User manual Milwaukee 6480-20

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If the small end of the taper is on the  
top, the stopper will not keep the cord  
in place.  
Step 1 - Adjusting the Rollers  
1. To check roller alignment, remove exten-  
sions (if present).  
If the saw does not cut at 90°, the guide  
tubes may not be perpendicular to the rollers.  
Unplug the saw cord before testing alignment  
or making adjustments. Check the alignment  
of the rollers before adjusting the guide tubes  
Step 3 - Adjusting the Blade - Parallelism  
The blade should be parallel to the guide  
tubes, otherwise tail burning may occur and  
the kerf will be wider than the set of the blade.  
Make the following adjustments only if the  
blade appears to be out of alignment. AL-  
WAYS check for alignment of the rollers and  
the guide tubes before adjusting the blade.  
Loosen the carriage lock and allow the  
saw carriage to return to the top of the  
guide tubes. Tighten the carriage lock.  
2. Retract the stand and lay the toolat  
so the roller nuts are easily accessible.  
With proper care, you may place the tool  
on a table with guide tubes up.  
3. The outermost rollers are stationary,  
so adjust all other wheels to the two  
outermost rollers. Lay the straight edge  
of the eld alignment tool across the roll-  
ers to verify alignment; all rollers should  
contact the edge.  
(see "Adjusting the Rollers").  
1. To check the guide tube alignment,  
remove the upper guard assembly to  
expose the blade. Mark a tooth to use as  
a reference. If using a high-speed steel  
blade, mark a tooth pointing toward the  
edge of the eld alignment tool.  
NOTE: If you discover there is too much  
or not enough slack in the cord, readjust  
as necessary.  
1. To check for blade parallelism, position  
the saw carriage for a cross-cut and  
make a sample cut. If the blade "heels",  
burns marks on the cut, etc., check both  
sides of the cut to determine which side  
of the blade is causing the problem.  
Run the cord over the top of the panel  
saw to get it out of the path of the saw.  
You are now ready to use your panel saw.  
Refer to the "Operation" section for instruc-  
tion on proper use.  
Clamp the eld alignment tool to the  
roller assembly and pull the saw car-  
riage down slowly so the marked refer-  
ence tooth just touches the vertical edge  
of the eld alignment tool. Continue to  
pull the saw carriage down. If the blade  
does not contact the square, or if the  
blade binds on the square, the guide  
tubes are not aligned.  
If a roller is "high" or "low" to the straight  
edge, clamp a straight edge at least 5'  
long to the top of the rollers so it lies at  
on the frame and against the outermost  
rollers, positioning the clamps above the  
outermost roller.  
Unplug the tool.  
3. Position the square on the rollers and  
lower the saw carriage so the square  
overhangs the blade.  
Panel Saw Alignment  
The panel saw is aligned during manufactur-  
ing to a tolerance of ±1/32". Field alignment  
is required only if the unit is mishandled or  
abused, or if motor or wheel replacement  
is required.  
With the straight edge clamped securely  
in place, rotate each roller to be sure  
that it neither jams nor has excessive  
clearance to the straight edge. If a roller  
runs "tight" or "loose" to the straight  
edge, loosen the roller nut. Roller nuts  
are torqued and require at least an 18"  
braker bar to loosen them.  
Place the square against the blade. The  
entire face of the blade should contact  
the square. If it does not, then the blade  
is not parallel to the workpiece.  
3. To align the guide tubes, determine  
which direction the top of the guide  
should move. If the blade runs into  
the square, the top guide goes to the  
square. If the blade runs away from the  
square, the top guide goes away from  
the square.  
Construct a eld alignment tool (Fig. 11):  
Index Pin Mounting nut  
For maximum accuracy, manufacture a test  
square (Fig. 11) to check the full movement  
of the saw. Construct the square using one  
Fig. 13  
' metal ruler and two 4' metal rulers. Using  
6. The rollers are mounted on an eccentric  
hub. Turning a roller when the roller nut  
is loose will cause the roller to change  
its position. You may have to lift the front  
roller carriage bar to rotate the eccentric  
hub. Turn the roller until it contacts the  
straight edge, being careful not to bend  
or bow the straight edge when reposi-  
tioning the wheel. Tighten the roller nut  
securely, making sure the roller does not  
change position. Repeat this process as  
needed for the remaining rollers.  
the 3'-4'-5' measurements assures square-  
ness. Drill holes and attach the rulers with  
pop rivets or small nuts and bolts. Use the  
Fig. 12  
' ruler to check squareness of the rollers  
Guide tube  
bracket nuts  
and the 4' ruler to check squareness of the  
guide tubes. The tool also acts as a giant  
square for layouts.  
The alignment process consists of 4 steps  
which must be performed in the following  
Reposition the tool upright.  
Mounting nut  
adjustment screw  
Loosen the guide tube bracket nuts  
(Fig. 12), but do not remove the tube  
Fig. 11  
5. Loosen (but do not remove) the two hex  
head nuts holding the index pin brackets  
NOTE: Figure 12 shows the counterbal-  
ance removed for illustration purposes.  
It is not necessary to remove the coun-  
terbalance to perform this procedure.  
(Fig. 13). If burn marks appear on the  
left side of the workpiece, rotate the  
saw slightly clockwise until the entire  
face of the blade contacts the square.  
If burn marks appear on the right side  
of the workpiece, rotate the saw slightly  
counterclockwise until the entire face of  
the blade contacts the square. ONLY  
make slight adjustments.  
5. Using a deadblow mallet, strike the  
bracket on the side and in the direction  
the tubes need to move.  
Recheck the squareness of the tubes  
to the rollers repeating the procedure  
as necessary.  
Line up on  
36" mark  
6. Securely tighten the two hex head nuts  
holding the index pin brackets.  
Tighten the nuts on the upper guide tube  
bracket nuts.  
7. Plug in the tool and make another  
sample cut. Repeat the procedure if  

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