8
9
Overload Protector
The overload protector automatically turns off
the tool when the motor is overloaded. The tool
can become overloaded when using a dull blade,
cutting material that is too thick, cutting materials
too quickly, or cutting hard metals such as stain-
less steel. To prevent the overload protector from
activating, always use a sharp blade and follow
the cutting instructions under the "Applications"
section. Do not attempt to defeat or override the
overload protector.
If the tool turns off automatically:
1. Release the trigger and unplug the tool.
2. Remove the blade from the workpiece.
APPLICATIONS
This tool is intended for cutting unhardened fer-
rous metal and non-ferrous metal. Refer to the
“Accessories” section for a list of blades to be
used for the proper applications of this tool. The
following precautions must be followed to reduce
the risk of injury:
• Do not cut stacked materials. Cut one piece at a time.
• Do not cut hardened steel.
• Cut materials with the wider edge of the shoe over
the clamped side of the material.
• Do not touch the blade, workpiece, chips, or chip
container with bare hands immediately after cut-
ting; they may be hot and could burn skin.
5.
Cool Down Period
(6 minutes running with no
load or 60 min. switched off.)
Cutting Materials Thicker than 1/4"
(3/4" Maximum Thickness)
CAUTION!
To reduce the risk of dam-
age to the tool or blade, do not exceed the
Feed Rate and Maximum Cut Time for materi-
als thicker than 1/4", as charted below.
Between Maximum Cut Times, allow the tool
to cool down for 6 minutes of running with no
load or 60 minutes switched off.
Cutting too fast or too long in heavy material
will damage the tool if the tool is not allowed
to cool.
Cutting too slow will cause excessive wear
on the blade.
Material
Thickness
Max
Cutting Time
(Seconds)
Max
Length
of Cut
Feed Rate
(sec./inch)
3/8"
30 - 45
15"
2 - 3
1/2"
18 - 36
9"
2 - 4
5/8"
18 - 30
6"
3 - 5
3/4"
20 - 25
5"
4 - 5
Cool Down
Period
6 min. of running with no load
or 60 min. switched off
3. Allow the tool to rest for a miniumum of two
minutes.
4. Reset the overload protector by pushing in the
button.
Note: If the tool does not start after pushing the
button, allow the tool to cool for a few minutes
and try again.
5. Allow the tool to run under no load to ensure the
tool has properly cooled.
6. Resume the cut. When restarting a saw in the
workpiece, 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.
When cutting materials over 1/4", certain guide-
lines must be followed to avoid serious damage to
the tool and/or blade. The correct combination of
the following factors will allow for a sucessful cut
through thicker materials:
1.
Material Thickness
(do not cut materials thicker
than 3/4")
NOTE:
If the material thickness is not shown
in the chart below, round up to the nearest
thickness listed in the chart and follow those
guidelines.
2.
Maximum Length of Cut
(the length of material
in inches through which the saw moves between
cool down periods)
3.
Feed Rate
(the speed at which the saw moves
through the material in seconds per inch)
4.
Maximum Cutting Time
(the total amount of
time that the saw can be under load between
cool down periods.
Cutting Thin or Corrugated Materials
Cut thin and corrugated materials at least 1" from
the edge of the workpiece to avoid injury or dam-
age to the tool caused by thin strips of metal being
pulled into the upper guard.
Cutting Large Sheets
Large sheets 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 sheets. Be sure to set the depth of
the cut so that you only cut through the workpiece,
not through the supports.
When cutting widths greater than 4", clamp 1"
lumber to workpiece and use the inside edge of
the shoe as a guide.
Pocket Cutting
Pocket cuts are made in the middle of the workpiece
when it can not be cut from an edge. We recom-
mend 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.
WARNING
To reduce the risk of electric
shock, check work area for hidden pipes and
wires before making pocket cuts.
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
To reduce the risk of injury,
always unplug the tool before attaching or
removing accessories. Use only specifi cally
recommended accessories. Others may be
hazardous.
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, bro-
ken 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 neces-
sary 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, spin-
dles, bearings, housing, etc.)
• Electrical inspection (switch, cord, armature, etc.)
• Testing to assure proper mechanical and electrical
operation
WARNING
To 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.
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.
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.
2. Pull the trigger and allow the motor to reach full
speed before beginning cut. Using the front of the
shoe as a hinge point, gradually lower the back
end of the saw into the workpiece. Release the
lower guard lever.
3. When the shoe rests fl at against workpiece,
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
®
reciprocating saw, jig saw or
small hand saw to fi nish the corners if they are
not completely cut through.
Troubleshooting
If the blade does not follow a straight line:
• Teeth are dull. This is caused by hitting a hard
object, 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
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
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.
Fig.4
