Milwaukee Jig Saw User Manual

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

Cat. No.

No de cat.

Cat. No.

6390-20

6394

HEAVY-DUTY CIRCULAR SAW WITH TILT-LOK™ HANDLE SCIES CIRCULAIRES INDUSTRIELLES AVEC POIGNEE

« TILT-LOK™ » SIERRA CIRCULAR PARA TRABAJO PESADO CON

EMPUÑADURA TILT-LOK™ (INCLINABLE-FIJABLE)

TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S MANUAL.

AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE ET BIEN COMPRENDRE LE MANUEL DE L'UTILISATEUR.

PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER Y ENTENDER EL MANUAL DEL OPERADOR.

GENERAL SAFETY RULES — FOR ALL POWER TOOLS

WARNING

Failure to follow all instructions listed below may result in electric shock, 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

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 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.

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.

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.

PERSONAL SAFETY

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.

2 3

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

23. 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.

SPECIFIC SAFETY RULES

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

2. DANGER! Keep hands away from

cutting area and blade. Keep your second hand on auxiliary handle or motor housing. If both hands are hold-

ing the saw, they cannot be cut by the blade.

Do not reach underneath the work-

piece. The guard cannot protect you from the blade below the workpiece.

Adjust the cutting depth to the thick-

ness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.

3. Check lower guard for proper closing

before each use. Do not operate the saw if lower guard does not move freely and close instantly. Never clamp

or tie the lower guard into the open position. If saw is accidentally dropped, lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.

4. Check the operation and condition

of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use. Lower guard may operate

sluggishly due to damaged parts, gummy deposits, or a buildup of debris.

5. Lower guard should be retracted

manually only for special cuts such as "Plunge Cuts" and "Compound Cuts". Raise lower guard by retracting handle and as soon as blade enters the material, the lower guard must be released. For all other saw-

ing, the lower guard should operate automatically.

6. Always observe that the lower guard

is covering the blade before placing saw down on bench or ﬂ oor. An

unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.

7. NEVER hold piece being cut in your

hands or across your leg. Secure the workpiece to a stable platform. It is

important to support the work properly to minimize body exposure, blade binding, or loss of control.

8. Hold power tools by insulated grip-

ping 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.

9. When ripping always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance for blade binding.

10. Always use blades with correct size

and shape (diamond vs. round) arbor holes. Blades that do not match the

mounting hardware of the saw will run eccentrically, causing loss of control.

11. Never use damaged or incorrect blade washers or bolts. The blade washers and bolts were specially designed for your saw, for optimum performance and safety of operation.

12. 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 speciﬁ cally designed to ﬁ lter out microscopic particles.

13. Causes and Operator Prevention of

KICKBACK:

KICKBACK is a sudden reaction to

a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator.

When the blade is pinched or bound

tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator.

If the blade becomes twisted or mis-

aligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward operator.

KICKBACK is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

14. Maintain a ﬁ rm grip with both hands

on the saw and position your arms to resist KICKBACK forces. Position your body to either side of the blade, but not in line with the blade.

KICKBACK could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.

When blade is binding, or when inter-

15.

rupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or KICKBACK may occur. Investigate and take cor-

rective actions to eliminate the cause of blade binding.

16. When restarting a saw in the work-

piece, center the saw blade in the kerf and check that saw teeth are not engaged into the material. If

saw blade is binding, it may walk up or KICKBACK from the workpiece as the saw is restarted.

17. Support large panels to minimize

the risk of blade pinching and KICKBACK. Large panels tend to sag under

their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.

18. Do not use dull or damaged blade. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and KICKBACK.

4 5

19. Blade depth and bevel adjusting lock-

ing levers must be tight and secure before making cut. If blade adjustment

shifts while cutting, it may cause binding and KICKBACK.

GROUNDING

WARNING

Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualiﬁ ed electri- cian 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 ﬁ t the outlet, have a proper outlet installed by a qualiﬁ ed 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.

20. Use extra caution when making a

"Plunge Cut" into existing walls or other blind areas. The protruding

blade may cut objects that can cause KICKBACK.

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.

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 sufﬁ x “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 qualiﬁ ed person before using it.

• Protect your extension cords from sharp objects, excessive heat and damp or wet areas.

Recommended Minimum Wire Gauge

Nameplate

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

for Extension Cords*

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

Extension Cord Length

25'

18 18 18 18 16 14 12

READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.

Symbology

Double Insulated

Volts Alternating Current/ Direct Current

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

Fig. A

Underwriters Laboratories, Inc.

Amps

Fig. B

6 7

Fig. C

Cat.

No.

6390-20

6394

Volts

120 AC/DC

120 AC Only

Speciﬁ cations

No Load

RPM

5 800 5 800

Blade

Size

7-1/4" 7-1/4"

Arbor

5/8" 5/8"

Volts Alternating Current

No Load Revolutions per Minute (RPM)

Depth of Cut

At 90°

0 to 2-15/32" 0 to 2-15/32"

Depth of Cut

at 45°

0 to 1-13/16" 0 to 1-13/16"

FUNCTIONAL DESCRIPTION

TOOL ASSEMBLY

1. Tilt-Lok™ handle

2. Handle lever release button

3. Handle release lever

4. Bevel scale

5. Bevel pointer

6. Bevel adjusting lever

7. Spindle lock button

8. Depth setting gauge (not shown)

9. Trigger

10. C

ord release button

11. Depth adjusting lever

12. Front handle

To reduce the risk of injury, alway unplug tool before attaching or removing accessories or making

adjustments. Use only speciﬁ cally recommended accessories. Others may be hazardous.

Removing and Replacing Positive-Lok®

Cat. No. 6394

Cords (Cat. No. 6394)

MILWAUKEE’S exclusive Positive-Lok® Cords provide instant ﬁ eld replacement or substitution. The Positive-Lok® feature se-

WARNING

Installing and Removing Blades

1. Unplug tool before installing or removing blades.

2. Place the saw on a ﬂ at surface with the blade facing upwards. To remove the bolt from the spindle, push in the spindle lock button. While holding in the spindle lock button, use the wrench provided with the tool to turn the bolt counterclockwise (Fig. 2). Remove the bolt and outer blade ﬂ ange.

Fig. 2

cures the cord ﬁ rmly to the tool.

Fig. 1

Cord release button

3. Slide the lower guard lever up to raise the lower guard. Remove the blade from the spindle. Always clean the spindle, upper guard and lower guard to remove any dirt and sawdust.

NOTE: Do not remove inner blade

ﬂ ange. Larger diameter of inner ﬂ ange (Fig. 3) should face the blade.

Fig. 3

Spindle

Bolt

1. To remove the Positive-Lok

Cord, push the cord release button in the direction shown and turn the cord nut 1/4 turn to the left. Pull the cord out.

2. T o replace the Positive-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. The cord release button will click back into

13. Sight line

place.

14. Rip fence slot

15. Lower guard

16. Blade ﬂ ange

17. Blade bolt

18. Blade

19. Shoe

20. Lower guard lever

21. Upper guard

22. Positive-Lok

cord

(Cat. No. 6394 only)

Selecting Blade

Always use sharp blades. Dull blades tend to overload the tool and increase the chance of KICKBACK (see "Operation"). Only use blades with a maximum safe operating speed greater than the no load RPM marked on the tool's nameplate. Read the blade manufacturer's instructions before use.

Outer ﬂ angeInner ﬂ ange

8 9

4. To install a blade, place the blade on the spindle with the teeth pointing in the same direction as the arrow on the lower guard (Fig. 4). Release the lower guard lever.

Fig. 4

5. Place the outer blade flange on the spindle and hand tighten the bolt. Larger diameter of outer ﬂ ange (Fig. 3) should rest on blade.

6. While holding the spindle lock button in, use the wrench to turn the bolt clockwise and tighten.

Adjusting Depth

1. Unplug tool.

2. To adjust the depth of the cut, hold the saw by the Tilt-Lok™ handle and loosen the depth adjusting lever by lifting it up and away from the shoe (Fig. 5).

Fig. 5

3. Raise or lower the shoe to the desired position. Markings in 1/4" increments are located on the inner side of the upper guard for depth setting. For the proper depth setting, the blade should extend no more than 1/4" below the material being cut (Fig. 6).

Fig. 6

Adjusting Bevel Angle

1. Unplug tool.

2. To adjust the angle of the cut, hold the saw by the Tilt-Lok™ handle and loosen the bevel adjusting lever by lifting it up towards the blade (Fig. 7).

Fig. 7

3. Hold the front handle and rotate the saw by the Tilt-Lok™ handle to the desired angle as indicated by the markings on the bevel scale (Fig. 8).

Fig. 8

Adjusting Tilt-Lok™ Handle Angle

This circular saw is equipped with an adjustable handle. The Tilt-Lok™ feature allows the user to adjust the angle of the handle for optimum cutting positions.

1. Unplug tool.

2. Press in and hold the handle lever release button.

3. Loosen the handle release lever by lifting it up and away from the Tilt-Lok™ handle (Fig. 9).

Fig. 9

4. To adjust the handle position, hold the front handle and rotate the Tilt-Lok™ handle to the desired angle as indicated by the handle rotation adjustment markings (Fig. 10). The Tilt-Lok™ feature has eight (8) detents which allow the handle to snap into position. Allow the detent to snap into place.

1/4"

4. Move the depth adjusting lever towards the shoe and push down to secure the position.

10 11

4. Move the bevel adjusting lever away from the blade and push down to secure the position.

Fig. 10

NOTE: The blade depth setting will

determine the range of Tilt-Lok™ positions available for the application. See “Adjusting Depth” for instructions on adjusting the blade depth.

5. Push the handle release lever back into the handle until it snaps into place.

WARNING

Do not operate saw with handle lever release button pressed in or with handle not locked into position.

NOTE: The saw will not operate if the

handle release lever is not properly secured.

WARNING

If the Tilt-Lok™ handle moves with the handle release lever in the locked position, do not operate saw. Return the circular saw to a MILWAUKEE service facility for repair immediately.

Adjusting the Blade to Shoe

The shoe has been adjusted at the factory to a 90 degree setting. Inspect the saw regularly to make sure the blade is 90 degrees to the shoe.

1. Unplug tool.

2. Set the bevel pointer to zero (Fig. 11).

Fig. 11

3. T o make sure the blade is 90 degrees to the shoe, place saw on the blade side and retract lower guard. Place a square against the blade and shoe to inspect the degree setting (Fig. 12).

Fig.12

Bevel adjustment screw

4. To adjust the degree setting, loosen the bevel adjusting lever up by lifting it up towards the blade. Turn the bevel adjustment screw in or out until the blade is at a 90 degree angle with the shoe.

5. Check that the bevel pointer is at 0 degrees. To adjust the bevel pointer, loosen the two screws in the front handle and reposition the bevel pointer to 0 degrees.

OPERATION

WARNING

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

Causes and Operator Prevention of KICKBACK:

KICKBACK is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator.

When the blade is pinched or bound tightly by the kerf, or cutting slot, closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator.

If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward operator.

KICKBACK is the result of tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

1. Maintain a ﬁ rm grip with both hands

on the saw and position your body and arm to allow you to resist KICKBACK forces. KICKBACK forces can

be controlled by the operator, if proper precautions are taken.

2. When blade is binding, or when inter-

rective actions to eliminate the cause of blade binding.

3. When restarting a saw in the work-

piece, center the saw blade in the kerf, or cut, and check that saw teeth are not engaged into the material. If

saw blade is binding, it may walk up or KICKBACK from the workpiece as the saw is restarted.

4. Support large panels to minimize

the risk of blade pinching and KICKBACK. Large panels tend to sag under

their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.

5. Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and KICKBACK.

6. Blade depth and bevel adjusting lock-

ing levers must be tight and secure before making cut. If blade adjustment

shifts while cutting, it may cause binding and KICKBACK.

7. Use extra caution when making a

“Pocket Cut” into existing walls or other blind areas. The protruding

blade may cut objects that can cause KICKBACK.

8. Set the depth of cut for no more than

1/8" to 1/4" greater than the thickness of the stock. The less blade exposed,

the less chance of binding and KICKBACK. Before cutting, be sure depth and bevel adjustments are tight.

9. Be cautious of pitchy, knotty, wet or warped stock. These are most likely to create pinching conditions and possible KICKBACK. Do not rip warped lumber. Avoid cutting nails.

10. Use a rip fence or edge guide when ripping. Guides improve control and reduce blade binding.

11. Stay alert. Any distraction can cause twisting or binding. Repetitive cuts may lull the user into careless movements.

12 13

General Operation

Always clamp the workpiece securely on a saw horse or bench (Fig. 13). See “APPLICATIONS” for the correct way to support your work in different situations.

Fig. 13

1. Draw a cutting line. Place the front of the shoe on the edge of the workpiece without making blade contact. Hold the Tilt-Lok™ handle with one hand and the front handle with the other (Fig. 14).

Fig. 14

2. Line up the sight line with your cutting line. Position your arms and body to resist KICKBACK. Pull the trigger, allowing the motor to reach full speed before beginning to cut.

3. While cutting, keep the shoe ﬂ at against the workpiece and maintain a firm grip. Do not force the saw through the workpiece. Forcing a saw can cause KICKBACK.

4. If making a partial cut, restarting in mid-cut or correcting direction, allow the blade to come to a complete stop. To resume cutting, center the blade in the kerf, back the saw away from cutting edge a few inches, pull the trigger and re-enter the cut slowly.

5. If the saw binds and stalls, maintain a ﬁ rm grip and release the trigger im- mediately. Hold the saw motionless in the workpiece until the blade comes to a complete stop.

6. After ﬁ nishing a cut, be sure the lower guard closes and the blade comes to a complete stop before setting the saw down.

Electric Brake (Cat. No. 6394)

Select models feature an electronic brake. The brake engages when the trigger is released, causing the blade to stop and allowing you to proceed with your work. Generally, the saw blade stops within two seconds. However, there may be a delay between the time you release the trigger and when the brake engages. Occasionally the brake may miss completely. If the brake misses frequently, the saw needs servicing by an authorized MILWAUKEE service facility. The brake is not a substitute for the guard, and you must always wait for the blade to stop completely before removing the saw from the workpiece. The correct brush grade must be used for proper operation of the brake. Use only the correct MILWAUKEE replacement brushes when servicing the tool.

Troubleshooting

If the blade does not follow a straight line:

• T eeth are dull. This is caused by hitting a hard object such as a nail or stone, dulling teeth on one side. The blade tends to cut to the side with the sharpest teeth.

• Shoe is out of line or bent

• Blade is bent

• Rip fence or guide is not being used

If the blade binds, smokes or turns blue from friction:

• Blade is dull

• Blade is on backwards

• Blade is bent

• Blade is dirty

• Workpiece is not properly supported

• Incorrect blade is being used

APPLICATIONS

Selecting Tilt-Lok™ Handle Positions

WARNING

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

APPLICATION SUGGESTED TILT-LOK POSITIONS*

For cuts made at or near waist level

For shallow cuts made at or near waist level

For cuts made below the waist, as in ﬂ ooring ap- plications

For cuts made overhead, as in ceiling applications

* These are only suggested positions; the actual optimum cutting position may vary depending on the actual application and user preference.

Fig. 15

Handle in lower positions (Fig. 16) allows for more leverage when pushing the saw through the workpiece.

Handle in lower positions allows the user to apply increased downward force during shallow cuts.

Handle in higher positions (Fig. 17) reduce the amount of “bending over” by the user. Higher handle positions allow the user to apply an increased downward force on the saw.

Handle in higher positions reduce the amount of extended reach by the user for overhead cuts. Higher handle positions allow the user to apply an increased upward force on the saw.

Fig. 17

The Tilt-Lok™ handle is a feature which allows the user to adjust the angle of the handle for optimum cutting positions. The Tilt-Lok™ handle has eight (8) detents which allow the handle to snap into position (Fig. 15). See “Adjusting Tilt-Lok™ Handle” for instuctions on adjusting the handle. Refer to the chart below for suggested handle positions.

Fig. 16

14 15

Cutting Large Panels

Large panels and long boards sag or bend if they are not correctly supported. If you attempt to cut without leveling and properly supporting the workpiece, the blade will tend to bind, causing KICKBACK.

Support large panels. Be sure to set the depth of the cut so that you only cut through the workpiece, not through the supports.

Fig. 18

Ripping Wood

Ripping is cutting lengthwise with the grain. Select the proper blade for your job. Use a rip fence for rips 4" wide or less. T o install the rip fence, slide the bar through the rip fence slot in either side of the shoe. The width of the cut is the distance from the inside of the blade to the inside edge of the rip fence. Adjust the rip fence for the desired width, and lock the setting by tightening the rip fence screws.

When ripping widths greater than 4", clamp or tack 1" lumber to workpiece and use the inside edge of the shoe as a guide.

Cross-Cutting Wood

Cross-cutting is cutting across the grain. Select the proper blade for your job. Advance the saw slowly to avoid splintering the wood.

Fig. 19

WARNING

To reduce the risk of electric shock, check work area for hidden pipes and wires before making pocket cuts.

Pocket Cutting

Pocket cuts are made in the middle of the workpiece when it can not be cut from an edge. We recommend using a Sawzall reciprocating saw or jig saw for this type of cut. However, if you must use a circular saw to make a pocket cut, USE EXTREME CAUTION. To maintain control of the saw during pocket cutting, keep both hands on the saw (Fig. 20).

Fig. 20

1. Beginning at a corner, line up the sight line with your cutting line. Tilt the saw forward, ﬁ rmly ﬁ xing the front of the shoe on the workpiece. The blade should be just above cutting line, but not touching it. Raise the lower guard using the lower guard lever.

2. Pull the trigger, allowing the blade to come up to full speed. Using the front of the shoe as a hinge point, gradually lower the back end of the saw into the workpiece.

3. When the shoe rests ﬂ at against work- piece, release the lower guard lever. Advance the saw to the far corner. Release the trigger and allow the blade to come to a complete stop before removing it from workpiece. Repeat the above steps for each side of the opening. Use a Sawzall small hand saw to ﬁ nish the corners if they are not completely cut through.

reciprocating saw, jig saw or

Cutting Masonry and Metal

Although MILWAUKEE Circular Saws are primarily designed and intended for cutting wood, they may also be used with abrasive cutting wheels or dry cutting diamond blades for cutting metal or masonry.

WARNING

Only use abrasive cutting wheels

with a maximum safe operating speed greater than the RPM marked on the tool's nameplate.

When cutting masonry, use a dry cutting diamond blade. Make successive passes at depths of less than 1/4" to achieve the desired depth. Cutting at a depth of more than 1/4" will damage the wheel. Frequently clean dust from air vents and guards. Always wear a dust mask.

When cutting light gauge sheet metal, use an aluminum oxide abrasive cutting wheel or an appropriate blade designed speciﬁ cally for cutting metal. Set the depth of cut for 1/8" to 1/4" greater than the thickness of the material you are cutting. Protect everyone in the area from sparks.

WARNING

ust, chips and grit can cause the guard to hang up at any time. If the saw is used with an abrasive cutting wheel or dry cutting diamond blade, reserve and mark it for that use only. Before using it for wood cutting, return it to a MILWAUKEE service facility for cleaning and testing.

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

• Electrical inspection (switch, cord,

• T esting to assure proper mechanical and

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.

(gears, spindles, bearings, housing, etc.)

armature, etc.)

electrical operation

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