Milwaukee Sawzall User Manual
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
Cat. No.
No de cat.
6515-20
18 VOLT SAWZALL
PASSE-PARTOUT SAWZALL 18 V
SIERRAS SABLE-SAWZALLS DE 18V
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.
GENERAL SAFETY RULES-FOR ALL BATTERY OPERATED TOOLS
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
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.
2 3
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.
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.
BA TTER Y T OOL USE AND CARE
23. Ensure the switch is in the off position 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.
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.
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.
SPECIFIC SAFETY RULES
1. Hold 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. 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. Keep hands away from all cutting
edges and moving parts.
4. Maintain labels and nameplates.
These carry important information.
If unreadable or missing, contact a
MILWAUKEE service facility for a free
replacement.
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.
Y our 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.
Symbology
Underwriters Laboratories, Inc.,
United States and Canada
Volts Direct Current
No Load Strokes
per Minute (SPM)
Specifi cations
Catalog
No.
6515-20
Volts
DC
18
Length of
Stroke
1-1/8"
Strokes
per Minute
0 - 2700
FUNCTIONAL DESCRIPTION
6
5
4
3
2
TOOL ASSEMBLY
WARNING
Recharge only with the charger
specifi ed for the battery pack. For
specifi c charging instructions, read
the operator's manual supplied with
your charger and battery pack.
WARNING
Always lock trigger or remove
battery pack before changing or
removing accessories. Only use
accessories specifically recommended for this tool. Others may
be hazardous.
Removing Battery Pack from Tool
To remove the battery pack, press in both
battery latches and slide the battery pack
off of the tool.
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.
Insert the battery pack by sliding battery
pack onto the body of the tool. Insert the battery pack until the battery latches lock.
Selecting a Blade
The Quik-Lok
with all 1/2" shank universal Sawzall
Use MILWAUKEE High Performance Super
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.
Installing and Removing Blades
Quik-Lok® Blade Clamp
Remove battery pack before changing
blades. Make sure the spindle and blade
clamp areas are clean. Metal chips and
sawdust may prevent the Quik-Lok® Blade
Clamp from clamping securely.
Fig. 1
®
Blade Clamp can be used
Collar
®
blades.
1
7
Blade
1. Depending on the job, the blade may
8
1. Handle
2. Trigger
3. Trigger lock switch
4. Nameplate
9
5. Insulating boot
6. Quik-Lok™ blade clamp
7. Blade
8. Adjustable pivot shoe
9. Shoe release lever
4 5
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 fi rmly
in place.
3. Twist collar in the opposite direction of
the arrow to ensure that the blade is
locked into the clamp.
4. Tug on blade to make sure it is securely
locked in place.
5. To remove a blade, twist collar in the
direction of the arrow while pulling on
the blade. Be careful when handling hot
blades.
®
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 QuikLok® Blade Clamp
• Remove battery pack 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 fi ngers
are holding the blade clamp open). The
shank of the broken blade should drop
out of the clamp.
• If shaking the tool doesn't work...
In most cases, a corner of the broken
blade will extend beyond the blade
clamp. Simply twist the collar and pull
the broken blade out of the clamp by this
corner.
• If the broken stub doesn't extend far
enough to be grabbed by its corner, use
a thin blade with small teeth (such as a
metal cutting blade) to hook the blade
that is jammed in the clamp while twisting the collar and pull it out.
Adjusting the Pivot Shoe
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.
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. 2).
Fig. 2
1/4 Turn
1. T o 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
workpiece throughout the stroke.
DO NOT OPERATE SAWZALL WITHOUT
SHOE. STRIKING THE SPINDLE AGAINST
WORKPIECE MAY DAMAGE THE RECIPROCATING MECHANISM.
Impact Protection System
This model is equipped with a unique patented gearing system that provides effi cient
power transmission and extended life in the
most diffi cult cutting applications. This du-
rable system will absorb impacts, blade lock
ups, and motor stalls. This model 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.
Fig. 3
Stroke
OPERATION
WARNING
To reduce the risk of injury, keep
hands away from the blade and
other moving parts. Always wear
safety goggles or glasses with side
shields.
Starting, Stopping and Controlling Speed
1. To start the tool, grasp the handle fi rmly
and pull the trigger.
2. To stop the tool, release the trigger . Al-
low the tool to come to a complete stop
before removing the blade from a partial
cut or laying the tool down.
Trigger Speed Control Switch
TM
The Sawzall
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.
Locking the Trigger
To lock the trigger, slide the trigger lock
switch until the "locked" symbol is visible. The
trigger will not work while the switch is in the
locked position. Always lock the trigger and
remove the battery pack before performing
maintenance and changing accessories.
Lock the trigger when storing the tool and
when the tool is not in use.
Fig. 4
Trigger Lock
Switch
is equipped with a trigger
Locked
Symbols
Unlocked
6 7
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 fi rmly and pull the trig-
ger. Then guide the tool along your cutting
line. Always hold the shoe fl at 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.
Plunge Cutting
®
Your MILWAUKEE Sawzall
plunge cutting directly into surfaces that can
not be cut from an edge, such as walls or
fl oors. 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 downward. (When
attempting to plunge cut in this manner, shoe
must be moved all the way out, as shown.)
Column B shows how to plunge cut with the
teeth of the blade facing upward. Do not
plunge cut into metal surfaces (see "Cutting
Metals").
Fig. 5
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.
1. Insert the blade into the tool.
With the teeth facing downward, hold the
tool as shown in Column A, resting the
edge of the shoe on the workpiece.
With the teeth facing upward, hold the
tool as shown in Column B, resting the
edge of the shoe on the workpiece.
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 the cutting line for
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.
BA
MAINTENANCE
WARNING
To reduce the risk of 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.
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
• Mechanical inspection and cleaning
(gears, spindles, bearings, housing,
etc.)
• Electrical inspection (battery pack,
charger, motor)
• T esting to assure proper mechanical and
electrical operation
Maintaining Tool
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.
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.
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.
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.
ACCESSORIES
WARNING
8 9
Always remove battery pack before
changing or removing accessories.
Only use accessories specifi cally
recommended for this tool. 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 listed on the back cover of this
operator’s manual.
See Pages 30 & 31
Sawzall® Blades.
for a listing of Super
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 a electric power tool which, after examina-
tion, 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, are requested for this warranty to be
effective. 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), all Ni-CD battery
packs, Work Lights (cordless fl ashlights), Job Site Radios, and Trade Titan™ Industrial W ork
Carts is one (1) year from the date of purchase. *The warranty period for Li-Ion battery packs
that do not contain V™-technology – 4.0 volts through 18.0 volts - is two (2) years from the
date of purchase.
*There is a separate warranty for V™-technology Li-Ion Battery Packs V™18 volts and above
that accompany V™-technology cordless 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 PARTICULAR USE OR PURPOSE, AND ALL
OTHER WARRANTIES.
This warranty applies to product sold in the U.S.A., Canada and Mexico only.
10 11
RÈGLES GÉNÉRALES DE SÉCURITÉ POUR LES OUTILS
ALIMENTÉS PAR BATTERIE
AVERTISSEMENT
LIRE SOIGNEUSEMENT TOUTES LES INSTRUCTIONS
Le non respect des instructions ci-après peut entraîner des chocs électriques, des
incendies et/ou des blessures graves. Le terme «outil électrique» fi gurant dans les
avertissements ci-dessous renvoie à l’outil électrique à alimentation par le réseau
(à cordon) ou par batterie (sans fi l).
CONSERVER CES INSTRUCTIONS
SÉCURITÉ DU LIEU
DE TRAVAIL
1. Maintenir la zone de travail propre et bien
éclairée. Les zones encombrées ou mal
éclairées sont favorables aux accidents.
2. Ne pas utiliser d’outil électrique dans
une atmosphère explosive, telle
qu’en en présence de liquides, de
gaz ou de poussières infl ammables.
Les outils électriques génèrent des
étincelles qui peuvent enfl ammer les
poussières ou les fumées.
3. Tenir les enfants et les personnes
non autorisées à l’écart pendant le
fonctionnement d’un outil électrique.
Un manque d’attention de l’opérateur risque
de lui faire perdre le contrôle de l’outil.
SÉCURITÉ ÉLECTRIQUE
4. La fi che de l’outil électrique doit cor-
respondre à la prise d’alimentation.
Ne jamais modifier la fiche d’une
manière quelconque. Ne pas utiliser
d’adaptateur avec les outils électriques mis à la terre (à la masse).
Des fi ches non modifi ées et des prises
d’alimentation assorties réduisent le
risque de choc électrique.
5. Éviter tout contact corporel avec des
surfaces reliées à la masse ou à la
terre telles que tuyaux, radiateurs,
cuisinières et réfrigérateurs. Un risque
de choc électrique plus élevé existe si le
corps est relié à la masse ou à la terre.
6. Ne pas exposer les outils électriques
à la pluie ou à l’humidité. Le risque de
choc électrique augmente si de l’eau
s’infi ltre dans un outil électrique.
7. Prendre soin du cordon. Ne jamais
utiliser le cordon pour transporter,
tirer ou débrancher l’outil électrique.
Tenir le cordon à l’écart de la chaleur ,
des huiles, des arêtes coupantes ou
des pièces en mouvement. Un cordon
endommagé ou emmêlé présente un
risque accru de choc électrique.
8. Se procurer un cordon d’alimentation
approprié en cas d’utilisation
d’un outil électrique à l’extérieur.
L’utilisation d’un cordon d’alimentation
pour usage extérieur réduit le risque de
choc électrique.
SÉCURITÉ INDIVIDUELLE
9. Être sur ses gardes, être attentif et
faire preuve de bon sens en utilisant
un outil électrique. Ne pas utiliser
un outil électrique en cas de fatigue
ou sous l’influence de drogues,
d’alcool ou de médicaments. Un
instant d’inattention lors de l’utilisation
d’un outil électrique peut entraîner des
blessures graves.
10. Utiliser un équipement de sécurité.
Toujours porter des lunettes de protection. Un équipement de sécurité
comprenant masque anti-poussière,
chaussures de sécurité anti-dérapantes,
casque ou dispositif de protection antibruit peut, dans les circonstances appropriées, réduire le risque de blessure.
11. Éviter tout démarrage accidentel de
l’outil. S’assurer que le commutateur
est en position OFF (Arrêt) avant de
brancher l’outil. Le port de l’outil avec
un doigt sur le commutateur ou son
branchement avec le commutateur en
position ON (Marche) sont favorables
aux accidents.
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