OPERATOR'S MANUAL MANUEL de L'UTILISATEUR MANUAL del OPERADOR

Cat. No. No de cat. 6480-20

HEAVY-DUTY 8" PANEL SAW SCIE À PANNEAU INDUSTRIELLE DE 203 mm (8") SIERRA PARA TABLEROS DE 203 mm (8") PARA SERVICIO PESADO

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. 14. Dress properly. Do not wear loose 24. Use the right tool. Do not use a tool or GENERAL SAFETY RULES clothing or jewelry. Contain long attachment to do a job for which it is not hair. Keep your hair, clothing, and recommended. For example, do not use gloves away from moving parts. a circular saw to cut tree limbs or logs. WARNING Loose clothes, jewelry, or long hair can Do not alter a tool. be caught in moving parts. When work- 25. Disconnect the plug from the power ing outdoors, wear rubber gloves and READ ALL INSTRUCTIONS source before making any adjust- insulated non-skid footwear. Keep hands ments, changing accessories, or stor- Failure to follow all instructions listed below, may result in electric shock, fi re and gloves away from moving parts. and/or serious personal injury. ing the tool. Such preventive safety mea- 15. Avoid accidental starting. Be sure sures reduce the risk of starting the tool SAVE THESE INSTRUCTIONS switch is off before plugging in. Do accidentally. not use a tool if the power switch does 26. Store idle tools out of reach of not turn the tool on and off. Do not carry WORK AREA SAFETY not fi t, contact a qualifi ed electrician children and other untrained to install a polarized outlet. Do not a plugged-in tool with your fi nger on the persons. Tools are dangerous in the change the plug in any way. Double switch. 1. Keep your work area clean and well hands of untrained users. insulation eliminates the need for lit. Cluttered benches and dark areas 16. Remove adjusting keys or wrenches the three wire grounded power cord and 27. Never leave the tool running unat- invite accidents. before turning on the tool. A wrench tended. Turn power off. Do not leave the grounded power supply system. or a key that is left attached to a rotating 2. Do not operate power tools in ex- tool until it comes to a complete stop. 8. Guard against electric shock. Prevent part of the tool may result in personal plosive atmospheres, such as in body contact with grounded surfaces injury. 28. Check for misalignment or binding the presence of fl ammable liquids, such as pipes, radiators, ranges and re- of moving parts, breakage of parts, gases, or dust. Power tools create 17. Do not overreach. Keep proper footing frigerators. When making blind or plunge and any other condition that may af- sparks which may ignite the dust or and balance at all times. Proper footing cuts, always check the work area for fect the tool’s operation. If damaged, fumes. and balance enables better control of the have the tool serviced before using. hidden wires or pipes. Hold your tool by tool in unexpected situations. 3. Keep bystanders, children, and insulated nonmetal grasping surfaces. Many accidents are caused by poorly visitors away while operating a power Use a Ground Fault Circuit Interrupter 18. Use safety equipment. Everyone maintained tools. tool. Distractions can cause you to lose (GFCI) to reduce shock hazards. in the work area should wear safety 29. Use only accessories that are rec- control. Protect others in the work area goggles or glasses with side shields 9. Do not expose power tools to rain or ommended by the manufacturer for from debris such as chips and sparks. complying with current safety standards. wet conditions. Water entering a power your model. Accessories that may be Provide barriers or shields as needed. Everyday eyeglasses only have impact tool will increase the risk of electric suitable for one tool, may become haz- resistant lenses. They are not safety ardous when used on another tool. 4. Protect others in the work area from shock. glasses. Wear hearing protection dur- debris such as chips and sparks. Pro- 10. Do not abuse the cord. Never use ing extended use and a dust mask 30. Maintain tools with care. Keep cut- vide barriers or shields as needed. the cord to carry the tools or pull the for dusty operations. Hard hats, face ting tools sharp and clean. Properly 5. Make workshop child proof with pad- plug from an outlet. Keep cord away shields, safety shoes, etc., should be maintained tools with sharp cutting edge locks, master switches, or by removing from heat, oil, sharp edges or mov- used when specifi ed or necessary. Keep are less likely to bind and are easier to starter keys. ing parts. Replace damaged cords a fi re extinguisher nearby. control. Do not use a damaged tool. immediately. Damaged cords increase Tag damaged tools “Do not use” until 19. Keep guards in place and in working repaired. ELECTRICAL SAFETY the risk of electric shock. order. 11. When operating a power tool out- 20. Never stand on tool. Serious injury SERVICE 6. Grounded tools must be plugged side, use an outdoor extension cord could occur if the tool is tipped or if into an outlet properly installed and marked “W-A” or “W”. These cords the cutting tool is unintentionally con- grounded in accordance with all 31. Tool service must be performed are rated for outdoor use and reduce tacted. only by qualifi ed repair personnel. codes and ordinances. Never remove the risk of electric shock. the grounding prong or modify the 21. Keep hands away from all cutting Service or maintenance performed by plug in any way. Do not use any PERSONAL SAFETY edges and moving parts. unqualifi ed personnel could result in a risk of injury. adaptor plugs. Check with a quali- 22. Use clamps or other practical way to fi ed electrician if you are in doubt 12. Know your power tool. Read this secure and support the workpiece to 32. When servicing a tool, use only iden- as to whether the outlet is properly manual carefully to learn your power a stable platform. Holding the work by tical replacement parts. Follow in- grounded. If the tools should electrically tool's applications and limitations as well hand or against your body is unstable structions in the Maintenance section malfunction or break down, grounding as potential hazards associated with this and may lead to loss of control. of this manual. Use of unauthorized provides a low resistance path to carry type of tool. parts or failure to follow Maintenance electricity away from the user. Instructions may create a risk of electric 13. Stay alert, watch what you are doing, TOOL USE AND CARE shock or injury. 7. Double Insulated tools are equipped and use common sense when operat- with a polarized plug (one blade is ing a power tool. Do not use tool while 23. Do not force tool. Your tool will per- wider than the other). This plug will tired or under the infl uence of drugs, form best at the rate for which it was fi t in a polarized outlet only one way. alcohol, or medication. A moment of designed. Excessive force only causes If the plug does not fi t fully in the inattention while operating power tools operator fatigue, increased wear and outlet, reverse the plug. If it still does may result in serious personal injury. reduced control. 2 3 • Keep blade clean and sharp. Un- ers out of the kick back path. Repetitive SPECIFIC SAFETY RULES sharpened or improperly set blades cuts which lull the operator into careless produce narrow kerf causing excessive movements can also cause kick back. A 1. Maintain labels and nameplates. 8. Never cut a workpieces with a width friction, blade binding and KICKBACK. brief "stretch" may be all that is neces- These carry important information. smaller than that of the saw carriage. Any blade with a small set, even though sary to avoid a problem. If unreadable or missing, contact a Proper support for the workpiece must sharp, may be likely to kick back. A dull MILWAUKEE service facility for a free be maintained to insure safety. When • When blade is binding, or when inter- blade encourages the operator to force rupting a cut for any reason, turn the replacement. the carriage moves over the workpiece, the saw, causing reduced control and it would be impossible to safely support switch off and hold the saw motion- 2. WARNING! Some dust created by blade binding. The excessive friction less in the material until the blade power sanding, sawing, grinding, drill- the workpiece for the cut. Use a tool generated can cause the blade to warp better suited for these applications. comes to a complete stop. Never ing, and other construction activities or bind. Use only blades which are rec- attempt to remove the saw from the contains chemicals known to cause 9. Always wait for blade to stop com- ommended for use with your tool. Do not work or pull the saw backward while cancer, birth defects or other reproduc- pletely before changing positions. use blades with incorrect size or shaped the blade is in motion or KICKBACK tive harm. Some examples of these Unplug the tool before transporting or mounting holes. Never use defective may occur. Investigate and take cor- chemicals are: moving it. or incorrect blade washers or bolts. Be rective actions to eliminate the cause sure the blade bolt is tight. Select the • lead from lead-based paint 10. Do not place hands on or under saw of blade binding. proper blade for the application. Blade carriage or in the path of the blade. • crystalline silica from bricks and cement speed specifi cations must be at least as • To remove the blade after stopping Do not attempt to retrieve a piece of and other masonry products, and high as nameplate RPM. mid-cut, allow the blade to stop and material that is cut off while the blade is then back up the saw (cross-cutting) or • arsenic and chromium from chemically- rotating. • Do not force tool. Let the saw do the board (rip-cutting). treated lumber. work. A saw is more readily controlled 11. Make workshop child proof with pad- • When restarting a saw in the work- Your risk from these exposures varies, and will do a better job when used in the locks, master switches, or by removing piece, center the saw blade in the depending on how often you do this manner for which it was designed. starter keys. See "Lock-Off Feature". kerf and check that saw teeth are type of work. To reduce your exposure • Stay alert. Watch what you are doing not engaged into the material. If to these chemicals: work in a well ven- 12. Replace guards after blade change. and use common sense. Do not allow saw blade is binding, it may walk up or tilated area, and work with approved Maintain guards in working order. yourself to be distracted. Do not oper- KICKBACK from the workpiece as the safety equipment, such as those dust 13. Direction of feed. Feed work into a ate tool when tired, under the infl uence saw is restarted. masks that are specifi cally designed to blade or cutter against the direction of of drugs or alcohol. Hold the tool or fi lter out microscopic particles. rotation of the blade or cutter only. material fi rmly and exercise control at • Avoid cutting nails. Inspect for and remove all nails before cutting. 3. Handle the counterbalance with care. 14. Causes and Operator Prevention of all times. Position yourself and co-work- The cable is under tension. Always as- KICKBACK: semble cable to saw carriage before KICKBACK is a sudden reaction to Symbology removing cable clip. Do not pull on cable a pinched, bound or misaligned saw by hand or attempt to disassemble or blade, causing an uncontrolled saw to repair the counterbalance. No Load Revolutions lift up and out of the workpiece toward Double Insulated 4. Do not defeat the guards or operate the operator. per Minute (RPM) the tool without the guards in place. When the blade is pinched or bound Canadian Standards 5. Do not use push sticks. Push sticks or tightly by the kerf closing down, the Association Amperes the workpiece can kick back, cause the blade stalls and the motor reaction blade to pinch, or become caught in the drives the unit rapidly back toward the Underwriters Do not place hands on or under saw blade and be thrown from the tool. operator when cross-cutting and throws Laboratories, Inc. carriage or in the path of the blade. 6. Cross-cutting (vertical cutting) must out the workpiece if ripping. always be done from the top down. If the blade becomes twisted or mis- Volts Alternating Do not expose to rain or use in Saw carriage should be raised to the aligned in the cut, the teeth at the back Current damp locations. uppermost position on the guide tubes edge of the blade can dig into the top and locked into position with the carriage surface of the wood causing the blade lock whenever the tool is not in use. See to climb out of the kerf and jump back "Cross-Cutting". toward operator. Specifi cations 7. Ripping (horizontal cutting) must rip- KICKBACK is the result of tool mis- Capacity * ping must always be done by moving use and/or incorrect operating pro- Cat. Volts Blade the workpiece through the saw in the cedures or conditions and can be No. AC Amps Speed Size Arbor Thickness Height direction of the arrow on the saw mo- avoided by taking proper precautions as tor. Saw carriage should be raised to the given below: 6480-20 120 15 5800 8-1/4" 5/8" 1-3/4" 50" top of the guide tubes and locked into position with the carriage lock whenever * For additional limitations, see the "Rip Cutting" and "Cross-cutting" sections. tool is not in use. See "Rip Cutting".

4 5 FUNCTIONAL DESCRIPTION GROUNDING EXTENSION CORDS Grounded tools require a three wire extension 12 9 1 1. Handle WARNING cord. Double insulated tools can use either a two or three wire extension cord. As the 2. Switch distance from the supply outlet increases, Improperly connecting the grounding 3. Lock you must use a heavier gauge extension cord. wire can result in the risk of electric Using extension cords with inadequately sized 4. Hex wrench 2 shock. Check with a qualifi ed electri- wire causes a serious drop in voltage, result- 5. Saw motor cian if you are in doubt as to whether ing in loss of power and possible tool damage. the outlet is properly grounded. Do not 3 6. Carriage Refer to the table shown to determine the modify the plug provided with the tool. required minimum wire size. Never remove the grounding prong 4 7. Spindle lock from the plug. Do not use the tool if the The smaller the gauge number of the wire, 8. Chatter guard cord or plug is damaged. If damaged, the greater the capacity of the cord. For 5 (not shown) have it repaired by a MILWAUKEE ser- example, a 14 gauge cord can carry a higher vice facility before use. If the plug will current than a 16 gauge cord. When using 9. Torque knobs 6 not fi t the outlet, have a proper outlet more than one extension cord to make up 10. Blade guard installed by a qualifi ed electrician. the total length, be sure each cord contains at least the minimum wire size required. If Grounded Tools: you are using one extension cord for more 18 Tools with Three Prong Plugs than one tool, add the nameplate amperes 8 7 and use the sum to determine the required 11 10 9 Tools marked “Grounding Required” have a minimum wire size. three wire cord and three prong grounding 11. Carriage lock plug. The plug must be connected to a prop- Guidelines for Using Extension Cords 17 erly grounded outlet (See Figure A). If the tool 12. Indexing pins 19 • If you are using an extension cord out- should electrically malfunction or break down, doors, be sure it is marked with the suffi x grounding provides a 13. Counterbalance cable “W-A” (“W” in Canada) to indicate that it low resistance path to Fig. A is acceptable for outdoor use. 14. Guide tubes carry electricity away 15. Frame of tool from the user, reduc- • Be sure your extension cord is prop- ing the risk of electric erly wired and in good electrical 16. Rear guard shock. condition. Always replace a damaged 17. Cord keeper extension cord or have it repaired by a The grounding prong in the plug is connected qualifi ed person before using it. 18. Saw motor cord through the green wire inside the cord to the 16 • Protect your extension cords from sharp 19. Counterbalance grounding system in the tool. The green wire in the cord must be the only wire connected objects, excessive heat and damp or wet to the tool's grounding system and must never areas. be attached to an electrically “live” terminal. Your tool must be plugged into an appropri- Recommended Minimum Wire Gauge ate outlet, properly installed and grounded in for Extension Cords* accordance with all codes and ordinances. Extension Cord Length The plug and outlet should look like those Nameplate in Figure A. Amperes 25' 50' 75' 100' 150' 0 - 2.0 18 18 18 18 16 Double Insulated Tools: Tools with Two Prong Plugs 2.1 - 3.4 18 18 18 16 14 15 3.5 - 5.0 18 18 16 14 12 Tools marked “Double Insulated” do not 5.1 - 7.0 18 16 14 12 12 14 14 require grounding. They have a special double insulation system which satisfies 7.1 - 12.0 16 14 12 10 OSHA requirements and complies with the 12.1 - 16.0 14 12 10 applicable standards of Underwriters Labo- 16.1 - 20.0 12 10 ratories, Inc., the Cana- dian Standard Associa- * Based on limiting the line voltage drop to tion and the National fi ve volts at 150% of the rated amperes. Electrical Code. Double Insulated tools may be READ AND SAVE ALL used in either of the 120 INSTRUCTIONS FOR volt outlets shown in Fig. B Fig. C FUTURE USE. Figures B and C. 6 7 1. Remove the (2) 1/4 - 20 nuts, (2) wash- Mounting the Saw Motor TOOL ASSEMBLY ers and (2) 1/4"-20 x 5/8" carriage bolts Fig. 4 1. While having another person hold the from the counterbalance. Leave the nut WARNING stand in the upright position, stand and bolt on the counterbalance cable in behind the tool. Remove the locking place. pin from the folded locking pin position 2. Remove the end of the cable from the Bracket To reduce the risk of injury, always with one hand while holding the stand inside of the counterbalance. The coun- unplug tool before attaching or base with your other hand so it does not terbalance must be installed off-center Spacer removing accessories or making unfold onto your feet. to the right (while facing the saw from adjustments. Use only specifi cally Studs 2. Unfold the stand slowly until the hole in the front): holes are cut into the top of 7/16" Nut recommended accessories. Others Saw the sliding center bar is aligned with the the tool frame. and washer may be hazardous. carriage hole in the center bar. 3. Secure the counterbalance to the tool Bolt using (2) carriage bolts, (2) washers, Assembly Order 3. Insert the locking pin through the holes Bracket and lock it securely. and (2) nuts. To avoid injury or damage to the tool, follow NOTE: The carriage bolts are installed the order of sections in "Tool Assembly". from the bottom up. Tighten nuts se- Set up the tool in the following order of WARNING curely. sections: 4. Hold the saw carriage securely while 1. Setting up the Stand To reduce the risk of injury or loosening the carriage lock. 9/16" Nuts 2. Installing the Counterbalance damage to components, do not at- 5. Raise the saw carriage until the oval and washers tempt to disassemble or repair the 3. Mounting the Saw Motor hole in the saw carriage aligns with the counterbalance. Do not pull on the eye hole in the counterbalance cable, Fig. 5 4. Installing Blades counterbalance cable. The cable making sure the cable is behind the saw Leveling 5. Adjusting the Rulers is under strong spring force. Unit carriage. screw must be properly assembled before 6. Installing the Blade Guard removing cable clip. 6. Tighten the carriage lock. 7. Installing the Cord Keeper 7. Remove the nut from the carriage bolt and insert the bolt through the hole in Installing the Counterbalance the saw carriage and the eye hole in Setting up the Stand the counterbalance cable. Thread the Use at least two people to remove pack- Fig. 2 nut onto the bolt and tighten securely. aging and set up the stand. One person 8. Bend the cable clip tabs down by Counterbalance should hold the stand in an upright position hand. The motor is shipped with (3) washers, (3) while the other removes the packaging and nuts, (1) spacer, and (1) bolt. Remove these sets the folding stand to make the tool free- Nut 9. Loosen the carriage lock and lower the items to mount the saw. standing. Washer saw carriage until the cable clip is fully exposed. 1. Loosen the carriage lock and lower the saw carriage to a comfortable work Counterbalance 10. Tighten the carriage lock. Fig. 1 cable height. 11. Remove the cable clip from the counter- 2. Tighten the carriage lock securely. Folded locking balance cable and save it for future use pin position (i.e., If you remove the counterbalance 3. Mount the motor to the saw carriage by in the future, you will need the cable clip inserting the studs on the saw motor Sliding Carriage Cable through the holes in the saw carriage clip to support the tension in the counterbal- center bar bolt ance.) (Fig. 4). 4. Install washers and nuts. Hand-tighten Unfolded locking Fig. 3 only. pin position Counterbalance 5. Align the hole in the bracket that extends cable Locking pin from the saw handle with the hole on the Carriage saw carriage. bolt 6. Place the spacer between the bracket Center bar Cable clip tabs on the carriage and bracket on the saw handle. 7. Insert the bolt through the saw handle Nut bracket, through the spacer, and through Stand base the hole in the carriage bracket. 8. Thread a nut onto the bolt. Hand-tighten only. 8 9 9. Make sure the plate on the saw motor Adjusting the Rulers Installing the Cord Keeper is fl ush against the leveling screw to WARNING ensure the saw is square (Fig. 5). This Fig. 7 Fig. 9 screw is factory set and does not require adjustments. To reduce the risk of injury, do not operate the saw without the guards Cord Saw 10. Tighten the two NUTS ON STUDS in place. keeper end FIRST and tighten the NUT ON BOLT blade LAST. Installing the Blade Guard Guide tube

Installing Blades Square Fig. 8 Blade guard

Fig. 6 Inner fl ange Torque knob holes Blade Cross-cut Cross-cut ruler ruler Chatter Torque guard knob hole Fig. 10 Rubber The tool is equipped with a rip ruler and Torque stopper Outer two cross-cut rulers (one on each side of knobs Bolt fl ange Cord the tool). The rip ruler is adjusted at the keeper factory, but the two cross-cut rulers must be adjusted. The blade must be installed before setting the cross-cut rulers (see “Installing Taut cord Blades”). 1. Make sure the tool is unplugged. 2. Loosen the carriage lock and lower the WARNING saw carriage. 3. To align the cross-cut ruler, use a square Saw car- that measures at least 14" on one Torque knob riage To reduce the risk of injury, do not side. operate the saw without the guards Always install the blade guard before operat- 4. Line up one edge of the square with the ing the saw. The guard is shipped with the in place (see "Installing the Blade tips on the saw blade and the other edge Guard"). chatter guard pushed up inside the blade of the square with the ruler. guard and three torque knobs installed. The cord keeper keeps the cord away 5. Slide the ruler so its measure matches Reach up into the blade guard and pull down from the saw blade and away from your 1. Make sure the tool is unplugged. the measure on the square. A magnet the chatter guard. Remove the knobs to workpiece. 2. While holding in the spindle lock button, holds the ruler in place, but you may install the guard. Leave the rubber washers use the wrench provided with the tool to wrap clear tape around the ruler and on the torque knobs to prevent the knobs 1. Pinch the ends of the cord keeper to- turn the bolt on the saw motor spindle frame for additional hold. from slipping. gether while slowly sliding them into the guide tubes (Fig. 9). This will be a very counterclockwise. Remove the bolt. 6. Repeat the steps above to adjust the 1. Make sure the tool is unplugged. tight fi t. Seat the ends securely. 3. Remove the outer fl ange, but leave the cross-cut ruler on the other side of the 2. To attach the guard, line up the torque 2. Remove the rubber stopper from the ring inner fl ange on the spindle. tool. knob holes on the blade guard and the in the cord keeper (Fig. 10). 4. Install the blade with the arrow pointing NOTE: After the tool is completely as- saw carriage (Fig. 8). 3. Uncoil the cord and place the plug end counterclockwise (Fig. 6). sembled, make a sample cut to verify 3. Install the three torque knobs. that the ruler is adjusted correctly. through the ring. 5. Replace the outer fl ange. 4. Return carriage to the top of guide tubes 4. Loosen the carriage lock and lower the 6. Tighten the bolt clockwise while holding and tighten carriage lock. saw carriage to the bottom of the guide in the spindle lock button. 5. Reverse the procedure to remove the tubes. Tighten the carriage lock. 7. Adjust the rulers (see "Adjusting the blade guard. 5. Pull the cord keeper so it is parallel to the Rulers") and install the blade guard (see fl oor. Pull on the cord to remove slack in "Installing the Blade Guard"). the cord. 6. Open the rubber stopper and pull it over the cord with the small end of the taper toward the bottom. 7. From above the cord keeper, press the rubber stopper into the ring on the cord keeper with the small end facing down. 10 11 If the small end of the taper is on the Step 1 - Adjusting the Rollers If the saw does not cut at 90°, the guide Step 3 - Adjusting the Blade - Parallelism top, the stopper will not keep the cord 1. To check roller alignment, remove exten- tubes may not be perpendicular to the rollers. The blade should be parallel to the guide in place. sions (if present). Unplug the saw cord before testing alignment tubes, otherwise tail burning may occur and 8. Loosen the carriage lock and allow the 2. Retract the stand and lay the tool fl at or making adjustments. Check the alignment the kerf will be wider than the set of the blade. saw carriage to return to the top of the so the roller nuts are easily accessible. of the rollers before adjusting the guide tubes Make the following adjustments only if the guide tubes. Tighten the carriage lock. With proper care, you may place the tool (see "Adjusting the Rollers"). blade appears to be out of alignment. AL- NOTE: If you discover there is too much on a table with guide tubes up. 1. To check the guide tube alignment, WAYS check for alignment of the rollers and or not enough slack in the cord, readjust 3. The outermost rollers are stationary, remove the upper guard assembly to the guide tubes before adjusting the blade. as necessary. so adjust all other wheels to the two expose the blade. Mark a tooth to use as 1. To check for blade parallelism, position outermost rollers. Lay the straight edge a reference. If using a high-speed steel the saw carriage for a cross-cut and 9. Run the cord over the top of the panel of the fi eld alignment tool across the roll- blade, mark a tooth pointing toward the saw to get it out of the path of the saw. make a sample cut. If the blade "heels", ers to verify alignment; all rollers should edge of the fi eld alignment tool. burns marks on the cut, etc., check both You are now ready to use your panel saw. contact the edge. 2. Clamp the fi eld alignment tool to the sides of the cut to determine which side Refer to the "Operation" section for instruc- 4. If a roller is "high" or "low" to the straight roller assembly and pull the saw car- of the blade is causing the problem. tion on proper use. edge, clamp a straight edge at least 5' riage down slowly so the marked refer- 2. Unplug the tool. long to the top of the rollers so it lies fl at ence tooth just touches the vertical edge Panel Saw Alignment on the frame and against the outermost of the fi eld alignment tool. Continue to 3. Position the square on the rollers and rollers, positioning the clamps above the pull the saw carriage down. If the blade lower the saw carriage so the square The panel saw is aligned during manufactur- outermost roller. does not contact the square, or if the overhangs the blade. ing to a tolerance of ±1/32". Field alignment 5. With the straight edge clamped securely blade binds on the square, the guide is required only if the unit is mishandled or 4. Place the square against the blade. The in place, rotate each roller to be sure tubes are not aligned. abused, or if motor or wheel replacement entire face of the blade should contact that it neither jams nor has excessive is required. 3. To align the guide tubes, determine the square. If it does not, then the blade clearance to the straight edge. If a roller which direction the top of the guide is not parallel to the workpiece. Construct a fi eld alignment tool (Fig. 11): runs "tight" or "loose" to the straight should move. If the blade runs into For maximum accuracy, manufacture a test edge, loosen the roller nut. Roller nuts the square, the top guide goes to the Fig. 13 Index Pin Mounting nut square (Fig. 11) to check the full movement are torqued and require at least an 18" square. If the blade runs away from the Brackets of the saw. Construct the square using one braker bar to loosen them. square, the top guide goes away from 6' metal ruler and two 4' metal rulers. Using 6. The rollers are mounted on an eccentric the square. the 3'-4'-5' measurements assures square- hub. Turning a roller when the roller nut ness. Drill holes and attach the rulers with is loose will cause the roller to change Fig. 12 pop rivets or small nuts and bolts. Use the its position. You may have to lift the front 6' ruler to check squareness of the rollers roller carriage bar to rotate the eccentric Guide tube and the 4' ruler to check squareness of the hub. Turn the roller until it contacts the bracket nuts guide tubes. The tool also acts as a giant straight edge, being careful not to bend square for layouts. or bow the straight edge when reposi- tioning the wheel. Tighten the roller nut The alignment process consists of 4 steps securely, making sure the roller does not which must be performed in the following change position. Repeat this process as order. needed for the remaining rollers. 7. Reposition the tool upright. Mounting nut Factory-set 4. Loosen the guide tube bracket nuts adjustment screw Fig. 11 (Fig. 12), but do not remove the tube bracket. 5. Loosen (but do not remove) the two hex head nuts holding the index pin brackets NOTE: Figure 12 shows the counterbal- (Fig. 13). If burn marks appear on the ance removed for illustration purposes. left side of the workpiece, rotate the It is not necessary to remove the coun- saw slightly clockwise until the entire terbalance to perform this procedure. face of the blade contacts the square. 5' 4' 5. Using a deadblow mallet, strike the If burn marks appear on the right side bracket on the side and in the direction of the workpiece, rotate the saw slightly the tubes need to move. counterclockwise until the entire face of 6. Recheck the squareness of the tubes the blade contacts the square. ONLY to the rollers repeating the procedure make slight adjustments. 4' frameLine support up on as necessary. 36" mark 6. Securely tighten the two hex head nuts 7. Tighten the nuts on the upper guide tube holding the index pin brackets. 3' bracket nuts. 7. Plug in the tool and make another 6' sample cut. Repeat the procedure if necessary. 12 13 Step 4 - Adjusting the Blade - Making the Cut: Perpendicularity WARNING 1. Rotate the saw motor to the cross-cut- If you remove the saw motor without making 3. Loosen the lock nut under the bracket. ting position (Fig. 14). To rotate the sure that the factory-set adjustment screw Tighten or loosen the adjustment screw Do not cut a workpieces that has a motor, pull out the indexing pins and contacts the plate on the saw motor, then depending on the angle adjustment width smaller than that of the saw rotate the saw motor. Lock the indexing the blade will not be perpendicular (90°) to required. ONLY make slight adjust- carriage. Proper support for the pins into the preset holes on the saw the workpiece, possibly resulting in inac- ments. workpiece must be maintained to carriage. The pins are spring-loaded curate cuts. 4. Tighten the lock nut, making sure the insure safety. When the carriage and should snap into place. 1. Unplug the tool. screw is against the upright plate. moves over the workpiece, it would 2. Loosen the carriage lock and allow 2. To adjust for perpendicularity, loosen the 5. Tighten the two hex nuts to secure the be impossible to safely support the the saw motor to raise to the top of the two mounting nuts on the front of the saw saw. workpiece for the cut. Use a tool bet- tool. The saw motor is attached to the ter suited for these applications. counterbalance cable and should raise motor. The adjustment screw is located 6. Plug in the tool and make a sample cut. to the right of these nuts (Fig. 13). to the top of the guide tubes by itself. If it Repeat the procedure if necessary. does not, see “Lubricating Guide Tubes” Cross-Cutting in the Maintenance section. A cross-cut is a vertical cut that must always 3. Plug in the tool. be done from the top to the bottom of a workpiece. 4. Place the workpiece on the rollers. Do not to drop the material; this may knock MILWAUKEE recommends using the Hold the rollers out of alignment or damage Down Bar Kit for frequent cutting of workpiec- the rollers. es thinner than 1/4" (see "Accessories"). OPERATION Slide the workpiece to the desired The workpiece must be supported by a mini- position using the cross-cut ruler as a mum of two rollers. When using the Midway measure. Fence Kit , material must extend at least 4" WARNING 4. Remove the outer fl ange, blade, and beyond the saw carriage on either side. 5. Start the motor and allow it to reach full inner fl ange. Clean the spindle, fl anges, speed before beginning the cut. For easier cutting and best performance, To reduce the risk of injury, wear bolt and blade to remove buildup of dust MILWAUKEE recommends using an Exten- 6. When the motor has reached full speed, safety goggles or glasses with side and debris. sion Kit when cross-cutting workpieces that slowly pull the saw motor down through shields. Unplug the tool before 5. Replace the inner fl ange. extend beyond the blade by 5' or more on the workpiece, keeping your hand on the changing accessories or making 6. Install the blade with the arrow pointing one side. Do not cross-cut workpieces that handle. adjustments. counterclockwise. exceed 8'. 7. Once the cut is complete, turn the tool 7. Replace the outer fl ange. Tighten the off and wait for the blade to come to a Selecting a Blade bolt clockwise using the wrench pro- WARNING complete stop. A Combination/Rip blade is supplied with vided while holding in the spindle lock 8. Raise the saw motor and allow the saw the tool. button. motor to return to the top of the guide To reduce the risk of injury, do not 8. Install the blade guard (see "Installing tubes. MILWAUKEE recommends using one of the place hands on or under saw carriage the Blade Guard"). blades listed in “Accessories". These blades or in the path of the saw blade. 9. Tighten the carriage lock. will provide the best tool performance and NOTE: It may be necessary to readjust NOTE: A coasting blade can mar the the best cut. Always keep blades clean and the rulers after changing or resharpening edge of a freshly cut workpiece. sharp for the best performance. A dull or dirty blades (see “Adjusting the Rulers”). Fig. 14 blade can bind and pinch, resulting in kick back or a poor cut. Indexing WARNING pins WARNING Changing Blades 1. Unplug the tool. To reduce the risk of injury, make Do not cut a workpieces that has a 2. Remove the blade guard (see "Installing sure the tool is OFF before plugging width smaller than that of the saw the Blade Guard"). in the tool. carriage. Proper support for the workpiece must be maintained to 3. To remove the bolt from the spindle, use insure safety. When the carriage Starting and Stopping the Motor the wrench provided with the tool to turn moves over the workpiece, it would the bolt counterclockwise while holding 1. To start the saw motor, lift the switch up. Cross-cut be impossible to safely support the in the spindle lock button. The switch will stay up until it is pushed ruler workpiece for the cut. Use a tool bet- down. ter suited for these applications. 2. To stop the saw motor, push the switch down.

14 15 Rip Cutting 2. Select the saw height based on your Making Cuts Less than 1" Lock-Off Feature A rip cut is a horizontal cut that can be done workpiece, following the measure on When making cuts that are less than 1", Unplug the tool before installing the padlock. from the LEFT TO THE RIGHT or from the the rip ruler. the chatter guard (located inside the blade There is a hole in the switch through which a RIGHT TO THE LEFT, but the work piece 3. Tighten the carriage lock securely. guard) must be on the workpiece and not on padlock (not supplied with tool) will fi t to lock must always be moved through the saw the cut-off piece. If the chatter guard is on the the tool when it is not in use. Use a padlock 4. Plug in the tool. in the direction of the arrow on the saw cut-off piece, it will jam on the workpiece and with a 1-1/2" shackle, 5/16" diameter (such motor. 5. Start the motor and allow it to reach full prevent the carriage from continuing through as the Master Lock 1KALJ). speed before beginning the cut. MILWAUKEE recommends using the Hold the cut. If the saw jams, turn the tool OFF Down Bar Kit for frequent cutting of workpiec- 6. Place the workpiece on the rollers. Do and wait for the blade to stop. Then back the es thinner than 1/4" (see "Accessories"). not to drop the material; this may knock saw out of the cut. the rollers out of alignment or damage The minimum length recommended for rip the rollers. cuts is 2-1/2' (work supported by four roll- ers). The same size applies if you use the Midway Fence Kit. WARNING MAINTENANCE For easier cutting and best performance, MILWAUKEE recommends using the Exten- To reduce the risk of injury and WARNING Lubricating Guide Tubes sion Kit when rip-cutting workpieces longer damage to the tool, do not use push than 6' (see "Accessories"). Do not rip-cut sticks. Push sticks or the workpiece The saw carriage should raise itself from the To reduce the risk of injury, always un- workpieces that exceed 8'. can kick back, cause the blade to bottom to the top of the guide tubes. How- plug your tool before performing any pinch, or become caught in the ever, if the tubes become caked with dust maintenance. Never disassemble the blade and be thrown from the tool. or debris, the saw carriage may get stuck or WARNING tool or try to do any rewiring on the it may not slide smoothly. Periodically clean tool's electrical system. Contact a the guide tubes with a damp cloth, following 7. When the motor has reached full speed, MILWAUKEE service facility for ALL the directions under "Cleaning". Then, use a To reduce the risk of injury, ripping slowly move the workpiece through the repairs. dry lubricant such as PTFE or spray silicone. must always be done by moving saw in the direction of the feed arrow Other lubricants will cause dust and debris the workpiece through the saw in on the saw motor. Avoid placing your Maintaining Tools to collect on the tubes, contaminating the the direction of the arrow on the hands, clothing or body parts under the bearings. saw motor. saw carriage. Do not look directly down Keep your tool in good repair by adopting a the line of cut because dust and debris regular maintenance program. Before use, are generated during operation. Do not examine the general condition of your tool. WARNING Fig. 15 use push sticks. Inspect guards, switches, tool cord set and extension cord for damage. Check for loose Indexing screws, misalignment, binding of moving To reduce the risk of injury, electric pins WARNING parts, improper mounting, broken parts and shock and damage to the tool, never any other condition that may affect its safe immerse your tool in liquid or allow a operation. If abnormal noise or vibration oc- liquid to fl ow inside the tool. To reduce the risk of injury, always curs, turn the tool off immediately and have shield bystanders from the tool. the problem corrected before further use. Cleaning Never look down the line of cut be- Do not use a damaged tool. Tag damaged cause dust and debris are generated tools “DO NOT USE” until repaired (see Clean dust and debris from vents. Keep during operation. “Repairs”). the tool handles clean, dry and free of oil or grease. Use only mild soap and a damp Under normal conditions, relubrication is not cloth to clean your tool since certain cleaning 8. After the cut is completed, turn the tool necessary until the motor brushes need to agents and solvents are harmful to plastics Rip ruler off and wait for the blade to come to a be replaced. After six months to one year, and other insulated parts. Some of these complete stop. depending on use, return your tool to the include: gasoline, turpentine, lacquer thinner, nearest MILWAUKEE service facility for the 9. Pull the scrap material and the fi nished paint thinner, chlorinated cleaning solvents, workpiece away from the tool. following: 1. Select ripping from the left or right, ammonia and household detergents con- based on preference. Rotate the saw 10. Return the saw carriage to the upper- • Lubrication taining ammonia. Never use fl ammable or motor to the ripping position (Fig. 15). most position on the guide tubes. • Brush inspection and replacement combustible solvents around tools. To rotate the motor, pull out the indexing 11. Tighten the carriage lock. • Mechanical inspection and cleaning pins and rotate the saw motor. Lock the Repairs NOTE: When done ripping, return the car- (gears, spindles, bearings, housing, indexing pins into the preset holes in riage to the cross-cut position. etc.) If your tool is damaged, return the entire tool the saw carriage. The pins are spring- to the nearest service center. loaded and should snap into place. • Electrical inspection (switch, cord, Be sure to shield bystanders from the armature, etc.) tool. • Testing to assure proper mechanical and electrical operation 16 17 ACCESSORIES FIVE YEAR TOOL LIMITED WARRANTY

Wheel Kit (49-22-8106) Every MILWAUKEE electric power tool (including battery charger) is warranted to the original WARNING Contains two wheels to allow 8" Saw to purchaser only to be free from defects in material and workmanship. Subject to certain excep- become more portable. tions, 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 To reduce the risk of injury, always Extension Kit (49-22-8108) fi ve (5) years* after the date of purchase. Return the electric power tool and a copy of proof unplug the tool before attaching or For easier cutting and best performance, of purchase to a MILWAUKEE factory Service/Sales Support Branch location or MILWAUKEE removing accessories. Use only spe- MILWAUKEE recommends using the Enx- Authorized Service Station, freight prepaid and insured, are requested for this warranty to be cifi cally recommended accessories. tension Kit when: cross-cutting workpieces effective. This warranty does not apply to damage that MILWAUKEE determines to be from Others may be hazardous. that extend beyond the blade by 5' or more repairs made or attempted by anyone other than MILWAUKEE authorized personnel, misuse, on one side; and when rip-cutting workpieces alterations, abuse, normal wear and tear, lack of maintenance, or accidents. For a complete listing of accessories refer to longer than 6'. your MILWAUKEE Electric Tool catalog or go * The warranty period for Hoists (lever, hand chain, & electric chain hoists), Ni-Cd battery on-line to www.milwaukeetool.com. To obtain Mid-Way Fence Kit (49-22-8110) packs, Work Lights (cordless fl ashlights), Job Site Radios, and Trade Titans™ Industrial Work a catalog, contact your local distributor or a Allows you to cut small panels waist high on Carts is one (1) year from the date of purchase. service center. the 8" Saw frame. Kit includes both right and *There is a separate warranty for Li-Ion Battery Packs that accompany the power tools: Hold Down Bar Kit (49-22-8100) left-hand sides, 30" rulers, a manual stop *Every MILWAUKEE Li-Ion Battery Pack is covered by an initial 1000 Charges/2 Years free block, and quick-change wood fences. Holds thin, fl exible material in place, provid- replacement warranty. This means that for the earlier of the fi rst 1000 charges or two (2) years ing chatter-free cutting. Spring arms have Saw Blades from the date of purchase/fi rst charge, a replacement battery will be provided to the customer built-in nylon rollers to prevent material For best performance and the most accurate for any defective battery free of charge. Thereafter, customers will also receive an additional from being marred. Will accept material up cut, MILWAUKEE recommends using the warranty on a pro rata basis up to the earlier of the fi rst 2000 charges or fi ve (5) Years from to 3/4" thick. following blades in the chart. 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 Li-Ion Battery Pack depending upon Quick-Stop Gauging Kit (49-22-8102) No. of Kerf the amount of use. During this additional warranty period, the customer pays for only the Allows you to quickly and accurately position Cat. No. Description Teeth Thickness Diameter useable service received over and above the fi rst 1000 Charges/2 years, based on the date a sliding aluminum stop block to cut different 48-40-4148 Framing/Ripping 18 .071" 8-1/4" of fi rst charge and number of charges found on the battery pack via MILWAUKEE’s Service lengths of material. 48-40-4150 Rip/Crosscut 24 .071" 8-1/4" Reader. After 1000 charges/2 years from the date of purchase/fi rst charge, the customer will 48-40-4152 Trim/Finish 40 .071" 8-1/4" be charged a prorated amount for the service rendered. Dust Collecting Kit (49-22-8105) 48-40-4154 Rip/Crosscut 24 .122" 8-1/4" Warranty Registration is not necessary to obtain the applicable warranty on a MILWAUKEE Self-contained kit collects dust and debris. 48-40-4156 Trim/Finish 40 .122" 8-1/4" product. However, proof of purchase in the form of a sales receipt or other information deemed Requires a vacuum. MILWAUKEE recom- 48-40-4158 Trim/Finish 60 .122" 8-1/4" suffi cient by MILWAUKEE, is requested. mends using vaccum model numbers: 8911, 8912, 8925 and 8935. The attachment host ACCEPTANCE OF THE EXCLUSIVE REPAIR AND REPLACEMENT REMEDIES DE- supplied with the kit has an inner diameter SCRIBED HEREIN IS A CONDITION OF THE CONTRACT FOR THE PURCHASE OF of 1-1/2". EVERY MILWAUKEE PRODUCT. IF YOU DO NOT AGREE TO THIS CONDITION, YOU SHOULD NOT PURCHASE THE PRODUCT. IN NO EVENT SHALL MILWAUKEE BE LI- Dust Collecting Kit ABLE 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 CON- Hold Down Bar Kit DITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, MILWAUKEE DISCLAIMS ANY IMPLIED WARRANTY Mid-way OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE, AND ALL Fence Kit OTHER WARRANTIES. This warranty applies to product sold in the U.S.A., Canada and Mexico only. Please consult MILWAUKEE’s website www.milwaukeetool.com or call 1.800.SAWDUST (1.800.729.3878) to locate your nearest service facility for warranty and non-warranty service Quick Stop Gauging Kit on a MILWAUKEE electric power tool.

Extension Kit

Wheel Kit

18 19 UNITED STATES - MILWAUKEE Service

MILWAUKEE prides itself in producing a premium quality product that is NOTHING BUT HEAVY DUTY®. Your satisfaction with our products is very important to us! If you encounter any problems with the operation of this tool, or you would like to locate the factory Service/Sales Support Branch or authorized service station nearest you, please call... 1-800-SAWDUST (1.800.729.3878) NATIONWIDE TOLL FREE Monday-Friday • 8:00 AM - 4:30 PM • Central Time or visit our website at www.milwaukeetool.com For service information, use the 'Service Center Search' icon found in the 'Parts & Service' section. Additionally, we have a nationwide network of authorized Distributors ready to assist you with your tool and accessory needs. Check your “Yellow Pages” phone directory under “Tools-Electric” for the names & addresses of those nearest you or see the 'Where To Buy' section of our website. Corporate After Sales Service - Technical Support Brookfi eld, Wisconsin USA •Technical Questions •Service/Repair Questions •Warranty 1-800-SAWDUST (1.800.729.3878) fax: 1.800.638.9582 email: [email protected] Monday-Friday • 8:00 AM - 4:30 PM • Central Time

Canada - Service MILWAUKEE MEXICO - Soporte de Servicio MILWAUKEE MILWAUKEE est fi er de proposer un produit de première qualité NOTHING BUT HEAVY DUTY®. Milwaukee Electric Tool, S.A. de C.V. Votre satisfaction est ce qui compte le plus! Blvd. Abraham Lincoln no. 13 Colonia Los Reyes Zona Industrial En cas de problèmes d’utilisation de l’outil ou Tlalnepantla, Edo. México C.P. 54073 pour localiser le centre de service/ventes ou le Tel. (55) 5565-1414 Fax: (55) 5565-6874 centre d’entretien le plus proche, appelez le... Adicionalmente, tenemos una red nacional de 416.439.4181 distribuidores autorizados listos para ayudarle fax: 416.439.6210 con su herramienta y sus accesorios. Por Milwaukee Electric Tool (Canada) Ltd favor, llame al (55) 5565-1414 para obtener los 755 Progress Avenue nombres y direcciones de los más cercanos a Scarborough, Ontario M1H 2W7 usted, o consulte la sección ‘Where to buy’ Notre réseau national de distributeurs agréés (Dónde comprar) de nuestro sitio web en se tient à votre disposition pour fournir l’aide www.milwaukeetool.com technique, l’outillage et les accessoires nécessaires. Composez le 416.439.4181 pour obtenir les noms et adresses des revendeurs les plus proches ou bien consultez la section «Où acheter» sur notre site web à l’adresse www.milwaukeetool.com

MILWAUKEE ELECTRIC TOOL CORPORATION 13135 West Lisbon Road • Brookfi eld, Wisconsin, U.S.A. 53005 58-14-6485d6 10/06 Printed in USA