
• Follow the "BATTERY PACK CARE AND USE" section of this
manual.
• Charge battery packs before use.
• Follow the charging instructions in your charger manual.
Pour étendre la durée de vie de la batterie:
• Suivre les instructions de la section «UTILISATION ET
ENTRETIEN DE LA BATTERIE» de ce manuel.
• Charger les batteries avant de les utiliser.
• Suivre les instructions de charge du manuel du chargeur.
Para extender la duración de la batería:
• Seguir la sección “USO Y CUIDADO DE LA BATERÍA” en este
manual.
• Cargar las baterías antes de usarlas.
• Seguir las instrucciones de carga en el manual del cargador.
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
TO REDUCE THE RISK OF INJURY, USER MUST READ OPERATOR'S MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE LE
MANUEL DE L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER EL MANUAL
DEL OPERADOR.
2 3
WORK AREA SAFETY
ELECTRICAL SAFETY
PERSONAL SAFETY
WARNING
READ ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in electric shock, fi re 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-operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
GENERAL SAFETY RULES-FOR ALL BATTERY OPERATED TOOLS
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 fl ammable 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.
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.
Unmodifi ed 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.
9. Stay alert, watch what you are do-
ing and use common sense when
operating a power tool. Do not use
a power tool while you are tired or
under the infl uence 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 fi nger 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 foot-
ing 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 connec-
tion of dust extraction and collection
facilities, ensure these are connected
and properly used. Use of these de-
vices can reduce dust-related hazards.
4 5
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 preven-
tive 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 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 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 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
28. Have your power tool serviced by a
qualifi ed repair person using only
identical replacement parts. This will
ensure that the safety of the power tool
is maintained.
23. Ensure the switch is in the off posi-
tion before inserting battery pack.
Inserting the battery pack into power
tools that have the switch on invites
accidents.
24. Recharge only with the charger speci-
fi ed by the manufacturer. A charger
that is suitable for one type of battery
pack may create a risk of fi re when used
with another battery pack.
BATTER Y T OOL USE AND CARE
SPECIFIC SAFETY RULES
25. Use power tools only with specifi cally
designated battery packs. Use of any
other battery packs may create a risk of
injury and fi re.
26. When battery pack is not in use, keep
it away from other metal objects like
paper clips, coins, keys, nails, screws,
or other small metal objects that can
make a connection from one terminal
to another. Shorting the battery terminals
together may cause burns or a fi re.
27. Under abusive conditions, liquid may
be ejected from the battery, avoid
contact. If contact accidentally occurs, fl ush with water. If liquid con-
tacts eyes, additionally seek medical
help. Liquid ejected from the battery
may cause irritation or burns.
1. Maintain labels and nameplates.
These carry important information.
If unreadable or missing, contact a
MILWAUKEE service facility for a free
replacement.
2. Hold tools by insulated gripping sur-
faces when performing an operation
where the cutting tool may contact
hidden wiring or its own cord. Con-
tact with a “live” wire will make exposed
metal parts of the tool “live” and shock
the operator.
3
1
2
4
5
6
7
1. Bit
2. Clutch adjusting ring
3. Speed switch selector
(Cat. No. 6546-1)
4. Lock switch
5. Battery pack
6. Battery pack release buttons
7. Forward/reverse switch
Direct Current
Properly Recycle
Nickel Cadmium Batteries
Symbology
FUNCTIONAL DESCRIPTION
Underwriters
Laboratories, Inc.
No Load Revolutions
per Minute (RPM)
Cat. No.
6539-1
6546-1
Volts
DC
2.4
2.4
Specifi cations
No Load RPM
190
400/200
3. 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 chemicallytreated 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
fi lter out microscopic particles.
6 7
BATTERY PACK CARE AND USE
EXTENDING AND MAINTAINING
BATTERY PACK LIFE
Charge the new battery pack overnight before use to allow the cells
to become fully charged. New
battery packs are not fully charged. Two
to ten normal charging/discharging cycles
may be required before the pack can take
its maximum charge.
Never completely discharge the
battery pack. MIL WAUKEE battery
packs do not develop a "memory"
when charged after only a partial discharge.
Taping-on triggers or leaving work lights on
for extended periods to completely discharge
the battery pack will reduce its life by upsetting the electrochemical balance and can
result in short-circuiting of the battery.
Do not charge batteries in hot or
cold places (below 40°F (5°C) or
above 105°F (40°C)). Temperature
extremes reduce the ability for battery pack
cells to hold a charge. Do not store batteries
where the temperature may exceed 120°F
(50°C), such as in a vehicle or metal building
during the summer.
To avoid overheating to a battery pack,
allow cordless tools cool down between
high torque drilling/cutting applications.
The increased energy discharge rate will
heat the battery pack cells faster than the
cells can release the heat. This could damage the cells.
After use, allow a hot battery pack to
cool to room temperature before inserting it
into the charger. If a hot battery is put on a
charger, charging will not begin until the battery has cooled to a safe temperature. See
your charger manual for more information
on charging temperatures. Charging a hot
battery will damage the cells.
Never forcibly heat up or cool down batteries. This will damage some cells in the
pack, causing them to not be able to hold
a charge.
Remove the battery pack from the tool
for charging when the tool can no longer
perform its intended function (i.e., drilling,
cutting, etc.).
Leave the battery pack on the
charger after it has reached a full
charge; the pack will continue to
receive a trickle charge to ensure capacity
is maintained.
Occasionally (once a week) leave the
batteries on the charger overnight to help
maintain cell balance.
Do not store the battery on the charger
(for more than 24 hours); this could reduce battery life.
Never leave batteries on chargers where
power interruptions are common. Damage
to the battery cells could occur.
Store batteries at room temperature away from moisture. Do not
store in damp locations where corro-
sion of terminals may occur.
Do not submerge your battery or cordless tools in water. This will damage the
battery and tool.
Charge unused batteries overnight at
least every six months to maximize battery life. Unused batteries discharge at a
rate of about 1% per day and will be fully
discharged after six months. For batteries
stored for a long time, two to ten normal
charging cycles may be required before the
pack is fully charged.
Do not use oil or solvents to clean or
lubricate your battery pack. The plastic
casing will become brittle and crack, causing
a risk of injury.
MILWAUKEE battery packs will operate for many years and/or hundreds of cycles when they
are used, charged, and stored according to these instructions. Properly using, charging, and
storing your battery pack can greatly extend its life.
WARNING
To reduce the risk of injury, wear
safety goggles or glasses with side
shields.
OPERATION
Installing Bits
Always remove the battery pack and set
the lock switch to “lock” before inserting or
removing bits. Select the proper style and
size screwdriver bit for the type of screw you
are using (see “Accessories”).
1. To install the bit, insert it into the bit
socket.
2. To remove the bit, pull it out of the bit
socket.
Adjusting the Handle
The handle is designed for convenience and
control. The durable, center pivot allows the
handle to be used in the conventional shape
or folded into a pistol grip. Access to the
forward/reverse switch and lock switch is
comfortable in either handle position.
The torque specifications shown here are approximate values obtained with a fully charged
battery pack.
NOTE: Because the settings shown in the table are
only a guide, use a piece of scrap material to test
the different clutch settings before driving screws
into the workpiece.
1 Speed
(in. lbs.)
5
5
12
12-16
12-16
22
2 Speed
(in. lbs.)
Lo
3.5
7
10.5
14
17.5
26
Hi
3.5
7
10.5
13
13
13
Clutch
Setting
1
2
3
4
5
6
Applications
Small screws in
softwood.
Medium screws
in softwood or
small screws in
hardwood.
Large screws
in softwoods.
Medium screws
in hardwood or
large screws in
hardwood with
Removing Battery Pack from Tool
Push in the release buttons (1) and pull the
battery pack away from the tool.
1
Fig. 1
WARNING
Charge only MILWAUKEE 2.4 Volt
battery packs in 2.4 Volt MIL WAUKEE
chargers. Other brands of batteries
may explode causing personal injury
and damage.
For specifi c charging instructions,
please read the operator's manual
supplied with your charger.
Inserting Battery Pack into Tool
The battery pack may feel warm after the
charging cycle. If it is warm, maximize the
output of the battery by allowing it to cool for a
few minutes before inserting it into the tool.
T o insert the battery pack into the tool, push
in the release buttons (1) and slide it into the
body of the tool.
Using the Adjustable Clutch
This tool has an adjustable clutch for driving
different types of screws into different materials. When properly adjusted, the clutch will
slip at a preset torque to prevent driving the
screw too deep and to prevent damage to
the screw or tool. Refer to the following table
to select the correct position for the type of
material and screw size you are using.
T o adjust the clutch, turn the clutch adjusting
ring so that the desired setting lines up with
the dot on motor housing as shown.
8 9
APPLICATIONS
Using the Lock Switch
When the battery pack is installed, the tool
is in operating condition. The lock switch
prevents accidental starting by locking the
forward/reverse switch. Always set the lock
switch to “lock” before performing maintenance, changing accessories, storing the tool
and any time the tool is not in use.
1. To lock, push the lock switch in the
direction marked on the tool.
2. To unlock, push the lock switch in the
opposite direction.
Selecting High or Low Speed
Fig. 4
Forward
Reverse
Fig. 2
Unlock
Lock
Selecting Forward or Reverse
Press the forward/reverse switch in the direction marked on tool for the desired rotation.
The switch will automatically return to the
center, OFF position when it is released.
To reduce the risk of injury, always
remove battery pack and lock trigger before attaching or removing
accessories. Use only specifi cally
recommended accessories. Others
may be hazardous.
WARNING
This tool provides a quick, convenient means
of installing and removing screws. Because of
the many screw sizes, types, thread engagements and materials available, it is diffi cult to
limit the application of this tool by screw size.
However, for applications in wood, a #8 wood
screw with a full pilot hole is recommended
as a practical limit.
Driving Screws
1. Select the proper style and size screwdriver bit for the type of screw being used
(see “Accessories”).
2. With the screwdriver bit fi rmly seated in
the head of the screw, place the tip of the
screw on the workpiece and apply fi rm
pressure.
3. Press the forward/reverse switch to
“forward”.
Removing Screws
Screws can be removed by reversing the
motor. If a screw is unusually tight and can
not be readily removed by the motor, lock the
bit. See “Locking the Bit”.
Locking the Bit
When the forward/reverse switch is off,
the bit automatically locks in place allowing you to use your screwdriver manually.
This feature is handy for tightening screws
that require more torque than the driver is
capable of delivering, when confi rming the
tightness of a screw or when loosening an
extremely tight screw.
1. For high speed (400 RPM) and less
torque, push the speed selector back.
2. For low speed (200 RPM) and more
torque, push the speed selector forward.
Fig. 3
High
Low
MAINTENANCE
WARNING
To reduce the risk of personal injury ,
always unplug the charger and remove the battery pack from the charger or tool before performing any
maintenance. Never disassemble the
tool, battery pack or charger. Contact
a MILWAUKEE service facility for
ALL repairs.
WARNING
To reduce the risk of personal injury
and damage, never immerse your
tool, battery pack or charger in liquid
or allow a liquid to fl ow inside them.
Maintaining Tool
Keep your tool, battery pack and charger
in good repair by adopting a regular maintenance program. After six months to one
year, depending on use, return the tool,
battery pack and charger to a MILWAUKEE
service facility for:
• Lubrication
• Brush inspection and replacement
• Mechanical inspection and cleaning
(gears, spindles, bearings, housing,
etc.)
• Electrical inspection (battery pack,
charger, motor)
• Testing to assure proper mechanical and
electrical operation
If the tool does not start or operate at full
power with a fully charged battery pack,
clean the contacts on the battery pack. If
the tool still does not work properly, return
the tool, charger and battery pack to a
MILWAUKEE service facility for repairs.
Maintaining Battery Pack
MILWAUKEE battery packs will operate for
many years and/or hundreds of cycles when
they are maintained and used according to
these instructions.
A battery pack that is stored for six months
without being used will discharge itself. Batteries discharge at a rate of about 1% per
day. Charge the battery every six months
even if it is unused to maximize battery life.
Do not tape the trigger in the “ON” position
and leave the tool unattended as this may
discharge the battery to a point where it will
no longer be able to recharge. Use a MIL-
WAUKEE battery pack only until it no longer
performs with the power and torque needed
for your application.
Store your battery pack in a cool, dry place.
Do not store it where the temperature may
exceed 120°F (50°C) such as in a vehicle
or metal building during the summer. High
temperatures will overheat the battery pack,
reducing battery life. If it is stored for several
months, the battery pack will gradually lose
its charge. One to three cycles of charging
and discharging through normal use will
restore the capacity of the battery pack. During the life of the battery pack, the operating
time between charges becomes shorter. If
the operating time becomes extremely short
after a proper charge, the usable life of the
battery pack has been reached and it should
be replaced.
Cleaning
Clean dust and debris from charger and tool
vents. Keep tool handles clean, dry and free
of oil or grease. Use only mild soap and a
damp cloth to clean the tool, battery pack
and charger 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 fl ammable or combustible sol-
vents around tools.
10 11
WARNING
To reduce the risk of explosion,
never burn a battery pack even if
it is damaged, dead or completely
discharged.
RBRC Battery Recycling Seals
The RBRC™ Battery Recycling Seals (see
"Symbology") on your tool battery packs
indicate that MILWAUKEE has arranged
for the recycling of that battery pack with
the Rechargeable Battery Recycling Corporation (RBRC). At the end of your battery
pack's useful life, return the battery pack to a
MILWAUKEE Branch Offi ce/Service Center
or the participating retailer nearest you. For
more information, visit the RBRC web site
at www.rbrc.org.
Disposing of Nickel-Cadmium Battery
Packs
Nickel-Cadmium battery packs are recyclable. Under various state and local laws, it
may be illegal to dispose of this battery into
the municipal waste stream. Dispose of your
battery pack according to federal, state and
local regulations.
Repairs
For repairs, return the tool, battery pack
and charger to the nearest service center
listed on the back cover of this operator's
manual.
2.4 Volt Battery Pack
Cat. No. 48-11-0100
2.4 Volt Charger
Cat. No. 48-59-0300
2.4 Volt Charger
Cat. No. 48-59-0181
Carrying Case
Cat. No. 48-55-0798
ACCESSORIES
For a complete listing of accessories refer to
your MILWAUKEE Electric T ool catalog or go
on-line to www.milwaukeetool.com. T o obtain
a catalog, contact your local distributor or a
service center.
WARNING
Always remove battery pack before
changing or removing accessories.
Only use accessories specifi cally
recommended for this tool. Others
may be hazardous.
FIVE YEAR TOOL LIMITED WARRANTY
Every MILWAUKEE electric power tool (including battery charger) is warranted to the original
purchaser only to be free from defects in material and workmanship. Subject to certain exceptions, MILWAUKEE will repair or replace any part on an electric power tool which, after
examination, is determined by MILWAUKEE to be defective in material or workmanship for
a period of fi ve (5) years* after the date of purchase. Return the electric power tool and a
copy of 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 apply to damage that MILWAUKEE determines to be from repairs made or attempted by
anyone other than MILWAUKEE authorized personnel, misuse, alterations, abuse, normal
wear and tear, lack of maintenance, or accidents.
* The warranty period for Hoists (lever, hand chain, & electric chain hoists), Ni-Cd battery
packs, Work Lights (cordless fl ashlights), Job Site Radios, and Trade Titan™ Industrial Work
Carts is one (1) year from the date of purchase.
*There is a separate warranty for V™-technology Li-Ion Battery Packs 18 volts or above that
accompany the power tools:
*Every MILWAUKEE V™-technology Li-Ion Battery Pack 18 volts or above is covered by an
initial 1000 Charges/2 Years free replacement warranty. This means that for the earlier of
the fi rst 1000 charges or two (2) years from the date of purchase/fi rst charge, a replacement
battery will be provided to the customer for any defective battery free of charge. Thereafter,
customers will also receive an additional warranty on a pro rata basis up to the earlier of the
fi rst 2000 charges or fi ve (5) Years from the date of purchase/fi rst charge. This means that
every customer gets an additional 1000 charges or three (3) years of pro rata warranty on
the V™-technology Li-Ion Battery Pack 18 volts or above depending upon the amount of use.
During this additional warranty period, the customer pays for only the useable service received
over and above the fi rst 1000 Charges/2 years, based on the date of fi rst charge and number
of charges found on the battery pack via Milwaukee’s V™-technology Service Reader.
Warranty Registration is not necessary to obtain the applicable warranty on a MILWAUKEE
product. However, proof of purchase in the form of a sales receipt or other information deemed
suffi cient by MILWAUKEE is requested.
ACCEPTANCE OF THE EXCLUSIVE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN IS A CONDITION OF THE CONTRACT FOR THE PURCHASE OF
EVERY MILWAUKEE PRODUCT. IF YOU DO NOT AGREE TO THIS CONDITION, YOU
SHOULD NOT PURCHASE THE PRODUCT. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY INCIDENTAL, SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES,
OR FOR ANY COSTS, ATTORNEY FEES, EXPENSES, LOSSES OR DELAYS ALLEGED
TO BE AS A CONSEQUENCE OF ANY DAMAGE TO, FAILURE OF, OR DEFECT IN ANY
PRODUCT INCLUDING, BUT NOT LIMITED TO, ANY CLAIMS FOR LOSS OF PROFITS.
THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED. WITHOUT LIMITING THE
GENERALITY OF THE FOREGOING, MILWAUKEE DISCLAIMS ANY IMPLIED W ARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR USE OR PURPOSE, AND ALL
OTHER WARRANTIES.
This warranty applies to product sold in the U.S.A., Canada and Mexico only.
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