Milwaukee Sawzall 6520-21 Device does not function when supplied with power.

Is your Milwaukee Sawzall 6520-21 not functioning when plugged in? Use this troubleshooting guide to help diagnose why.

Using a Milwaukee Sawzall with a damaged or frayed power cord is hazardous and can lead to electrical shock or fire. If you notice damage to the cord, stop using the Milwaukee Sawzall immediately to prevent any further risk.

First, disconnect the Milwaukee Sawzall from any power source. Then, inspect the entire length of the cord to locate the damaged area. If the cord damage is near the plug, you can replace the plug itself. For damage along the length of the cord, it’s best to replace the entire cord to ensure safe operation.

• Cut off the damaged plug, strip the insulation from the end of the cord, and attach a new plug with matching prongs.
• Be sure to match the wire colors properly (typically black, white, and green) to ensure proper grounding and safe function.

• Open the Milwaukee Sawzall casing, disconnect the cord’s internal connections, and attach a compatible replacement cord.
• Reassemble the casing securely before testing the Milwaukee Sawzall.

An inoperable trigger can prevent the Milwaukee Sawzall from starting or cause it to cut out unexpectedly, often due to dust, wear, or internal component issues.

1. Inspect for Obstructions: Examine the trigger area for any dust or debris buildup. Use compressed air or a small brush to remove any visible particles that may be blocking the trigger's movement.
2. Check for Wear or Damage: Look for any visible cracks or wear on the trigger. If the trigger is damaged, it may need replacement.
3. Open the Handle to Access Internal Parts: Disconnect the Milwaukee Sawzall from any power source, then carefully open the handle casing to access the trigger switch mechanism. Check for any loose wires or faulty connections that could be preventing the trigger from functioning.
4. Test the Trigger Mechanism: With the casing open, gently press the trigger to see if the mechanism is responding. If it isn’t, you may need to replace the trigger switch.

Once you've checked and, if necessary, repaired the components, reassemble the Milwaukee Sawzall and test the trigger. Ensure smooth operation before returning to full use.

Exposure to moisture, extreme temperatures, or prolonged sunlight can cause corrosion, rust, or wear on your Milwaukee Sawzall, impacting its performance and safety.

Begin by thoroughly inspecting the Milwaukee Sawzall for any visible rust, moisture, or corrosion, especially around the motor housing, blade clamp, and battery or power connections.

Use a wire brush or sandpaper to gently remove rust from any exposed metal parts. Apply a rust inhibitor afterward to prevent further damage.

 If the Milwaukee Sawzall has moisture inside, carefully disassemble the casing to allow airflow and use a clean, dry cloth to wipe down internal parts. For hard-to-reach areas, use compressed air to remove any remaining moisture. Avoid plugging in or using the Milwaukee Sawzall until it’s completely dry.

Look for signs of corrosion on electrical connections. If corrosion is present, use a contact cleaner spray to clean the affected areas, ensuring safe connectivity.

Reassemble the Milwaukee Sawzall carefully and test it in a safe environment to confirm all components are functioning properly.

Using a Milwaukee Sawzall in dusty or dirty environments can lead to sediment build-up on moving parts, vents, and internal components, reducing performance and potentially causing overheating.

Inspect all exterior and interior parts of the Milwaukee Sawzall for dust or debris, paying close attention to the blade clamp, motor vents, and housing.

Use a dry brush or compressed air to remove sediment from external surfaces, focusing on any air intake or exhaust vents.

(if heavily clogged): Disassemble the casing and use compressed air or a soft brush to remove sediment from internal components. Avoid using liquids to prevent damage to electrical parts.

Once cleaned, reassemble the Milwaukee Sawzall and perform a brief test to confirm the Milwaukee Sawzall is operating smoothly. Regular cleaning will help prevent future build-up.

A burnt out motor can be a major safety hazard, replacing the entire motor should be a last resort, check for other potential wiring issues first.

 The following list is common symptoms of a burnt out motor:

• Reduced power Output
• Burning smell
• Excessive heat production
• Unusual noises, consisting of screeching or grinding
• Complete failure to start

Now if you have identified that the motor is indeed burnt out.

• Replace the Motor.