Use and Care Manual

ManualsBrandsMilwaukee ManualsSaw6480-20

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 sufﬁ x “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

qualiﬁ ed person before using it.

• Protect your extension cords from sharp objects,

excessive heat and damp or wet areas.

READ AND SAVE ALL

INSTRUCTIONS FOR FUTURE USE.

Recommended Minimum Wire Gauge

for Extension Cords*

Extension Cord Length

* Based on limiting the line voltage drop to

ﬁ ve volts at 150% of the rated amperes.

Nameplate

Amperes

0 - 2.0

2.1 - 3.4

3.5 - 5.0

5.1 - 7.0

7.1 - 12.0

12.1 - 16.0

16.1 - 20.0

25'

75'

100'

150'

50'

EXTENSION CORDS

ASSEMBLY

Assembly Order

To avoid injury or damage to the tool, follow the

order of sections in "Tool Assembly". Set up the

tool in the following order of sections:

1. Setting up the Stand

2. Installing the Counterbalance

3. Mounting the Saw Motor

4. Installing Blades

5. Adjusting the Rulers

6. Installing the Blade Guard

7. Installing the Cord Keeper

Setting up the Stand

Use at least two people to remove packaging and

set up the stand. One person should hold the stand

in an upright position while the other removes the

packaging and sets the folding stand to make the

tool free-standing.

Installing the Counterbalance

Fig. 1

Fig. 2

Fig. 3

Counterbalance

cable

Nut

Washer

Carriage

bolt

Cable

clip

Counterbalance

cable

Carriage

bolt

Cable clip tabs

Nut

WARNING To reduce the risk of injury,

always unplug tool before attaching or remov-

ing accessories or making adjustments. Use

only speciﬁ cally recommended accessories.

Others may be hazardous.

position with one hand while holding the stand

base with your other hand so it does not unfold

onto your feet.

2. Unfold the stand slowly until the hole in the

sliding center bar is aligned with the hole in the

center bar.

3. Insert the locking pin through the holes and lock

it securely.

WARNING To reduce the risk of injury

or damage to components, do not attempt to

disassemble or repair the counterbalance.

Do not pull on the counterbalance cable.

The cable is under strong spring force. Unit

must be properly assembled before removing

cable clip.

1. Remove the (2) 1/4 - 20 nuts, (2) washers

and (2) 1/4"-20 x 5/8" carriage bolts from the

counterbalance. Leave the nut and bolt on the

counterbalance cable in place.

2. Remove the end of the cable from the inside of

the counterbalance. The counterbalance must

be installed off-center to the right (while facing

the saw from the front): holes are cut into the top

of the tool frame.

3. Secure the counterbalance to the tool using (2)

carriage bolts, (2) washers, and (2) nuts.

NOTE: The carriage bolts are installed from the

bottom up. Tighten nuts securely.

Symbology

Double Insulated Volts Alternating Current

Underwriters Laboratories, Inc. Amperes

Underwriters Laboratories, Inc.,

Recognized Component

Do not place hands on or under

saw carriage or in the path of the

blade.

No Load Revolutions per Minute

(RPM)

Do not expose to rain or use in

damp locations.

Sliding

center bar

Folded locking

pin position

Locking pin

Center bar

Unfolded locking

pin position

Stand base

1. While having another person hold the stand in

the upright position, stand behind the tool. Re-

move the locking pin from the folded locking pin

4. Hold the saw carriage securely while loosening

the carriage lock.

5. Raise the saw carriage until the oval hole in

the saw carriage aligns with the eye hole in the

counterbalance cable, making sure the cable is

behind the saw carriage.

6. Tighten the carriage lock.

7. Remove the nut from the carriage bolt and insert

the bolt through the hole in the saw carriage and

the eye hole in the counterbalance cable. Thread

the nut onto the bolt and tighten securely.

8. Bend the cable clip tabs down by hand.

9. Loosen the carriage lock and lower the saw car-

riage until the cable clip is fully exposed.

10.Tighten the carriage lock.

11.Remove the cable clip from the counterbalance

cable and save it for future use (i.e., If you re-

move the counterbalance in the future, you will

need the cable clip to support the tension in the

counterbalance.)

Mounting the Saw Motor

Fig. 4

Bracket

Studs

9/16" Nuts

and washers

Spacer

7/16" Nut

and washer

Bolt

Bracket

Saw

carriage

Fig. 5

Leveling

screw

The motor is shipped with (3) washers, (3) nuts,

(1) spacer, and (1) bolt. Remove these items to

mount the saw.

1. Loosen the carriage lock and lower the saw car-

riage to a comfortable work height.

2. Tighten the carriage lock securely.

3. Mount the motor to the saw carriage by inserting

the studs on the saw motor through the holes in

the saw carriage (Fig. 4).