Milwaukee Tool 6538-21 - Manual (Page 4)

6 7
WARNING To reduce the risk of injury, be
sure the blade always extends beyond the shoe
and work throughout the stroke. Blades may
shatter if they impact the work or shoe (Fig. 4).
Fig. 4
Stroke
Impact Protection System
All models are equipped with a unique patented
gearing system that provides effi cient power trans-
mission and extended life in the most diffi cult cutting
applications. This durable system will absorb im-
pacts, blade lock ups, and motor stalls. These mod-
els 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.
Rotating the Handle (Cat. No. 6523-21)
The 6523-21 Orbital Sawzall
® handle can rotate
continuously in either direction, allowing the user to
achieve optimal cutting positions and comfort. The
handle can be locked into one of eight (8) detent
positions, one at every 45° angle.
To rotate the handle:
1. Unplug the tool.
2. Press in the handle rotation button.
3. Rotate the handle to the desired position.
4. Release the handle rotation button. This will lock
the handle fi rmly into position.
NOTE: Make sure the handle does not rotate
before using the tool.
Fig. 5
Handle
rotation
button
WARNING Do not operate the Sawzall
with the handle rotation button pressed in
or with the handle not locked into position.
WARNING If the handle can not be locked
into position, do not operate the Sawzall ® . Re-
turn the Sawzall ® to a Milwaukee service facility
immediately for repair.
1. For straight reciprocating
action, move the orbit con-
trol switch to the straight cut
symbol (1).
2. For orbital action, move the orbit
control switch towards the
orbital cut symbol (2).
The amount of orbital action may
be adjusted by moving the orbital
control switch to any position
between the two symbols. For
larger orbital action, move the
orbit control switch closer to
the orbital cut symbol (2). For
smaller orbital action, move the
orbit control switch closer to the
straight cut symbol (1).
Orbital action may be adjusted
when the tool is running.
NOTE: Orbital action will not
operate if the blade is installed upside down.
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. Allow the tool
to come to a complete stop before removing the
blade from a partial cut or laying the tool down.
Orbit Control Switch
The Orbital Sawzall
® is equipped with an orbit con-
trol switch. The tool may be operated with straight
reciprocating (non orbital) or orbital action. Straight
reciprocating action should be used when a smooth
cut is needed. Orbital action is recommended for
fast, aggressive cutting. The optimal orbital action
should be determined by the user for their specifi c
cutting requirements.
Selecting the Speed Range
The speed control dial controls the maximum
strokes per minute. The speed will remain vari-
able to the chosen dial setting by use of the trigger
switch. Refer to the chart for recommended dial
settings.
* These are only suggested settings; the actual optimal set-
ting may vary depending on line voltage, blade selected
and user preference.
MATERIAL SUGGESTED DIAL
Mild Steel
Wood
Nail-Embedded Wood
Stainless Steel
Drywall
Fiberglass
Plastics
Cast Iron
Non-Ferrous Metals
2-3
5
5
1-3
4-5
1-3
1-3
2-3
2-3
WARNING To reduce the risk of
personal injury, always hold tool securely.
Fig. 6
2
1
Trigger Speed Control Switch
These 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 pres-
sure on the trigger. The further the trigger is pulled,
the greater the speed. To stop the tool, release
the trigger and allow the tool to stop completely
before removing from a partial cut or before laying
the tool down.
General Cutting
For straight or contour cutting from an edge, line
the blade up with your cutting line. Before the blade
contacts the workpiece, grasp the handle 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 increas-
ing speed as you cut. When cutting into metals or
hard materials that can not be cut from an edge,
drill a starting hole larger than the widest part of
the blade. Extend blade life by using a solid blade
cutting lubricant.
Plunge Cutting
Your MILWAUKEE Sawzall
® is ideal for plunge cut-
ting directly into surfaces that can not be cut from
an edge, such as walls or fl oors. Orbital action is
recommended for plunge cutting. Plunge cutting
may be done two ways depending on how the
blade is inserted. Column A shows how to plunge
cut with the teeth of the blade facing down. Column
B shows how to plunge cut with the teeth of the
blade facing up.
NOTE: Orbital action will not operate if the blade
is installed upside down.
Do not plunge cut into metal surfaces (see “Cut-
ting 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
as shown.
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.
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.
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.
Cat. No. 6520-21, 6536-21,
and 6538-21
Fig. 8
Cat. No. 6523-21 Fig. 7
A B