milwaukee 6509-31 Sawzall Reciprocating Saw User Manual

milwaukee 6509-31 Sawzall Reciprocating Saw User Manual

WARNING To reduce the risk of injury, user must read and understand operator’s manual.

GENERAL POWER TOOL SAFETY WARNINGS

Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire 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 battery-operated (cordless) power tool.

WORK AREA SAFETY

• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• Do not operate power tools in explosive atmo- spheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
• Keep children and bystanders away while operat- ing a power tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

• 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. Unmodified 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 condi- tions. 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 ground fault circuit interrupter (GFCI) protected supply. Use of an GFCI reduces the risk of electric shock.

PERSONAL SAFETY

• 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 influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective equipment such as a 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 up or carrying the tool. Carrying power tools with your finger on the switch or energizing 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 jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
• 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 let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

POWER TOOL USE AND CARE

• 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 remove the battery pack, if detachable, 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 and accessories. 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.
• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

SERVICE

Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

SPECIFIC SAFETY RULES FOR SAWZALL RECIPROCATING SAW

• Hold power tools by insulated gripping surfaces when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a ″live″ wire may make exposed metal parts of the power tool ″live″ and could give the operator an electric shock.
• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the workpiece 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.
• To reduce the risk of injury, when working in dusty situations, wear appropriate respiratory protection or use an OSHA compliant dust extraction solution.
• Always use common sense and be cautious when using tools. It is not possible to anticipate every situation that could result in a dangerous outcome. Do not use this tool if you do not understand these operating instructions or you feel the work is beyond your capability; contact Milwaukee Tool or a trained professional for additional information or training.
• Maintain labels and nameplates. These carry important information. If unreadable or missing, contact a MILWAUKEE service facility for a free replacement.
• 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 specially designed to filter out microscopic particles.

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 suffix “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 qualified person before using it.
• Protect your extension cords from sharp objects, excessive heat and damp or wet areas.

**Recommended Minimum Wire Gauge
For Extension Cords***

• Based on limiting the line voltage drop to five volts at 150% of the rated amperes.

READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE

GROUNDING

Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualified 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 fit the outlet, have a proper outlet installed by a qualified electrician.

Grounded Tools (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 mal- function 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 approFig. A priate 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 (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 Fig. B Fig. C 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.

SYMBOLOGY

Double Insulated

Volts

Alternating Current

Amps

No Load Strokes per Minute (SPM)

Read Operator’s Manual

UL Listing for Canada and U.S

SPECIFICATIONS

• Cat. No……………………………………………… 6509-31
• Volts…………………………………………………….120 AC
• Amps ………………………………………………………….12
• No Load RPM…………………………………….. 0 – 3000
• Stroke Length …………………………………………… 3/4″
• Cat. No……………………………………………… 6519-30
• Volts…………………………………………………….120 AC
• Amps ………………………………………………………….12
• No Load RPM…………………………………….. 0 – 3000
• Stroke Length …………………………………………1-1/8″

FUNCTIONAL DESCRIPTION

1. Cord
2. Handle
3. Trigger
4. Quik-Lok® blade clamp
5. Blade
6. Pivot shoe
7. Insulating boot

ASSEMBLY

To reduce the risk of injury, always unplug tool before changing or removing accessories. Only use accessories specifically recommended for this tool. Others may be hazardous.

Selecting a Blade Use MILWAUKEE Sawzall® Blades for best perfor- mance. When selecting a blade, choose the right type and length.

Many types of blades are available for a vari- ety 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.
   
   Depending on the job, the blade may be inserted with the teeth facing upward or downward.

4. Release the collar and the spring loaded mecha- nism will clamp the blade firmly 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 direction of the arrow while pulling on the blade. Be careful when handling hot blades.

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 fingers 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 firmly 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

Do not operate Sawzall without a shoe. Striking the spindle against the work may damage the reciprocating mechanism.

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.

OPERATION

To reduce the risk of injury, always wear proper eye protection marked to comply with ANSI Z87.1.

When working in dusty situations, wear appro- priate respiratory protection or use an OSHA compliant dust extraction solution.

Always unplug tool before attaching or removing accessories or making adjustments. Use only specifically recommended accessories. Others may be hazardous.

Impact Protection System
Select models are equipped with a unique pat- ented gearing system that provides efficient power transmission and extended life in the most difficult cutting 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 firmly 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. Al- ways 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, re- lease 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 firmly and pull the trigger. Then guide the tool along your cutting line. Always hold the shoe flat 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.

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 floors. 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 “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 up- ward, 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 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.

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

MAINTENANCE

To reduce the risk of injury, always unplug the tool before performing any maintenance. Never disassemble the tool. Contact a MILWAUKEE service facility for ALL repairs.

Maintaining Tools

Keep your tool in good repair by adopting a regular maintenance program. Inspect your tool for issues such as undue noise, misalignment or binding of moving parts, breakage of parts, or any other condi- tion that may affect the tool operation. Return the tool to a MILWAUKEE service facility for repair. After six months to one year, depending on use, return the tool to a MILWAUKEE service facility for inspection.

To reduce the risk of personal injury, electric shock and damage, never immerse your tool in liquid or allow a liquid to flow inside it.

Cleaning
Clean dust and debris from any vents. Keep tool clean, dry and free of oil or grease. Use only mild soap and a damp cloth to clean, since certain clean- ing 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 deter- gents containing ammonia. Never use flammable or combustible solvents around tools.

Repairs
For repairs, return the tool to the nearest authorized service center.

ACCESSORIES

Use only recommended accessories. Others may be hazardous.
For a complete listing of accessories, go online to www.milwaukeetool.com or contact a distributor.

SERVICE – UNITED STATES

1-800-SAWDUST (1.800.729.3878)
Monday-Friday, 7:00 AM – 6:30 PM CST or visit www.milwaukeetool.com

Contact Corporate After Sales Service Technical Support with technical, service/repair, or warranty questions.

Email : metproductsupport@milwaukeetool.com

Become a Heavy Duty Club Member at www.milwaukeetool.com to receive important notifications regarding your tool purchases.

SERVICE – CANADA
Milwaukee Tool (Canada) Ltd
1.877.948.2360
Monday-Friday, 7:00 AM – 4:30 PM CST
or visit www.milwaukeetool.ca

References

• Milwaukee® Tool Official Site | Nothing but HEAVY DUTY® | Milwaukee Tool
• Milwaukee® Tool Official Site | Nothing but HEAVY DUTY® | Milwaukee Tool

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