Impact Protection System, Orbit Control Switch

WARNINGToreducetheriskofinjury,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 efﬁcient power trans- mission and extended life in the most difﬁcult 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.

WARNING Do not operate the Sawzall with the handle rotation button pressed in or with the handle not locked into position.

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 ﬁrmly into position.

NOTE: Make sure the handle does not rotate before using the tool.

	Fig. 5	Handle
	Fig. 5	rotation
		rotation
		button

WARNING Ifthehandlecannotbelocked into position, do not operate the Sawzall®. Re- turn the Sawzall® to a Milwaukee service facility immediately for repair.

WARNING To reduce the risk of personal injury, always hold tool securely.

Starting, Stopping and Controlling Speed

1.To start the tool, grasp the handle ﬁrmly 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 speciﬁc cutting requirements.

1. For straight reciprocating	Fig. 6	1
action, move the orbit con-
trol switch to the straight cut
symbol (1).

2.Fororbitalaction,movetheorbit 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). For2 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.

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.

MATERIAL	SUGGESTED DIAL

Mild Steel	2-3
Wood	5
Nail-Embedded Wood	5
Stainless Steel	1-3
Drywall	4-5
Fiberglass	1-3
Plastics	1-3
Cast Iron	2-3
Non-Ferrous Metals	2-3

*These are only suggested settings; the actual optimal set- ting may vary depending on line voltage, blade selected and user preference.

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 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 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.

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.

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. 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 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.

Fig. 7	Cat. No. 6523-21
A	B

Fig. 8 Cat. No. 6520-21, 6536-21, and 6538-21

6523-21, 6520-21, 6538-21, 6536-21 specifications

Milwaukee Tool has established itself as a leader in the power tool industry, consistently pushing the boundaries of performance and innovation. Among its wide array of products, the Milwaukee 6536-21 and 6523-21 models stand out as powerful and reliable options for professionals and DIY enthusiasts alike.

The Milwaukee 6536-21 is a cordless band saw that boasts incredible versatility and cutting performance. It is equipped with a brushless motor that provides superior power and efficiency, allowing users to achieve a more extended run time and overall longer tool life. This model features a 5-inch cutting capacity, making it suitable for a variety of applications including cutting copper, PVC, and other materials up to 5 inches in diameter.

One of the significant highlights of the 6536-21 is its built-in LED light that illuminates the cutting area, enhancing visibility in tight or dimly lit spaces. Additionally, the saw is designed for optimal portability, as it is lightweight and compact, enabling users to maneuver easily when tackling projects overhead or in confined spaces. The adjustable speed dial allows for customized cutting speeds, enhancing precision and control for various materials.

On the other hand, the Milwaukee 6523-21 is a powerful cordless recriprocating saw that offers unmatched cutting capabilities for a wide range of materials. The saw is equipped with a brushless motor as well, which delivers significant power and runtime. With a stroke length of 1-1/8 inches and a variable speed trigger, users can achieve fast and efficient cuts, whether they are working with wood, metal, or other materials.

Both models utilize Milwaukee's Redlink Plus intelligence system. This technology enables communication between the tool and the battery, ensuring optimized performance and preventing overheating or over-discharging. The 6523-21 also features an easy-to-use blade clamp that allows for quick blade changes without the need for additional tools.

In summary, the Milwaukee 6536-21 and 6523-21 are exemplary tools that embody the company's commitment to innovation, durability, and user-centric design. With their powerful motors, enhanced mobility, and intelligent features, they are ideal for professionals who demand the best performance from their tools in any working environment. Whether you are seeking to cut large pipes or tackle construction tasks, these models can probably cater to your needs effectively.

Milwaukee 6538-21 Impact Protection System, Rotating the Handle Cat. No, Orbit Control Switch

Models: 6523-21 6520-21 6538-21 6536-21