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6
7
OPERATION
WARNING To reduce the risk of injury,
wear safety goggles or glasses with side
shields.
WARNING Always remove battery
pack before changing or removing acces-
sories. Only use accessories specifically
recommended for this tool. Others may be
hazardous.
Causes and Operator Prevention of KICK-
BACK:
KICKBACK is a sudden reaction to a pinched,
bound or misaligned saw blade, causing an un-
controlled saw to lift up and out of the workpiece
toward the operator.
When the blade is pinched or bound tightly by the
kerf, or cutting slot, closing down, the blade stalls
and the motor reaction drives the unit rapidly back
toward the operator.
If the blade becomes twisted or misaligned in
the cut, the teeth at the back edge of the blade
can dig into the top surface of the wood causing
the blade to climb out of the kerf and jump back
toward operator.
KICKBACK is the result of tool misuse and/or
incorrect operating procedures or conditions and
can be avoided by taking proper precautions as
given below:
• Maintain a fi rm grip with both hands on the
saw and position your body and arm to allow
you to resist KICKBACK forces. KICKBACK
forces can be controlled by the operator, if proper
precautions are taken.
• When blade is binding, or when interrupting
a cut for any reason, release the trigger and
hold the saw motionless in the material until
the blade comes to a complete stop. Never
attempt to remove the saw from the work or
pull the saw backward while the blade is in
motion or KICKBACK may occur. Investigate
and take corrective actions to eliminate the cause
of blade binding.
• 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.
• Support large panels to minimize the risk of
blade pinching and KICKBACK. Large panels
tend to sag under their own weight. Supports must
be placed under the panel on both sides, near the
line of cut and near the edge of the panel.
• Do not use dull or damaged blades. Unsharp-
ened or improperly set blades produce narrow
kerf causing excessive friction, blade binding and
KICKBACK.
• Blade depth lever must be tight and secure be-
fore making cut. If blade adjustment shifts while
cutting, it may cause binding and KICKBACK.
• Use extra caution when making a “Pocket Cut”
into existing walls or other blind areas. The
protruding blade may cut objects that can cause
KICKBACK.
• Set the depth of cut for no more than 1/8" to
1/4" greater than the thickness of the stock.
The less blade exposed, the less chance of bind-
ing and KICKBACK. Before cutting, be sure depth
and bevel adjustments are tight.
• Be cautious of pitchy, knotty, wet or warped
stock. These are most likely to create pinching
conditions and possible KICKBACK. Do not rip
warped lumber. Avoid cutting nails.
• Stay alert. Any distraction can cause twisting
or binding. Repetitive cuts may lull the user into
careless movements.
General Operation
Always clamp the workpiece securely on a saw
horse or bench. See “APPLICATIONS” for the
correct way to support your work in different situ-
ations.
1. Draw a cutting line. Place the front of the shoe on
the edge of the workpiece without making blade
contact. Hold the handle with one hand and the
front handle with the other (Fig. 3).
6. If the saw binds and stalls, maintain a fi rm grip
and release the trigger immediately. Hold the
saw motionless in the workpiece until the blade
comes to a complete stop.
7. After fi nishing a cut, be sure the lower guard
closes and the blade comes to a complete stop
before setting the saw down.
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 or
cutting materials too quickly. To prevent the over-
load 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.
2. Remove the blade from the workpiece.
3. 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.
4. Allow the tool to run under no load to ensure the
tool has properly cooled.
5. 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.
Troubleshooting
If the blade does not follow a straight line:
• Teeth are dull. This is caused by hitting a hard
object such as a nail or stone, 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
• Blade is loose.
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
• Battery charge is low
Electric Brake
The electric brake engages when the trigger is
released, causing the blade to stop and allowing
you to proceed with your work. Generally, the saw
blade stops within two seconds. However, there
may be a delay between the time you release the
trigger and when the brake engages. Occasionally
the brake may miss completely. If the brake misses
frequently, the saw needs servicing by an autho-
rized MILWAUKEE service facility. The brake is not
a substitute for the guard, and you must always wait
for the blade to stop completely before removing
the saw from the workpiece.
Fig. 3
2. Line up the sight line with your cutting line. Posi-
tion your arms and body to resist KICKBACK.
3. To start the saw, push the lock-off button down
while pulling the trigger. Allow the motor to reach
full speed before beginning cut.
Note: LED comes on when the lock-off button is
pushed down.
4. While cutting, keep the shoe fl at against the
workpiece and maintain a fi rm grip. Do not force
the saw through the workpiece. Forcing a saw
can cause KICKBACK. Use a light, continuous
pressure to make the cut while following the cut
line through the transparent guard or sight line.
5. If making a partial cut, restarting in mid-cut or
correcting direction, allow the blade to come to
a complete stop. To resume cutting, center the
blade in the kerf, back the saw away from cut-
ting edge a few inches, push the lock-off button
down while pulling the trigger and re-enter the
cut slowly.
This tool is intended for cutting unhardened ferrous
metal, non-ferrous metal, plastics, fi ber cement
board, and wood. Refer to the “Accessories” sec-
tion 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 saw blade, workpiece, or cutting
chips with bare hands immediately after cutting;
they may be hot and could burn skin.
• Adjust the cutting angle of the blade to the work-
piece, so the blade goes through the thinnest
sections.
Cutting Angled Materials
When cutting angle materials, tilt the tool back to
avoid having the lower guard rest on the angle.
APPLICATIONS
Incorrect Technique
Correct Technique
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 or tack
1" lumber to workpiece and use the inside edge of
the shoe as a guide.
Fig. 4