Milwaukee SAWZALL 6509-31, SAWZALL 6519-30 Operator's Manual
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
SAWZALL® RECIPROCATING SAW
PASSE-PARTOUT SAWZALL
®
SIERRAS SABLE SAWZALL
®
Cat. No.
No de Cat.
6509-31
6519-30
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.
2
3
• Hold power tools by insulated gripping sur-
faces 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.
• 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.
• Keep hands away from all cutting edges and
moving parts.
• Maintain labels and nameplates. These carry
important information. If unreadable or missing,
contact a MILWAUKEE service facility for a free
replacement.
• 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.
Specifi cations
Cat. No.
Volts
AC
Amps
No Load
RPM
Stroke
Length
6509-31
6519-30
120
120
12120 - 3 000
0 - 3 000
3/4”
1-1/8”
PERSONAL SAFETY
GENERAL POWER TOOL SAFETY WARNINGS
WORK AREA SAFETY
ELECTRICAL SAFETY
• Keep work area clean and well lit. Cluttered or
dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the presence of fl ammable
liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
• Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
• 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.
• 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.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase
the risk of electric shock.
• 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.
• When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use
of a cord suitable for outdoor use reduces the risk
of electric shock.
• If operating a power tool in a damp location
is unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD reduces
the risk of electric shock.
up or carrying the tool. Carrying power tools with
your fi nger on the switch or energising power tools
that have the switch on invites accidents.
• 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.
• Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from moving parts. Loose clothes, jewel-
lery or long hair can be caught in moving parts.
WARNING READ ALL SAFETY WARNINGS AND INSTRUCTIONS.
Failure to follow the warnings and instructions may result in electric shock, fi re and/or
serious injury. Save all warnings and instructions for future reference. The term
"power tool" in the warnings refers to your mains-operated (corded) power tool or batteryoperated (cordless) power tool.
POWER TOOL USE AND CARE
• If devices are provided for the connection of
dust extraction and collection facilities, ensure
these are connected and properly used. Use of
dust collection can reduce dust-related hazards.
• 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.
• 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.
• 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 measures reduce the risk of
starting the power tool accidentally.
• Store idle power tools out of the reach of children and do not allow persons unfamiliar with
the power tool or these instructions to operate
the power tool. Power tools are dangerous in the
hands of untrained users.
• 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.
• Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
• Use the power tool, accessories and tool bits
etc., in accordance with these instructions,
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.
• 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 infl uence of drugs, alcohol or
medication. A moment of inattention while oper-
ating power tools may result in serious personal
injury.
• Use personal protective equipment. Always
wear eye protection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions
will reduce personal injuries.
• Prevent unintentional starting. Ensure the
switch is in the off-position before connecting
to power source and/or battery pack, picking
SPECIFIC SAFETY RULES
BATTER Y T OOL USE AND CARE
SERVICE
• 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.
• Recharge only with the charger specifi 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.
• Use power tools only with specifi cally desig-
nated battery packs. Use of any other battery
packs may create a risk of injury and fi re.
• 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 termi-
nals together may cause burns or a fi re.
• Under abusive conditions, liquid may be ejected from the battery, avoid contact. If contact
accidentally occurs, fl ush with water. If liquid
contacts eyes, additionally seek medical help.
Liquid ejected from the battery may cause irritation
or burns.
Grounded Tools: Tools with Three Prong Plugs
Tools marked “Grounding Required” have a three
wire cord and three prong grounding plug. The
plug must be connected to a properly grounded
outlet (See Figure A). If the tool should electrically
malfunction or break down, grounding provides a
low resistance path to carry electricity away from
the user, reducing the risk of electric shock.
The grounding prong in the plug is connected
through the green wire inside the cord to the
grounding system in the tool. The green wire in the
cord must be the only wire connected to the tool's
grounding system and must never be attached to
an electrically “live” terminal.
Your tool must be plugged into an appropriate
outlet, properly installed and grounded
in accordance with all codes and ordinances. The plug and outlet should
look like those in Figure A.
Double Insulated Tools:
Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require
grounding. They have a special double insulation system which satisfi es 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.
GROUNDING
WARNING Improperly connecting the
grounding wire can result in the risk of electric shock. Check with a qualifi ed electrician
if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug
provided with the tool. Never remove the
grounding prong from the plug. Do not use
the tool if the cord or plug is damaged. If
damaged, have it repaired by a MILWAUKEE
service facility before use. If the plug will not
fi t the outlet, have a proper outlet installed by
a qualifi ed electrician.
Fig. A
Fig. B
Fig. C
4
5
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.
READ AND SAVE ALL
INSTRUCTIONS FOR FUTURE USE.
Recommended Minimum Wire Gauge
for Extension Cords*
Extension Cord Length
* Based on limiting the line voltage drop to
fi ve volts at 150% of the rated amperes.
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
25'
18
18
18
18
16
14
12
75'
18
18
16
14
12
10
100'
18
16
14
12
10
150'
16
14
12
12
50'
18
18
18
16
14
12
10
EXTENSION CORDS
ASSEMBLY
WARNING To reduce the risk of
injury, always unplug tool before attaching or removing accessories or making adjustments. Use only specifi cally recommended
accessories. Others may be hazardous.
Blade
Collar
Fig. 1
Selecting a Blade
Use MILWAUKEE Sawzall
®
Blades for best performance. When selecting a blade, choose the right
type and length.
Many types of blades are available for a variety of applications: cutting metal, wood, nailembedded 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.
Installing and Removing Blades
Quik-Lok® Blade Clamp
1. Unplug the tool.
2. Be sure the spindle and blade clamp areas are
clean. Metal chips and sawdust may prevent the
Quik-Lok® Blade Clamp from clamping securely
(see "Maintenance").
3. To install a blade, twist the collar in the direction
of the arrow while inserting the blade into the
clamp until the tang butts against the collar.
Removing Broken Blades from the Quik-Lok®
Blade Clamp
1. Unplug the tool.
2. 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 on the
tool 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. 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.
Blade Clamp (Accessory 49-22-5016)
1. Unplug the tool before changing blades.
2. Be sure the spindle and blade clamp area are
clean. Metal chips and sawdust may prevent the
blade clamp screw from clamping securely.
3. To install a blade, loosen the blade clamp screw,
turning it counterclockwise. Insert the blade until
the tang butts against the spindle.
NOTE: The blade must be inserted all the way
into the spindle so that the tang on the blade
seats fi rmly in the blade clamp.
Depending on the job, the blade may be inserted
with the teeth facing upward or downward.
4. Insert the hex key into the blade clamp screw,
turning it clockwise. Tighten securely.
5. To remove a blade, insert hex key into the blade
clamp screw and turn it counterclockwise 1 full
turn. Then slide the blade out of the spindle. Be
careful when handling hot blades.
FUNCTIONAL DESCRIPTION
Cord1.
Handle2.
Trigger3.
Quik-Lok4.
®
blade clamp
Blade5.
Pivot shoe6.
Insulating boot7.
7
2
1
5
4
3
6
Double Insulated
Volts Alternating Current
Amps
No Load Strokes per Minute
(SPM)
Underwriters Laboratories, Inc.,
United States and Canada
SYMBOLOGY
Stroke
WARNING Do not operate Sawzall
without a shoe. Striking the spindle
against the work may damage the reciprocating mechanism.
WARNING T o 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
Depending on the job, the blade may be inserted
with the teeth facing upward or downward.
4. Release the collar and the spring loaded mechanism will clamp the blade fi rmly in place.
5. Twist the collar in the opposite direction of the
arrow to ensure that the blade is locked into the
clamp.
6. Tug on blade to make sure it is securely locked
in place.
7. To remove a blade, twist the collar in the direc-
tion of the arrow while pulling on the blade. Be
careful when handling hot blades.
6
7
Impact Protection System
Select models are equipped with a unique patented
gearing system that provides effi cient power trans-
mission and extended life in the most diffi cult cut-
ting applications. This durable system will absorb
impacts, blade lock ups, and motor stalls. These
models can be used for extreme cutting applications such as large diameter pipe, thick metal,
pallets, and heavy demolition and renovation work
as well as for general purpose cutting.
Starting, Stopping and Controlling Speed
To start the tool, grasp the handle fi rmly and pull
the trigger.
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.
Trigger Speed Control Switch
MILWAUKEE 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. T o 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 fi rmly
and pull the trigger. 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. Extend blade life by using a solid blade
cutting lubricant such as MILWAUKEE Band Saw
Blade Lubricant Cat. No. 49-08-4206.
OPERATION
WARNING To reduce the risk of injury,
wear safety goggles or glasses with side
shields.
WARNING To reduce the risk of injury,
always unplug tool before attaching
or removing accessories or making adjustments. Use only specifi cally recommended
accessories. Others may be hazardous.
WARNING To reduce the risk of explo-
sion, 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. 3
AB
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. T ag damaged tools “DO NOT USE”
until repaired (see “Repairs”).
Under normal conditions, relubrication is not necessary until the motor brushes need to be replaced.
After six months to one year, depending on use,
return your tool to the nearest MILWAUKEE service
facility for the following:
• Lubrication
• Brush inspection and replacement
• Mechanical inspection and cleaning (gears,
spindles, bearings, housing, etc.)
• Electrical inspection (switch, cord, armature, etc.)
• T esting to assure proper mechanical and electrical operation
MAINTENANCE
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 fl ammable or combustible
solvents around tools.
Repairs
If your tool is damaged, return the entire tool to the
nearest service center.
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.
WARNING T o reduce the risk of injury ,
electric shock and damage to the tool, never
immerse your tool in liquid or allow a liquid
to fl ow inside the tool.
ACCESSORIES
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.
WARNING T o reduce the risk of injury ,
always unplug the tool before attaching or
removing accessories. Use only specifi cally
recommended accessories. Others may be
hazardous.
Plunge Cutting
Your MILWAUKEE Sawzall® is ideal for 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 down. Column B shows
how to plunge cut with the teeth of the blade facing up. Do not plunge cut into metal surfaces (see
“Cutting Metals”).
1. Insert the blade into the tool.
If you inserted the blade with the teeth facing
downward, hold the tool as shown in Column A,
resting the edge of the shoe on the workpiece.
If you inserted the blade with the teeth facing
upward, hold the tool as shown in Column B,
resting the edge of the shoe on the workpiece.
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 fi rmly 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.
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